Flexible machining system and shell machining method

Abstract

The invention relates to the technical field of machining, and provides a flexible machining system and a shell machining method.The flexible machining system comprises a first numerical control vertical lathe, a second numerical control vertical lathe, a first horizontal machining center, a first pound press and a first laser marking machine; the first horizontal machining center is provided with a face milling cutter, an inner hole milling cutter, a side face groove milling cutter and a facing head. A horizontal machining center clamp is arranged on the first horizontal machining center. The device is complete in type so as to meet various process requirements, the machining efficiency and the product precision are improved, and the machining difficulty of the inner cavity inclined hole is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of mechanical processing, and in particular to a flexible processing system and a shell processing method. Background Art

[0002] The shell products on the excavator are of many types and small batches. Its main processing content is the installation stoppers and installation holes on both sides, as well as the inner cavity inclined holes with side grooves and bottom cleaning. The processing content is many and the precision requirements are high. The optimal process solution is to use the smallest processing unit, the least processing equipment, and highly integrated processing. Such shell products have many advantages such as high precision, high yield rate, low cost, etc., and are very competitive.

[0003] like Figure 1-4 As shown, the shell 1 of the excavator has a convex end, a concave end, and a peripheral block 106. The outside of the convex end has a convex stop 101, a convex end inner hole 102, a convex end sealing groove 103, a convex end mounting surface 104, and a convex end mounting hole 105. The concave end has a concave end sealing groove 107, a concave end positioning hole 108, a concave end mounting surface 109, and a concave end mounting hole 110. The peripheral block 106 has surfaces and holes. The inner cavity of the shell 1 has multiple concentric inner cavity inclined holes 111, the bottom of the inner cavity inclined holes needs to be cleaned, and there are disconnected grooves on the side and need to be cleaned; depending on the different functions of the excavator shell product, the surfaces and holes that need to be processed on the periphery will change accordingly.

[0004] There is a small through hole in the center of the bottom surface of the inner cavity inclined hole 111 of the housing 1, and the rest of the parts need to be processed. There are three inner holes 112 on the side that need to be processed, especially the outermost inner hole is disconnected and consists of four arcs. There is a groove 113 on the side, which is also disconnected into four arcs, and the end of the groove 113 is cleaned in the radial direction. The most difficult part of the inner cavity inclined hole to be processed is at the root 114 of the hole bottom, which is cleaned in both the radial and axial directions, which brings great difficulties to the milling process.

[0005] Initially, ordinary equipment was used for processing, which required multiple processes such as turning, milling, and drilling. The process route was long, the process steps were numerous, and the processing accuracy was low. Later, when CNC lathes and machining centers became popular, in order to improve the integration of the processing technology, three CNC vertical lathes and two vertical machining centers were used. In order to reduce turnover, the above equipment was closely arranged together. Such processing units and process methods have limitations and are only suitable for large batches and unchanging processes. There are few types of existing technical equipment, which are only suitable for products with relatively simple processing technology and large batches. When the processed products are of many types and small batches, there will be a variety of process requirements. The existing processing system cannot meet the above requirements at all due to the small number of equipment types. It is not flexible. Even if the equipment is simply added and the equipment types are expanded, it will inevitably increase the moving distance of operators between each station, which also brings insecurity.

[0006] The existing processing system has five processes for processing shell products. The first process is to complete the processing of the convex end mounting surface 104, the convex stop 101, the convex end inner hole 102, the convex end sealing groove 103, etc. on a CNC vertical lathe; the second process is to complete the processing of the concave end mounting surface 109, the concave end positioning hole 108, the concave end sealing groove 107, etc. on another CNC vertical lathe; the third process is to complete the processing of the concave end mounting hole 110, etc. on a vertical machining center; the fourth process is to complete the processing of the convex end mounting hole 105, the surface and hole on the peripheral block 106, etc. on another vertical machining center; the fifth process is to complete the processing of the inner cavity inclined hole 111 on another CNC vertical lathe. This processing method has many processes, low precision of shell products due to large cumulative errors, and low production efficiency due to many auxiliary working hours, which has obvious shortcomings.

[0007] In addition, traditional equipment uses turning tools such as turning tools and slotting tools to process the inner cavity inclined hole 111. The fixture and shell products on the CNC vertical lathe rotate during processing and cutting. The overall weight is large and there is a certain amount of imbalance, which limits the rotation speed. It can only be processed at a low speed, and the processing efficiency is also limited. In addition, although the turning tool is relatively simple, the many steps will inevitably lead to a significant increase in auxiliary working hours such as debugging and turnover, and there is no advantage in the case of small batches. Summary of the invention

[0008] The present invention mainly solves the technical problems that the prior art has few types of processing system equipment, is only suitable for products with relatively simple processing technology and large batches, has no flexibility, and has difficulty in processing inner cavity inclined holes. A flexible processing system and a shell processing method are proposed, with a full range of equipment to meet various process requirements, improve processing efficiency and product precision, and reduce the difficulty of processing inner cavity inclined holes.

[0009] The present invention provides a flexible processing system, comprising: a first CNC vertical lathe, a second CNC vertical lathe, a first horizontal machining center, a first pound press and a first laser marking machine; The first horizontal machining center is equipped with a face milling cutter, an internal hole milling cutter, a side slot milling cutter and a horizontal rotary table; A horizontal machining center fixture is provided on the first horizontal machining center; The horizontal machining center fixture includes: a base plate, a vertical plate, a centering plate, an angular positioning seat, a push beam, a lower support seat, a right support seat, a lever clamping cylinder, a push clamping cylinder, a support cylinder, a steel ball bolt, and a quick clamp; The bottom plate is mounted on the first horizontal machining center; a vertical plate is arranged on the bottom plate, and a through hole is arranged in the middle of the vertical plate; the centering plate is mounted on the through hole of the vertical plate; the centering plate has an inner hole; An angular positioning seat, a lower supporting seat, and a right supporting seat are respectively arranged on the bottom plate; a steel ball bolt is arranged on the top of the angular positioning seat; A first supporting cylinder is arranged on the top of the lower supporting seat; A second supporting cylinder is arranged on the inner side of the right supporting seat; A pushing crossbeam is arranged on the upper part of the vertical plate; a push-type clamping cylinder and a third supporting cylinder are arranged on the bottom surface of the pushing crossbeam; the push-type clamping cylinder and the steel ball bolt are on the same vertical axis; The vertical plate is provided with a quick clamp and a plurality of lever clamping cylinders around the centering disk.

[0010] Preferably, it also includes: a first marble detection platform and a second marble detection platform.

[0011] Preferably, it also includes: one or more of a third CNC vertical lathe, a CNC horizontal lathe, a first vertical machining center, a second horizontal machining center, a second vertical machining center, a second pound press, and a second laser marking machine.

[0012] Preferably, the second vertical machining center is a five-axis vertical machining center.

[0013] Preferably, it also includes: multiple AGV automatic transfer vehicles.

[0014] Preferably, it also includes: a plurality of chip removal vehicles.

[0015] Preferably, two corner panels are provided on the back side of the vertical panel.

[0016] Preferably, a reversing valve, a joint and an accumulator are respectively arranged on the bottom plate; The accumulator is located on the back of the vertical plate; The joint is connected to the reversing valve pipeline, and the reversing valve is connected to the push-type clamping cylinder pipeline.

[0017] Preferably, a pressure gauge is provided on the vertical plate; A first sequence valve and a second sequence valve are arranged on the back of the vertical plate; The first sequence valve is connected to the reversing valve pipeline; the first sequence valve is connected to a plurality of lever clamping cylinder pipelines; The second sequence valve is connected to the first sequence valve pipeline; the second sequence valve is connected to the first support cylinder, the second support cylinder, and the third support cylinder pipeline.

[0018] Correspondingly, the present invention also provides a shell processing method, comprising the following process: Step 1: First, transfer the shell of the excavator from the blank warehouse to the first CNC vertical lathe, then clamp the shell blank to the fixture installed on the workbench of the first CNC vertical lathe, turn the convex end of the shell upward, and first turn the convex stopper, the inner hole of the convex end, and the sealing groove of the convex end; after processing, unload the product and put it on the workbench of the first CNC vertical lathe, and then the operator controls the AGV automatic transfer vehicle to automatically transfer the product to the second CNC vertical lathe; Step 2, clamp the shell onto the installed fixture on the workbench of the second CNC vertical lathe, with the concave end of the shell product facing upward, use the processed convex stop and fixture to position and clamp, and then turn the concave end positioning hole and concave end sealing groove; after processing, unload the product and place it on the workbench of this station, and then the operator controls the AGV automatic transfer vehicle to automatically transfer the product to the first horizontal machining center.

[0019] Step 3, clamp the shell onto the horizontal machining center fixture installed on the workbench of the first horizontal machining center, place the shell horizontally, with the concave end facing the spindle end of the first horizontal machining center, still use the processed convex stop and fixture to position and clamp, and then process the convex end mounting hole, concave end mounting hole and the surface and hole of the peripheral block; Step 4, process the inner cavity inclined hole, install the face milling cutter on the spindle of the first horizontal machining center, and use the circular interpolation milling method to process the bottom surface of the inner cavity inclined hole. The processing is divided into three times in the axial direction. The first two times are rough processing, and the processing amount is between 2mm and 3mm, and the last time is fine processing, and the processing amount is between 0.1mm and 0.2mm; install the inner hole milling cutter on the spindle of the first horizontal machining center, and also use the circular interpolation milling method to mill multiple general tolerance inner holes; install the inner hole machine clamp rough milling cutter on the spindle of the first horizontal machining center, and perform rough milling on the strict tolerance inner hole, and then replace it with the inner hole machine clamp fine milling cutter to perform fine milling on the strict tolerance inner hole; install the side slot milling cutter on the spindle of the first horizontal machining center, and perform multiple rough processing in the lateral direction, and the processing amount is between 0.8mm and 1.5mm, and fine processing generally requires one time, and the processing amount is controlled between 0.05mm and 0.1mm; Step 5, install the flat rotary disk on the spindle of the first horizontal machining center, control the flat rotary disk to move to the center coordinates of the X-axis and Y-axis of the inner cavity inclined hole, rotate the spindle forward, and then the CNC system controls each axis to move until the starting point of the inner bevel angle of the root of the hole bottom moves to the tool tip of the flat rotary disk. At this time, the CNC system will start the servo motor of the flat rotary disk, and drive the tool tip to move outward through the transmission mechanism inside the flat rotary disk. At the same time, the shell moves along the Z axis to the spindle end, and stops moving in the Z axis direction after reaching the axial depth of the root of the hole bottom. Through the linkage of the two, the processing of the inner bevel angle of the root of the hole bottom is completed; then the tool tip of the flat rotary disk continues to move outward, and stops moving after reaching the radial depth of the root of the hole bottom, completing the processing of the outer root cleaning of the root of the hole bottom, and then retracts the tool and transfers the flat rotary disk into the tool library for direct call during the next processing; the operator unloads the processed shell, and then controls the AGV automatic transfer vehicle to automatically transfer the shell to the first pound press; Step 6, install the shell onto the fixture installed on the workbench of the first pound press, start each cylinder, seal and clamp the shell, and then start pounding. If the control panel of the first pound press shows that the pounding is unqualified, the operator will remove it and control the AGV automatic transfer vehicle to transfer it to the waste area; if it is qualified, the operator will remove it; When processing the excavator shell again, repeat the above steps 1 to 6.

[0020] The flexible processing system and shell processing method provided by the present invention have the following advantages compared with the prior art: 1. The flexible processing system of the present invention includes a first CNC vertical lathe, a second CNC vertical lathe, a third CNC vertical lathe, a CNC horizontal lathe, a first vertical machining center, a first horizontal machining center, a second horizontal machining center, a second vertical machining center, a pound press, a laser marking machine, an AGV automatic transfer vehicle, etc. The equipment is complete in variety and can meet various process requirements. It has high processing efficiency, high product precision, and strong versatility. The processing technology of the excavator shell is simplified, and the turning process of the inner cavity inclined hole is changed to milling. The present invention is adapted to the characteristics of a wide variety of shell products, small batches, and flexible process changes. It is not only suitable for the processing of almost all excavator shell products, but also suitable for the processing of most end covers, shafts, boxes, brackets and other products. This flexible processing unit completely solves the shortcomings of existing processing units. It can not only process one product, but also produce multiple products at the same time when the production plan is reasonably arranged.

[0021] 2. Through the application of the flexible processing system of the present invention, the requirements for shortening and optimizing the processing technology of excavator shell products are flexibly met. Compared with the previous processing technology, the shell products have many advantages such as low unit production cost, high yield rate, high processing precision, etc. The flexible processing system is highly inclusive and can adapt to the needs of various different processing technologies such as long process, short process, simple process, complex process, etc. It is not only limited to excavator shell products, but also can be applied to most small and medium-sized products. It can be widely used and can fundamentally solve the above-mentioned problems.

[0022] 3. Equipped with AGV automatic transfer vehicle to solve the turnover between various workstations. It can automatically transfer products, tooling, etc. Through the collaboration between operators, it greatly saves the moving distance of personnel, shortens the auxiliary working hours, and is fully flexible.

[0023] 4. The inner cavity oblique hole of the excavator shell product can be improved to be processed on the horizontal machining center using a special milling cutter. In this way, the vertical machining center process and the CNC vertical lathe process can be merged into the horizontal machining center process to complete, further improving the process integration. For the inner cavity oblique hole, special milling cutters such as face milling cutters, inner hole milling cutters, side slot milling cutters, and CNC flat rotary discs for bottom cleaning are used. On the horizontal machining center, the fixture and shell products are in a stationary state during machining and cutting, and the milling cutter is rotating. Since the cutter is much smaller than the fixture and shell products, and has been dynamically balanced and can be processed at high speed, the cutting time of the inner cavity oblique hole will not be more than before, and may even be reduced. In addition, after the combined process, the auxiliary time for debugging and turnover is significantly reduced, which has a very obvious advantage in the case of small batches, and the overall processing efficiency is also significantly improved.

[0024] 5. The bottom surface of the inner cavity inclined hole is processed with a face milling cutter; the three inner holes on the side are processed with different milling cutters; the side grooves are processed with a forming milling cutter, and the cutting edge of the milling cutter has the same shape as the groove of the inner cavity inclined hole. The processing of the grooves is gradually completed through the circular interpolation function of the horizontal machining center; the root of the bottom of the hole is difficult to mill because it has been cleaned in both the radial and axial directions. For this reason, a flat rotary disk with CNC function is used for processing. When the cutter head on the flat rotary disk contacts the bottom surface of the inner cavity inclined hole, the axial processing is realized through the axial feed function of the horizontal machining center, and the radial processing is realized through the CNC function of the flat rotary disk, thus realizing the cleaning of the root of the bottom of the hole. Through the use of the above series of special milling cutters, the milling of the inner cavity inclined hole is realized, effectively shortening the processing technology of the shell product. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a front view of the excavator housing product to be processed according to the present invention; Figure 2is a bottom view of the excavator housing product to be processed according to the present invention; Figure 3 It is a cross-sectional view of the inner cavity oblique hole of the excavator housing product to be processed according to the present invention; Figure 4 It is an enlarged view of the root of the inner cavity oblique hole of the excavator shell product to be processed in the present invention; Figure 5 The flexible processing system provided by the present invention is schematically shown in FIG. Figure 1 ; Figure 6 The flexible processing system provided by the present invention is schematically shown in FIG. Figure 2 ; Figure 7 It is a structural schematic diagram of the numerically controlled horizontal car of the present invention; Figure 8 It is a structural schematic diagram of the CNC vertical lathe of the present invention; Fig. 9 It is a structural schematic diagram of the horizontal machining center of the present invention; Fig.10 It is a structural schematic diagram of the vertical machining center of the present invention; Fig.11 It is a structural schematic diagram of a five-axis vertical machining center of the present invention; Fig.12 It is a schematic structural diagram of the pound press of the present invention; Fig.13 It is a structural schematic diagram of the laser marking machine of the present invention; Fig.14 It is a structural schematic diagram of the marble detection platform of the present invention; Fig.15 It is a structural schematic diagram of the bottom surface of the milling internal inclined hole of the present invention; Fig.16 It is a structural schematic diagram of a general tolerance inner hole for milling an internal inclined hole according to the present invention; Fig.17 It is a structural schematic diagram of the rough milling of the internal inclined hole with a close tolerance of the internal hole of the present invention; Fig.18 It is a structural schematic diagram of the precision milling of the internal inclined hole with a close tolerance of the internal hole of the present invention; Fig.19 It is a structural schematic diagram of the milling of the side groove of the internal inclined hole of the present invention; Fig. 20 It is a structural schematic diagram of the bottom cleaning of an internal inclined hole of the present invention; Fig.21 The structure of the horizontal machining center fixture of the present invention is shown in FIG. Figure 1 ; Fig. 22 The structure of the horizontal machining center fixture of the present invention is shown in FIG. Figure 2 ; Fig.23The clamping state diagram of the horizontal machining center fixture of the present invention is shown in FIG. Figure 1 ; Fig.24 The clamping state diagram of the horizontal machining center fixture of the present invention is shown in FIG. Figure 2 .

[0026] Figure numerals: 1, housing; 2, first CNC vertical lathe; 3, second CNC vertical lathe; 4, AGV automatic transfer vehicle; 5, third CNC vertical lathe; 6, CNC horizontal lathe; 7, first vertical machining center; 8, first horizontal machining center; 9, face milling cutter; 10, inner hole milling cutter; 11, inner hole machine clamp rough milling cutter; 12, inner hole machine clamp fine milling cutter; 13, side slot milling cutter; 14, flat rotary table; 15, first pound press; 16, first laser marking machine; 17, first marble detection platform; 18, second horizontal machining center; 19, second vertical machining center; 20, first pound press; 21, first laser marking machine; 22, second marble detection platform; 101, convex stopper; 102, convex end inner hole; 103, convex end sealing groove; 104, convex end mounting surface; 105, convex end mounting hole; 106, peripheral block; 107, concave end sealing groove; 108, concave end positioning hole; 109, concave end mounting surface; 110, concave end mounting hole; 111, inner cavity oblique hole; 112, inner hole; 113, groove; 114, hole bottom root; 801, bottom plate; 802, vertical plate; 803, angle plate; 804, centering plate; 805, angular positioning seat; 806, pushing beam; 807, lower support seat; 808, right support seat; 809, lever clamping cylinder; 810, push clamping cylinder; 811, support cylinder; 812, first sequence valve; 813, second sequence valve; 814, reversing valve; 815, connector; 816, pressure gauge; 817, accumulator; 818, ball bolt; 819, quick clamp. DETAILED DESCRIPTION

[0027] In order to make the technical problems solved by the present invention, the technical solutions adopted and the technical effects achieved clearer, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It is understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention. It should also be noted that, for the convenience of description, only the parts related to the present invention are shown in the accompanying drawings, rather than all the contents.

[0028] like Figure 5-20 As shown, a flexible processing system provided by an embodiment of the present invention includes: a first CNC vertical lathe 2, a second CNC vertical lathe 3, a first horizontal machining center 8, a first pound press 15 and a first laser marking machine 16.

[0029] A flexible processing system of the present invention further includes: one or more of a third CNC vertical lathe 5, a CNC horizontal lathe 6, a first vertical machining center 7, a second horizontal machining center 18, a second vertical machining center 19, a second pound press 20, and a second laser marking machine 21. The second vertical machining center 19 is a five-axis vertical machining center.

[0030] The flexible processing system of the present invention further includes: a first marble detection platform 17 and a second marble detection platform 22 .

[0031] A flexible processing system of the present invention further includes: a plurality of chip removal vehicles.

[0032] The two end faces of the shell 1 are generally suitable for vertical machining centers in terms of milling, drilling, boring and reaming, while the milling, drilling, boring and reaming of the circumferential side faces are generally suitable for horizontal machining centers. When the end faces and circumferential side faces have strict geometric tolerance requirements, the five-axis vertical machining center can meet such special requirements. It can complete the processing of five faces and holes at one time, or even more. In terms of turning, it is equipped with CNC horizontal lathes and CNC vertical lathes. Small products such as end covers and shafts are suitable for CNC horizontal lathe turning processing, and medium and large products such as boxes and brackets are suitable for CNC vertical lathe turning processing. In terms of auxiliary, it is equipped with auxiliary devices such as pound presses, laser marking machines, and marble inspection platforms. In summary, the functions of this processing system are complete, can meet the requirements of a variety of processes, and can directly submit finished products. It not only has integrity, but also has flexibility.

[0033] A horizontal machining center fixture is provided on the first horizontal machining center 8 and / or the second horizontal machining center 18. Figure 21-24 As shown, the horizontal machining center fixture includes: a base plate 801, a vertical plate 802, a centering plate 804, an angular positioning seat 805, a pushing beam 806, a lower support seat 807, a right support seat 808, a lever clamping cylinder 809, a push clamping cylinder 810, a support cylinder 811, a steel ball bolt 818, and a quick clamp 819.

[0034] The bottom plate 801 is installed on the first horizontal machining center 8; the bottom plate 801 is provided with a vertical plate 802, and a through hole is provided in the middle of the vertical plate 802; two angle plates 803 are provided on the back of the vertical plate 802. The bottom plate 801, the vertical plate 802, and the angle plates 803 are connected and fixed by hexagon socket screws and cylindrical pins. This is the main body of the horizontal machining center fixture, which adopts a thickened design, especially the use of large angle plates 803, which has sufficient rigidity to ensure the smooth processing of the shell.

[0035] The centering disc 804 is installed on the through hole of the vertical plate 802; the centering disc 804 has an inner hole, and the inner hole of the centering disc 804 is adapted to the convex stop 101 of the shell 1. The centering disc 804 plays a key centering role. Its outer circle and the middle hole of the vertical plate 802 are precisely positioned, and its inner hole and the outer stop 101 of the shell 1 are precisely positioned. It is made of alloy tool steel with high wear resistance, and can maintain high-precision positioning for a long time, providing a guarantee for the processing of high-precision shells. The centering disc 804 and the vertical plate 802 are both designed with targeted hollowing, so that they can effectively avoid when processing the convex end mounting hole.

[0036] The bottom plate 801 is provided with an angular positioning seat 805, a lower support seat 807, and a right support seat 808; a steel ball bolt 818 is provided on the top of the angular positioning seat 805; the steel ball bolt 818 can automatically rotate slightly with the positioning surface of the outer peripheral block 106 of the housing 1 to adjust the contact positioning, and the positioning is more accurate. The steel ball bolt 18 is screwed on the top of the angular positioning seat 805, and the exposed length can be adjusted arbitrarily according to the needs, so that the positioning has great flexibility, and the back-up tightening nut is adjusted to make the positioning more secure.

[0037] A first supporting cylinder 811 is arranged on the top of the lower supporting seat 807; a second supporting cylinder 820 is arranged on the inner side of the right supporting seat 808; a pushing beam 806 is arranged on the upper part of the vertical plate 802; a push-type clamping cylinder 810 and a third supporting cylinder 821 are arranged on the bottom surface of the pushing beam 806; a pushing-type clamping cylinder 810 is arranged on the lower left part of the pushing beam 806, and the pushing-type clamping cylinder 810 and the steel ball bolt 818 are on the same vertical axis, so that the shell 1 can be accurately positioned and reliably clamped in the angular direction after clamping.

[0038] The vertical plate 802 is provided with a quick clamp 819 and a plurality of lever clamping cylinders 809 around the centering plate 804. In this embodiment, four clamping points are provided around the centering plate 804, and the four lever clamping cylinders 9 play the role of main clamping. The front end of the pressure plate of the lever clamping cylinder 809 is chamfered to avoid interference when machining the mounting hole.

[0039] The wall thickness of the inclined hole inside the shell 1 is relatively thin, and the shell 1 is prone to deformation and vibration during processing. For this reason, floating supports are designed at the corresponding peripheral parts. The first support cylinder 811 is set on the lower support seat 807, the second support cylinder 820 is set on the right support seat 808, and the third support cylinder 821 is set in the middle of the pushing beam 806. When the shell product is clamped, the three support cylinders will operate to support the outer periphery of the shell 1. In this way, the shell will not be deformed during processing, which makes the processing smooth and improves the processing accuracy.

[0040] The bottom plate 801 is provided with a reversing valve 814, a connector 815 and an accumulator 817 respectively; the accumulator 817 is located on the back of the vertical plate 802; the connector 815 is connected to the reversing valve 814 by pipeline, and the reversing valve 814 is connected to the push-type clamping cylinder 810 by pipeline.

[0041] A pressure gauge 816 is provided on the vertical plate 802; a first sequence valve 812 and a second sequence valve 813 are provided on the back of the vertical plate 802; the first sequence valve 812 is connected to the reversing valve 814 by pipeline; the first sequence valve 812 is connected to the plurality of lever clamping cylinders 809 by pipeline; the second sequence valve 813 is connected to the first sequence valve 812 by pipeline; the second sequence valve 813 is connected to the first supporting cylinder 811, the second supporting cylinder 820 and the third supporting cylinder 821 by pipeline.

[0042] When the horizontal machining center fixture is in use, place the excavator shell 1 horizontally, with the convex end facing the fixture, the side boss to be processed facing right, and move toward the centering plate 804 on the fixture. Move slowly and pay attention to leaving a safe gap with the parts on the fixture to avoid collisions, until the convex stop on the product is accurately positioned with the positioning hole on the centering plate 804. Turn the shell 1 so that the positioning surface of the peripheral block 106 of the side boss contacts and positions the steel ball bolt 818 on the angular positioning seat 805. At this time, immediately pull the quick clamp 819 to pre-clamp the shell 1 to ensure that the shell 1 will not move in the fixture and maintain accurate positioning, while also preventing the product from falling and causing safety accidents.

[0043] Then connect the oil pipe of the hydraulic station to the joint 815 of the fixture, unscrew the reversing valve 814, supply hydraulic oil, first push the push clamping cylinder 810 on the crossbeam 806 to complete the angular clamping; then the first sequence valve 812 is opened, the four lever clamping cylinders 809 are actuated, the shell product is firmly clamped on the centering plate 804, and the main clamping of the shell 1 is completed; then the second sequence valve 13 is opened, the first support cylinder 811, the second support cylinder 820, and the third support cylinder 821 are actuated to complete the floating clamping of the outer periphery of the shell 1, and the positioning and clamping of the shell 1 in the horizontal machining center fixture is completed. Loosen the quick clamp 819 and pull it to the bottom to prevent the clamp from loosening during processing and interfering with the processing.

[0044] Close the reversing valve 814, unplug the oil pipe of the hydraulic station, and confirm the positioning point and clamping point of the shell product again. After they are correct, start processing the shell 1.

[0045] After the processing is completed, the oil pipe of the hydraulic station is connected to the joint 815 of the fixture again, and the reversing valve 814 is unscrewed to drain the hydraulic oil. Each hydraulic cylinder starts to move and returns to the initial position. Close the reversing valve 814 and unplug the oil pipe of the hydraulic station. Use compressed air to remove the waste chips and waste liquid remaining on the fixture and the product, and then slowly take out the shell product.

[0046] When processing the next shell product, repeat the above steps.

[0047] The housing 1 is placed horizontally in a horizontal machining center fixture so that the convex end mounting hole 105, the concave end mounting hole 110, the surface and hole of the peripheral block 106, and the inner cavity inclined hole 111 of the housing 1 can be processed in one clamping.

[0048] The first horizontal machining center 8 and / or the second horizontal machining center 18 are equipped with special milling tools such as a face milling cutter 9, an inner hole milling cutter 10, a side slot milling cutter 13 and a flat rotary disc 14, so as to realize efficient milling of the inner cavity inclined hole 111 of the housing 1 of the excavator. The flat rotary disc 14 has a numerical control function and is used to clean the root 114 of the hole bottom.

[0049] The face milling cutter 9 adopts a small-diameter machine-clamped face milling cutter to process the bottom surface of the inner cavity inclined hole 111, and the processing is performed through circular arc interpolation. The bottom surface of the inner cavity inclined hole 111 is a circular ring shape. The diameter of the face milling cutter is greater than the width of the circular ring. The circular ring can be processed in one cut when milling the surface. In addition, the face milling cutter 9 adopts a special 85° parallelogram blade with high hardness and high wear resistance. It has the advantages of large rake angle, high cutting efficiency, large tip radius and high milling surface roughness. Using this face milling cutter 9 can quickly process high-quality bottom surfaces of the inner cavity inclined hole 111.

[0050] The inner hole milling cutter 10 and the inner cavity inclined hole 111 of the shell 1 are divided into two categories: general tolerance inner hole and strict tolerance inner hole. The general tolerance inner hole adopts a welded carbide milling cutter, and the blade is made of tungsten steel. It has high hardness and can be processed with a large amount of cutting. At the same time, it has very high wear resistance, that is, it has a very long life, which greatly reduces the auxiliary cost of frequent tool replacement.

[0051] The strict tolerance inner hole is processed by two tools, the inner hole machine clamp rough milling cutter 11 and the inner hole machine clamp fine milling cutter 12. They also use high-hardness and high-wear-resistant 85° parallelogram special blades, and install a large number of blades, so that the milling process will be more stable. The inner hole after milling has higher processing accuracy such as cylindricity and coaxiality, which can well guarantee the size requirements of the strict tolerance inner hole. The milling of the above inner hole milling cutters also adopts the method of circular arc interpolation, so that it has universality. One milling cutter can mill the inner cavity inclined holes 111 of various specifications of housings 1, greatly reducing the cost of the tool.

[0052] The side groove milling cutter 13, the groove 113 on the side of the inner cavity inclined hole 111 is very difficult to process. It is composed of four disconnected arcs. The process of milling it belongs to intermittent cutting. The impact on the milling cutter during intermittent cutting will be very large, and then the milling is not stable, which eventually leads to the failure to meet the size requirements of the side groove and reduces the processing efficiency. In addition, the end of the groove 113 needs to be rooted, which brings great difficulties to milling. For this reason, a molded side groove milling cutter 13 is designed. The shape of the cutting part of the blade used is the same as the shape of the side groove, and it is directly processed and formed. This molded side groove milling cutter 13 also adopts a welded carbide milling cutter, and the blade is also made of tungsten steel. In this way, it fully possesses the advantages mentioned above. In addition, the number of blades is increased, which greatly improves the stability of cutting, solves the problem of intermittent cutting well, and can not only meet the size requirements of the side groove, but also improve processing efficiency.

[0053] The flat rotary disc 114 is mainly composed of a tool handle, a servo motor and its fixed seat, a transmission mechanism, a tool, etc. For the shell 1 mentioned in the present invention, a small and medium-sized CNC flat rotary disc is selected, and its tool handle is inserted into the spindle hole of the horizontal machining center, accurately positioned and clamped. The fixed seat of the servo motor is installed on the fixed seat of the spindle of the horizontal machining center, and the servo motor is installed on the other end. The power supply and control cable of the servo motor are connected to the CNC system of the horizontal machining center, so that the CNC flat rotary disc and other moving axes of the horizontal machining center can be linked to process the shell 1. The transmission mechanism is mainly composed of a motor transmission shaft, a transmission shaft gear, a variety of bevel gears, a driving gear, a rack, etc. After multi-stage effective transmission, the rotational motion of the flat rotary disc servo motor is finally converted into the radial motion of the tool. Through the linkage with other moving axes of the horizontal machining center, the root cleaning of the bottom of the shell hole 114 is completed. Through the use of the flat rotary disc 14, milling root cleaning completely replaces the previous turning root cleaning, which is the most critical point to improve the process of the shell 1.

[0054] In order to reduce the moving distance of operators between various workstations, the traditional processing system arranges the equipment closely, which makes the working area narrow. Although the walking distance is reduced, it also increases many safety hazards. A flexible processing system of the present invention also includes: multiple AGV automatic transfer vehicles 4. The present invention is equipped with multiple AGV automatic transfer vehicles 4, which can be controlled by operators at any position. Through the mutual assistance of operators, the problem of large walking distance is effectively solved. The transportation of products, tools, etc. is all completed automatically, which not only greatly reduces the labor intensity, but also significantly shortens the transportation time, and indirectly improves the processing efficiency of the product. The use of the AGV automatic transfer vehicle 1 makes the transportation of processed products, etc. in this system all become automatic operations, which makes it unnecessary to arrange the placement of various equipment closely in order to reduce the walking distance of operators. More importantly, it greatly reduces the labor intensity of operators. Through the mutual assistance of operators in the system, they can operate nearby without following the products to move around the entire system area, which significantly reduces the walking distance, and also reduces various waiting wastes such as transportation, loading and unloading of processed products. In this flexible processing system, multiple products can be processed simultaneously, and multiple AGV automatic transfer vehicles 4 can be configured according to specific conditions to optimize the handling process and eliminate waiting time for transfer.

[0055] Each equipment's operating area will be equipped with a workbench, which mainly has two layers. The upper layer can be used to place processed products, and there are fences around the edges to prevent them from falling during transportation. The lower layer can be used to place tools, consumables, etc. When transportation is required, the operator calls the AGV automatic transfer vehicle 4, which will enter the empty space at the bottom of the workbench. The lifting tray of the AGV automatic transfer vehicle 4 contacts the bottom surface of the lower layer and lifts up the workbench. The workbench is then transferred to the next operating station together with the processed products, and then operated by the nearest operator. The AGV automatic transfer vehicle 4 has an obstacle detection function. When an obstacle is detected within a set distance, it will automatically stop or re-plan the transfer route until the workbench is delivered to the designated station, which can provide safety protection for the entire transfer process. Through the use of the AGV automatic transfer vehicle 4, the transfer path can be arbitrarily designed according to the needs of the processing technology, which is flexible and reliable.

[0056] When the flexible processing system of the present invention is working, generally, two operators are deployed per shift, and the area outside the equipment is used as a buffer zone, where materials such as blanks, semi-finished products, finished products, consumables, tools, etc. can be placed flexibly according to needs. The equipment of the present invention is complete in variety and powerful in function.

[0057] The flexible processing system of the present invention has the following specific processing technology for processing the shell 1 of the excavator: first CNC vertical lathe 2-transfer-second CNC vertical lathe 3-transfer-first horizontal machining center 8-transfer-first pound press 15-transfer-first laser marking machine 16-first marble inspection platform 17, after which qualified products are put into the finished product warehouse, and unqualified products are transferred to the unqualified product area.

[0058] The present invention provides a shell processing method, comprising the following steps: Step 1, first transfer the excavator shell product from the blank warehouse to the first CNC vertical lathe 2, then clamp the shell 1 blank to the fixture installed on the workbench of the first CNC vertical lathe 2, turn the convex end of the shell 1 upward, and first turn the convex stop 101, the convex end inner hole 102, the convex end sealing groove 103, etc. After processing, unload the product, remove the burrs, and put it on the workbench of the first CNC vertical lathe 2. Then the operator controls the AGV automatic transfer vehicle 4 to automatically transfer the product to the next second CNC vertical lathe 3.

[0059] Step 2, clamp the shell 1 to the fixture installed on the workbench of the second CNC vertical lathe 3, with the concave end 6 of the shell product facing upward, use the processed convex stop 101 and the fixture to position and clamp, and then turn the concave end positioning hole 108 and the concave end sealing groove 107. After processing, unload the product, remove the burrs, handle it with care to avoid bumps, scratches and other defects on the shell 1, and put it on the workbench of this station, and then the operator controls the AGV automatic transfer vehicle 4 to automatically transfer the product to the first horizontal machining center 8.

[0060] Step 3, clamp the shell 1 to the horizontal machining center fixture installed on the workbench of the first horizontal machining center 8, place the shell 1 horizontally with the concave end facing the spindle end of the first horizontal machining center, still use the processed convex stop 101 and the fixture to position and clamp, and then process the surfaces and holes of the convex end mounting hole 105, the concave end mounting hole 110 and the peripheral block 106.

[0061] Step 4, process the inner cavity inclined hole 111. First, install the face milling cutter 9 on the spindle of the first horizontal machining center 8, and use the circular interpolation milling method to process the bottom surface of the inner cavity inclined hole 111. The processing is divided into three times in the axial direction. The first two times are rough processing, and the processing amount is between 2mm and 3mm. The last time is fine processing, and the processing amount is between 0.1mm and 0.2mm. After that, install the inner hole milling cutter 10 on the spindle of the first horizontal machining center 8, and also use the circular interpolation milling method to mill multiple general tolerance inner holes. Then install the inner hole machine clamp rough milling cutter 11 on the spindle of the first horizontal machining center 8, and perform rough milling on the strict tolerance inner hole. Then replace it with the inner hole machine clamp fine milling cutter 12 to perform fine milling on the strict tolerance inner hole. Subsequently, the side groove milling cutter 13 is installed on the spindle of the first horizontal machining center 8. The lateral depth of the groove on the side of the inner cavity is large and cannot be machined in one time. Multiple rough machining is performed on the side, and the machining amount is between 0.8mm and 1.5mm. In general, fine machining is required once, and the machining amount is controlled between 0.05mm and 0.1mm. However, when the bottom surface of the side groove 113 has defects such as ripples after machining, additional fine machining is required to repair the above defects. After use, the milling cutter mentioned above will be transferred to the tool library by the mechanical arm of the first horizontal machining center 8, and will be quickly transferred out by the mechanical arm when it is used next time.

[0062] Step 5, install the flat rotary disk 14 on the spindle of the first horizontal machining center 8, control the flat rotary disk 14 to move to the center coordinates of the X-axis and Y-axis of the inner cavity inclined hole 111, rotate the spindle forward, and then the CNC system controls each axis to move until the starting point of the inner bevel angle of the hole bottom root 114 moves to the tool tip of the flat rotary disk 14. At this time, the CNC system will start the servo motor of the flat rotary disk 14, and drive the tool tip to move outward through the transmission mechanism inside the flat rotary disk 14. At the same time, the housing 1 moves along the Z-axis toward the spindle end. After reaching the axial depth of the hole bottom root 114, the movement in the Z-axis direction is stopped. Through the linkage of the two, the inner bevel processing of the hole bottom root 114 is completed; then the tool tip of the flat rotary disk 14 continues to move outward, and stops moving after reaching the radial depth of the hole bottom root 114, so that the processing of the outer root of the hole bottom 104 is completed, and then the tool is withdrawn and the flat rotary disk 14 is transferred to the tool library for direct call in the next processing, so that the main processing procedures of the excavator shell 1 are completed. After that, the operator unloads the processed shell, and then controls the AGV automatic transfer vehicle 4 to automatically transfer the shell 1 to the first pound press 15.

[0063] Step 6, install the shell 1 on the fixture installed on the workbench of the first pound press 15, start each cylinder, seal and clamp the shell 1, and then start pounding. If the control panel of the first pound press 15 shows that the pounding is unqualified, the operator will remove it and control the AGV automatic transfer vehicle 4 to transfer it to the scrap area. If qualified, the operator will remove it. Since the first pound press 15 and the first laser marking machine 16 are not only small in size, but also placed at a close distance, the operator can directly take the product to the workbench of the first laser marking machine 16, install it on the marking fixture, perform the marking operation, remove it after the marking is qualified, and control the AGV automatic transfer vehicle 4 to transfer it to the first marble inspection platform 17, and conduct inspection according to the requirements of the product inspection form. If qualified, it will be transferred to the finished product area, and if unqualified, it will be transferred to the scrap area. At this point, all processes have been completed according to the process requirements of the shell 1 of the excavator.

[0064] When the housing 1 of the excavator is processed again, the above steps 1 to 6 are repeated.

[0065] The flexible processing system of the present invention can satisfy Figure 1-4 The process requirements of the excavator shell 1 are shown; at the same time, it can also meet the processing requirements of other small shell products, medium and large shell products, end covers, shaft products, etc.

[0066] a) Small shell products: There are external surfaces and holes that need to be processed, whether in one rotation direction or multiple rotation directions. The main processing technology of this type of excavator shell products in this flexible processing system is: CNC horizontal lathe-CNC horizontal lathe-five-axis vertical machining center. The CNC horizontal lathe is very suitable for processing small products. The five-axis vertical machining center is not only suitable for small and medium-sized products, but also can complete the processing of external surfaces and holes at one time. This processing technology is easy to operate and highly efficient.

[0067] b) Medium and large shell products: There are external surfaces and holes that need to be processed, all in one rotation direction. The main processing technology of this type of excavator shell products in this flexible processing system is: CNC vertical lathe-CNC vertical lathe-horizontal machining center, and the shells to which this invention applies belong to this type of product. If the external surfaces and holes are in multiple rotation directions, the main processing technology is CNC vertical lathe-CNC vertical lathe-five-axis vertical machining center.

[0068] c) In addition to excavator shell products, other products can also be processed. For example, the processing technology of end covers and shaft products in this flexible processing system is: CNC horizontal lathe-CNC horizontal lathe-vertical machining center; the processing technology of box and bracket products in this flexible processing system is: CNC vertical lathe-CNC vertical lathe-horizontal machining center or five-axis vertical machining center, etc.

[0069] In summary, this flexible processing system can cope with the processing technology requirements of most types of products, and can complete processing with the optimal processing technology. It is efficient, stable and reliable, making the processed products high in precision, low in cost and highly competitive.

[0070] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that modifying the technical solutions described in the aforementioned embodiments, or replacing some or all of the technical features therein by equivalents, does not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A flexible processing system, characterized in that: include: A first CNC vertical lathe (2), a second CNC vertical lathe (3), a first horizontal machining center (8), a first pound press (15) and a first laser marking machine (16); The first horizontal machining center (8) is equipped with a face milling cutter (9), an inner hole milling cutter (10), a side slot milling cutter (13) and a horizontal rotary disc (14); A horizontal machining center fixture is arranged on the first horizontal machining center (8); The horizontal machining center fixture comprises: a base plate (801), a vertical plate (802), a centering plate (804), an angular positioning seat (805), a pushing crossbeam (806), a lower support seat (807), a right support seat (808), a lever clamping cylinder (809), a push clamping cylinder (810), a support cylinder (811), a steel ball bolt (818), and a quick clamp (819); The bottom plate (801) is mounted on a first horizontal machining center (8); a vertical plate (802) is arranged on the bottom plate (801), and a through hole is arranged in the middle of the vertical plate (802); the centering plate (804) is mounted on the through hole of the vertical plate (802); the centering plate (804) has an inner hole; An angular positioning seat (805), a lower support seat (807), and a right support seat (808) are respectively arranged on the bottom plate (801); a steel ball bolt (818) is arranged on the top of the angular positioning seat (805); A first supporting cylinder (811) is disposed on the top of the lower supporting seat (807); A second supporting cylinder (820) is disposed on the inner side of the right supporting seat (808); A pushing crossbeam (806) is disposed on the upper portion of the vertical plate (802); a push-type clamping cylinder (810) and a third supporting cylinder (821) are disposed on the bottom surface of the pushing crossbeam (806); the pushing clamping cylinder (810) and the steel ball bolt (818) are on the same vertical axis; The vertical plate (802) is provided with a quick clamp (819) and a plurality of lever clamping cylinders (809) around the centering disk (804).

2. A flexible processing system according to claim 1, characterized in that: Also includes: A first marble detection platform (17) and a second marble detection platform (22).

3. A flexible processing system according to claim 1, characterized in that: Also includes: One or more of a third CNC vertical lathe (5), a CNC horizontal lathe (6), a first vertical machining center (7), a second horizontal machining center (18), a second vertical machining center (19), a second pound press (20), and a second laser marking machine (21).

4. A flexible processing system according to claim 3, characterized in that: The second vertical machining center (19) is a five-axis vertical machining center.

5. A flexible processing system according to claim 1, characterized in that: Also includes: Multiple AGV automatic transfer vehicles (4).

6. A flexible processing system according to claim 1, characterized in that: Also includes: Multiple chip removal vehicles.

7. A flexible processing system according to claim 1, characterized in that: Two corner plates (803) are arranged on the back side of the vertical plate (802).

8. A flexible processing system according to claim 7, characterized in that: A reversing valve (814), a connector (815) and an accumulator (817) are respectively arranged on the bottom plate (801); The energy accumulator (817) is located on the back side of the vertical plate (802); The connector (815) is connected to the pipeline of the reversing valve (814), and the reversing valve (814) is connected to the pipeline of the push-type clamping cylinder (810).

9. A flexible processing system according to claim 8, characterized in that: A pressure gauge (816) is provided on the vertical plate (802); A first sequence valve (812) and a second sequence valve (813) are provided on the back of the vertical plate (802); The first sequence valve (812) is connected to the reversing valve (814) through a pipeline; the first sequence valve (812) is connected to the plurality of lever clamping cylinders (809) through pipelines; The second sequence valve (813) is connected to the first sequence valve (812) via a pipeline; the second sequence valve (813) is connected to the first support cylinder (811), the second support cylinder (820), and the third support cylinder (821) via a pipeline.

10. A shell processing method, characterized in that: The process includes: Step 1, firstly, the shell (1) of the excavator is transferred from the blank warehouse to the first CNC vertical lathe (2), then the blank of the shell (1) is clamped on the fixture installed on the workbench of the first CNC vertical lathe (2), and the convex end of the shell (1) is facing upward, and the convex stop (101), the convex end inner hole (102), and the convex end sealing groove (103) are first turned; after processing, the product is unloaded and placed on the workbench of the first CNC vertical lathe (2), and then the operator controls the AGV automatic transfer vehicle (4) to automatically transfer the product to the second CNC vertical lathe (3); Step 2, the housing 1 is clamped onto a fixture installed on the workbench of the second CNC vertical lathe (3), the concave end (6) of the housing product is facing upward, and the concave end (6) is positioned and clamped with the processed convex stop (101), and then the concave end positioning hole (108) and the concave end sealing groove (107) are turned; after processing, the product is unloaded and placed on the workbench of this station, and then the operator controls the AGV automatic transfer vehicle (4) to automatically transfer the product to the first horizontal machining center (8); Step 3, clamping the housing (1) to a horizontal machining center fixture installed on a workbench of a first horizontal machining center (8), placing the housing (1) horizontally with the concave end facing the spindle end of the first horizontal machining center, still using the processed convex stop (101) and the fixture to position and clamp, and then processing the convex end mounting hole (105), the concave end mounting hole (110) and the surface and hole of the peripheral block (106); Step 4, machining the inner cavity inclined hole (111), installing the face milling cutter (9) on the spindle of the first horizontal machining center (8), and machining the bottom surface of the inner cavity inclined hole (111) by using the circular interpolation milling method, and machining is performed three times in the axial direction, the first two times are rough machining, the machining amount is between 2mm and 3mm, and the last time is fine machining, the machining amount is between 0.1mm and 0.2mm; installing the inner hole milling cutter (10) on the spindle of the first horizontal machining center (8), and also using the circular interpolation milling method. Milling a plurality of general tolerance inner holes; installing an inner hole machine clamp rough milling cutter (11) on the spindle of the first horizontal machining center (8) to perform rough milling on the close tolerance inner hole, and then replacing it with an inner hole machine clamp fine milling cutter (12) to perform fine milling on the close tolerance inner hole; installing a side slot milling cutter (13) on the spindle of the first horizontal machining center (8) to perform multiple rough machining on the side, with a machining amount between 0.8 mm and 1.5 mm, and fine machining generally requires one time, with a machining amount controlled between 0.05 mm and 0.1 mm; Step 5, install the flat rotary disk (14) on the spindle of the first horizontal machining center (8), control the flat rotary disk (14) to move to the center coordinates of the X-axis and Y-axis of the inner cavity inclined hole (111), rotate the spindle forward, and then the numerical control system controls each axis to move until the starting point of the inner bevel angle of the hole bottom root (114) moves to the tool tip of the flat rotary disk (14). At this time, the numerical control system will start the servo motor of the flat rotary disk (14), and drive the tool tip to move outward through the transmission mechanism inside the flat rotary disk (14). At the same time, the housing (1) moves along the Z-axis to the spindle end to reach the hole bottom root (114). After reaching the axial depth of the hole bottom (114), the movement in the Z-axis direction is stopped, and the inner bevel processing of the hole bottom root (114) is completed through the linkage of the two; then the tool tip of the flat rotary disk (14) continues to move outward, and stops moving after reaching the radial depth of the hole bottom root (114), completing the root cleaning processing of the outer side of the hole bottom root (104), and then retracts the tool and transfers the flat rotary disk (14) into the tool library for direct call during the next processing; the operator unloads the processed shell, and then controls the AGV automatic transfer vehicle (4) to automatically transfer the shell (1) to the first pound press (15); Step 6, install the shell (1) on the fixture installed on the workbench of the first pound press (15), start each cylinder, seal and clamp the shell (1), and then start pound pressing. If the control panel of the first pound press (15) shows that the pound pressing is unqualified, the operator removes it and controls the AGV automatic transfer vehicle (4) to transfer it to the waste area; if it is qualified, the operator removes it; When the housing (1) of the excavator is processed again, the above steps 1 to 6 are repeated.

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