External intelligent alignment machining method for large aluminum alloy barrel

Abstract

The invention provides an outside-machine intelligent alignment machining method for a large aluminum alloy barrel, and belongs to the technical field of machining. The problem that the inner circle of the cylinder is difficult to align at present is solved; comprising the following steps: measuring cylinder data; barrel body posture adjustment, wherein according to the calculated barrel body position adjustment data, an intelligent alignment device arranged outside the lathe is adopted to achieve automatic alignment of the barrel body; after the barrel is aligned, rough machining is conducted on the barrel, machining is conducted on the frame face of the other end of the barrel, after rough machining is completed, the barrel is hoisted to intelligent overturning equipment through a crane to be overturned and turned round, a matched outer flange positioning plate is installed on the machined end frame of the barrel, and after overturning is completed, the movable positioning plate of the unmachined end frame on the barrel is removed; preparation is made for the next working procedure; barrel datum conversion; the method is applied to alignment of the large aluminum alloy barrel.

Description

Technical Field

[0001] The invention provides an off-machine intelligent alignment processing method for a large aluminum alloy cylinder, belonging to the technical field of mechanical processing. Background Art

[0002] The aluminum alloy cylinder is welded by a cylinder and two end frames. Figure 1 As shown in the figure, the inner diameter of the cylinder is about φ2000mm~2400mm, and the length of various cylinders ranges from 2000mm to 4800mm. During the processing of the cylinder, the maximum mass is more than 3000Kg. After processing, the thickness of the cylinder wall is usually required to be greater than 14mm, the inner roundness is required to be 0.3mm, and the verticality between the end frame and the axis is 0.08mm. Among them, the inner diameter size, height size, relative position size and tolerance of the end frame end face and the inner diameter are the key elements of the cylinder, see Table 1. Such key elements directly determine the performance of the product.

[0003] Table 1 Cylinder tolerance indicators.

[0004] The above key elements are all completed by the vertical lathe processing process. The operation process involves the alignment of the workpiece. Since the cylinder is affected by welding deformation, alignment is difficult. At present, the main method is to use benchwork to mark to estimate the cylinder deviation, and the vertical lathe is aligned in the machine with reference to the processing line. It takes about 3 to 4 hours to align each cylinder. The entire alignment process is completed in the machine tool, which seriously affects the effective processing time of the machine tool and cannot meet the processing needs of mass production cylinders.

[0005] In order to solve a series of problems such as the difficulty in aligning the inner circle of the cylinder, the poor precision and low efficiency of manual alignment, and the difficulty in controlling wall thickness, an off-machine intelligent alignment technology was proposed to improve the efficiency of cylinder processing and realize rapid production change. Summary of the invention

[0006] In order to solve the above technical problems, the present invention proposes an off-machine intelligent alignment processing method for a large aluminum alloy cylinder.

[0007] The technical solution adopted by the present invention is: a large aluminum alloy cylinder off-machine intelligent alignment processing method, comprising the following steps: S1: Cylinder data measurement: Use a laser sensor to scan the inner wall of the cylinder and transmit the data to the data twin system. The data twin system processes the measured data to generate a virtual cylinder object. At the same time, the ideal cylinder model is generated in the data twin system according to the size requirements of the drawing. The two models of the cylinder are compared with the software to calculate the cylinder posture adjustment data. S2: cylinder posture adjustment: according to the cylinder position adjustment data calculated in step S1, the cylinder is automatically aligned by using an intelligent alignment device arranged outside the lathe; The intelligent alignment device comprises a base, a base plate is installed on the base, a plurality of aligning adjustment plates that can be raised and lowered are evenly arranged on the circumference of the base plate, a movable positioning plate is placed on the base plate, a plurality of positioning pins that cooperate with the movable positioning plate are also arranged at intervals on the base plate, a plurality of hydraulic servo actuators are evenly arranged around the base, and a control system is also installed in the base, the control system is used to control the movement of the hydraulic servo actuator and the alignment adjustment plate; First, a base plate is installed on the vertical lathe, and the base plate is adjusted to be concentric with the vertical lathe. Then, a movable positioning plate is installed on one end frame of the cylinder. Then, the movable positioning plate and the cylinder are placed on the base plate of the intelligent alignment device. The cylinder is automatically aligned through the intelligent alignment device. S3: Automatic turning over of the cylinder: After the cylinder is aligned, the combination of the cylinder and the movable positioning plate is transferred to the base plate of the vertical lathe, so that the movable positioning plate matches the base plate of the vertical lathe, and then the cylinder is rough-processed and the other end frame surface is processed. After the rough processing is completed, the cylinder is hoisted to the intelligent turning equipment by a crane for turning and turning, and the matching outer flange positioning plate is installed on the processed end frame of the cylinder. After the turning is completed, the movable positioning plate of the unprocessed end frame on the cylinder is removed to prepare for the next process; S4: Cylinder reference conversion: During the process of turning over the cylinder, the machined end frame is used as the reference for positioning, and an outer flange positioning plate matching the outer circle of the machined end frame is installed. The combination of the cylinder and the outer flange positioning plate matching the outer circle is moved to the vertical lathe, and the positioning pin holes on the outer flange positioning plate are matched with the base plate on the vertical lathe to complete the semi-finishing of the cylinder, and the concave and convex buckles and sealing grooves are finished, and finally the inner circle and cross-section processing of the cylinder are completed.

[0008] A vertical lathe turret is arranged in the center of the base of the intelligent alignment device, a linear guide rail is installed on the vertical lathe turret, a laser measuring head of a laser sensor is installed on the linear guide rail, and a control system is used to control the movement of the vertical lathe turret and the linear guide rail.

[0009] The alignment adjustment plates are provided with four, and the evenly spaced parts are on the circumference of the base, and are used to realize the vertical alignment of the cylinder. The lifting and lowering of the alignment adjustment plates are driven by hydraulic cylinders.

[0010] Four hydraulic servo actuators are evenly arranged around the base, and the four hydraulic servo actuators realize the horizontal alignment of the cylinder.

[0011] The alignment adjustment plate is a universal ball platform structure.

[0012] The movable positioning plates are provided in multiple sets.

[0013] In step S2, the steps of adjusting the cylinder in the vertical and horizontal directions by using the intelligent alignment device are as follows: First, the vertical alignment of the cylinder is achieved through four alignment adjustment plates of the universal ball platform structure, and then four hydraulic servo actuators are used to directly push the cylinder to achieve horizontal alignment of the cylinder.

[0014] In step S4, the cylinder reference conversion is realized by a cylinder quick-change structure, wherein the cylinder quick-change structure includes a base plate and a movable positioning plate having the same structure as that in the intelligent alignment device, and the base plate and the movable positioning plate are placed in the vertical lathe and the adjustment device respectively.

[0015] The laser sensor in step S1 is installed on the linear guide rail of the intelligent alignment device, and the laser sensor can fully scan the inner wall of the cylinder through the movement of the vertical lathe turret and the linear guide rail.

[0016] The data twin system converts the posture difference into the coordinate value of the control system of the intelligent alignment device, controls the horizontal and vertical adjustment devices through the control system, and adjusts the horizontal and vertical postures through hydraulic drive, ultimately controlling the inner circular axis of the cylinder and the theoretical axis within the error range required by the technology.

[0017] The beneficial effects of the present invention compared with the prior art are as follows: the present invention provides a large aluminum alloy cylinder outside the machine intelligent alignment processing method, which mainly includes the key processes of cylinder inner surface data measurement, vertical and horizontal automatic adjustment, cylinder flipping, reference conversion, etc. By transferring the alignment inside the vertical lathe to the outside of the machine, and using an intelligent alignment method instead of the manual alignment method on the vertical lathe, the alignment positioning accuracy is improved, human errors are eliminated, labor intensity is reduced, and wall thickness consistency is guaranteed, which meets mass production requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The present invention will be further described below in conjunction with the accompanying drawings: Figure 1 It is a schematic diagram of the cylinder appearance structure; Figure 2 This is a process flow chart of the cylinder body off-machine intelligent alignment processing proposed by the present invention; Figure 3 This is the flow chart of the intelligent alignment of the cylinder outside the machine proposed by the present invention; Figure 4 A schematic diagram of the three-dimensional structure of the intelligent alignment device proposed by the present invention; Figure 5 A top view of the intelligent alignment device proposed by the present invention; Figure 6 A side view of the intelligent alignment device proposed by the present invention; Figure 7 Adjust the flow chart for off-machine intelligence; Figure 8It is a structural schematic diagram of the outer flange positioning plate; Fig. 9 It is a structural schematic diagram of the matching of the outer flange positioning plate and the end frame; In the figure: 1 is the base, 2 is the base plate, 3 is the mobile positioning plate, 4 is the vertical lathe turret, 5 is the measuring column, 6 is the linear guide rail, 7 is the laser measuring head, 8 is the alignment adjustment plate, and 9 is the hydraulic servo actuator. DETAILED DESCRIPTION

[0019] like Figures 1 to 9 As shown, the present invention provides a method for intelligent alignment outside the machine for large aluminum alloy cylinders. This method is applied before rough turning and after aging treatment of the cylinders, realizing the separation of alignment outside the machine and operation inside the machine, and achieving zero change of production. Figure 2 shown.

[0020] The structure of the intelligent alignment device in the present invention is as follows: Figure 4-6 As shown, it includes a base 1, on which a base plate 2 is installed, and four alignment adjustment plates 8 are evenly arranged on the circumference of the base plate 2, and the four alignment adjustment plates 8 can realize up and down movement through corresponding lifting mechanisms, and a plurality of positioning pins are also arranged at intervals on the base plate 2, and a movable positioning plate 3 is placed on the base plate 2, and the movable positioning plate 3 can cooperate with the base plate 2, and a vertical lathe turret 4 is arranged in the center of the base 1, and a linear guide 6 is installed on the vertical lathe turret 4, and a laser measuring head 7 of a laser sensor is installed on the linear guide 6, and four hydraulic servo actuators 9 are evenly arranged around the base 1, and the four hydraulic servo actuators 9 can realize horizontal alignment of the cylinder, and a control system is also installed in the base 1, and the control system is used to control the movement of the hydraulic servo actuator 9, the vertical lathe turret 4, the linear guide 6 and the alignment adjustment plate 8.

[0021] A base plate 2 that cooperates with the movable positioning plate 3 is also installed on the vertical lathe. After the cylinder is horizontally and vertically aligned on the intelligent alignment device outside the machine, the cylinder is placed together with the movable positioning plate 3 on the base plate 2 of the vertical lathe, and there is no need to align the cylinder on the vertical lathe.

[0022] The alignment adjustment plate 8 can be driven by a hydraulic cylinder, and the alignment adjustment plate 8 is a platform with a plurality of universal balls on the top. The alignment of the cylinder in the vertical direction can be achieved through four alignment adjustment plates 8.

[0023] Furthermore, multiple sets of movable positioning plates 3 can be provided. When multiple vertical lathes are available, multiple movable positioning plates 3 can be used to realize the off-machine alignment of multiple cylinders, and then multiple cylinders can be placed on different vertical lathes for simultaneous processing without waiting, which can improve production efficiency.

[0024] The arrangement of the vertical lathe turret 4 and the linear guide rail 6 enables the laser measuring head 7 to scan the inner wall of the cylinder from top to bottom in all directions, and can collect a complete laser point cloud of the inner wall of the cylinder, thereby constructing a three-dimensional model of the inner wall of the cylinder.

[0025] The process of the cylinder body's off-machine intelligent alignment is as follows: place the mobile positioning plate 3 on the base plate 2 of the off-machine intelligent alignment device, place the cylinder body on the mobile positioning plate 3 (with the front end frame end face facing down) for automatic alignment of the cylinder body, and after the cylinder body is aligned, place the combination of the cylinder body and the mobile positioning plate 3 on the base plate 2 of the machine tool together, unify the positioning reference in the off-machine intelligent alignment device and the reference of the internal circle processing equipment of the vertical lathe, and the cooperation of the mobile positioning plate 3 and the base plate 2 can achieve fast and accurate positioning, and then directly perform rough processing and rear end frame end face processing. After the rough processing is completed, the cylinder body is turned around by using the intelligent flipping equipment. During the turning process, the processed rear end frame is used as the reference, and the mobile positioning plate 3 matching the outer circle of the end frame is installed, and the combination of the cylinder body and the mobile positioning plate 3 is transferred to the vertical lathe for semi-finishing and finishing, and concave and convex buckles and sealing grooves are made, and finally the cylinder body production is completed. Since there is no need to align again on the machine tool for direct processing, multiple sets of mobile positioning plates 3 can be set up, and rapid production change can be achieved under the condition of having a set of off-machine intelligent alignment devices.

[0026] The method of realizing the intelligent alignment processing of the cylinder outside the machine by using the intelligent alignment device proposed in the present invention mainly involves four steps: cylinder data measurement, cylinder posture adjustment, cylinder automatic flipping and cylinder reference conversion.

[0027] S1: Cylinder data measurement: The inner diameter of the large cylinder is measured by the laser measuring head 7 in the intelligent alignment device, and the data is transmitted to the data twin system. The data twin system processes the measured data and generates a virtual cylinder object. At the same time, the ideal cylinder model is generated in the data twin system according to the size requirements of the drawing. The two models of the cylinder are compared by software, and the cylinder posture adjustment data is calculated so that the wall thickness meets the design requirements after the inner circle is processed and formed. The posture adjustment data is transmitted to the control system of the intelligent alignment device, and a control instruction is generated to drive the servo electric cylinder of the hydraulic servo actuator 9 and the hydraulic cylinder of the alignment adjustment plate 8 to adjust the posture of the cylinder.

[0028] Specifically, the inner wall of the cylinder is scanned by a laser sensor, and the measurement data is transmitted to the data twin system. The data twin system analyzes and compares the measurement data with the theoretical data and calculates the posture difference. The posture difference is then converted into the coordinate value of the control system. The control system controls the horizontal and vertical adjustment devices, and adjusts the horizontal and vertical postures through hydraulic drive, so that the inner cylindrical axis of the cylinder and the theoretical axis are finally controlled within the error range required by the technology.

[0029] S2: Cylinder posture adjustment: First, install a base plate 2 on the vertical lathe, and adjust the base plate 2 to make it concentric with the vertical lathe, then assemble the cylinder and the movable positioning plate 3, that is, install the movable positioning plate 3 on one end frame of the cylinder, and then place the movable positioning plate 3 together with the cylinder on the base plate 2 of the intelligent alignment device, and realize automatic alignment of the cylinder through the intelligent alignment device.

[0030] The intelligent alignment device can be adjusted in both vertical and horizontal directions to meet the alignment requirements. Vertical adjustment is used for vertical alignment, which is achieved through four alignment adjustment plates 8 with universal ball platform structures. The movement of the four alignment adjustment plates 8 is achieved by hydraulic cylinders. Horizontal adjustment is used for radial alignment, which requires adjustment of two degrees of freedom, and is achieved by directly pushing the cylinder with a hydraulic servo actuator 9. During the radial alignment process, the hydraulic servo actuator 9 performs flexible support control on the cylinder to avoid unnecessary damage to the cylinder.

[0031] S3: Automatic cylinder flipping: After the cylinder is aligned, the combination of the cylinder and the movable positioning plate 3 is transferred to the base plate 2 of the vertical lathe, so that the movable positioning plate 3 matches the base plate 2 of the vertical lathe, and rough processing is performed. The cylinder is then hoisted by a crane, and the crane slowly places the cylinder on the intelligent flipping device, and a matching outer flange positioning plate is installed on the processed end frame of the cylinder. The fixture of the intelligent flipping device rotates 180 degrees, tightens inward under the action of the hydraulic cylinder, and clamps the outer flange of the cylinder to ensure that the cylinder does not become a cantilever beam and produce too much deformation during the flipping process. Then the intelligent flipping device drives the fixture and the cylinder to rotate 180 degrees together, and removes the movable positioning plate 3 on the top after flipping (that is, the movable positioning plate 3 of the unprocessed end frame). Prepare for the next process.

[0032] Specifically, the intelligent flipping device can use a hydraulic system as a driving device. The cylinder is placed on the intelligent flipping device, and the clamp is rotated 180 degrees. It is tightened inward under the action of the hydraulic cylinder to clamp the cylinder to ensure that the cylinder does not deform too much during the flipping process.

[0033] This embodiment does not limit the specific structure of the intelligent turning device, as long as it can achieve the purpose of turning the cylinder.

[0034] S4: Cylinder base conversion: The base conversion of the cylinder is realized by the cylinder quick-change structure, wherein the cylinder quick-change structure includes the same structure as the base plate 2, the outer flange positioning plate, the quick clamping mechanism, the stopper positioning, etc., which are used for rapid positioning and clamping. There are six positioning pins on the base plate 2 for positioning the outer flange, and the zero-point positioning method is used to improve the positioning accuracy.

[0035] The function of the outer flange positioning plate is similar to that of the movable positioning plate 3, but there are differences. The outer flange positioning plate must match the rough-machined end frame of the cylinder. There is a gap of less than 0.03mm between the outer flange positioning plate and the end frame to ensure the coaxiality requirements of the outer flange positioning plate and the end frame after assembly. Figure 8 and 9 As shown, Figure 8 The structure of the outer flange positioning plate. Fig. 9 It is a structural schematic diagram of the matching of the outer flange positioning plate and the end frame.

[0036] The base plate 2 and the movable positioning plate 3 used in the present invention are set, and are placed in the vertical lathe and the intelligent alignment device respectively; an external flange positioning plate is also provided, which is placed in the vertical lathe position and is used to transfer the positioning accuracy through the outer circle during the U-turn processing. And the external flange positioning plate is also matched with the base plate 2.

[0037] The present invention adopts the base plate 2, the movable positioning plate 3 and the outer flange positioning plate to realize intelligent alignment of the cylinder and after flipping the cylinder, the cylinder reference and the lathe reference are quickly converted, and the quick-change repeated positioning accuracy is no more than 0.03mm.

[0038] 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 they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do 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 large aluminum alloy cylinder off-machine intelligent alignment processing method, characterized by: The following steps are involved: S1: Cylinder data measurement: Use a laser sensor to scan the inner wall of the cylinder and transmit the data to the data twin system. The data twin system processes the measured data to generate a virtual cylinder object. At the same time, the ideal cylinder model is generated in the data twin system according to the size requirements of the drawing. The two models of the cylinder are compared with the software to calculate the cylinder posture adjustment data. S2: cylinder posture adjustment: according to the cylinder position adjustment data calculated in step S1, the cylinder is automatically aligned by using an intelligent alignment device arranged outside the lathe; The intelligent alignment device comprises a base, a base plate is installed on the base, a plurality of aligning adjustment plates that can be raised and lowered are evenly arranged on the circumference of the base plate, a movable positioning plate is placed on the base plate, a plurality of positioning pins that cooperate with the movable positioning plate are also arranged at intervals on the base plate, a plurality of hydraulic servo actuators are evenly arranged around the base, and a control system is also installed in the base, the control system is used to control the movement of the hydraulic servo actuator and the alignment adjustment plate; First, a base plate is installed on the vertical lathe, and the base plate is adjusted to be concentric with the vertical lathe. Then, a movable positioning plate is installed on one end frame of the cylinder. Then, the movable positioning plate and the cylinder are placed on the base plate of the intelligent alignment device. The cylinder is automatically aligned through the intelligent alignment device. S3: Automatic turning over of the cylinder: After the cylinder is aligned, the combination of the cylinder and the movable positioning plate is transferred to the base plate of the vertical lathe, so that the movable positioning plate matches the base plate of the vertical lathe, and then the cylinder is rough-processed and the other end frame surface is processed. After the rough processing is completed, the cylinder is hoisted to the intelligent turning equipment by a crane for turning and turning, and the matching outer flange positioning plate is installed on the processed end frame of the cylinder. After the turning is completed, the movable positioning plate of the unprocessed end frame on the cylinder is removed to prepare for the next process; S4: Cylinder reference conversion: During the process of turning over the cylinder, the machined end frame is used as the reference for positioning, and an outer flange positioning plate matching the outer circle of the machined end frame is installed. The combination of the cylinder and the outer flange positioning plate matching the outer circle is moved to the vertical lathe, and the positioning pin holes on the outer flange positioning plate are matched with the base plate on the vertical lathe to complete the semi-finishing of the cylinder, and the concave and convex buckles and sealing grooves are finished, and finally the inner circle and cross-section processing of the cylinder are completed.

2. According to claim 1, a large aluminum alloy cylinder off-machine intelligent alignment processing method is characterized by: A vertical lathe turret is arranged in the center of the base of the intelligent alignment device, a linear guide rail is installed on the vertical lathe turret, a laser measuring head of a laser sensor is installed on the linear guide rail, and a control system is used to control the movement of the vertical lathe turret and the linear guide rail.

3. According to claim 2, a large aluminum alloy cylinder off-machine intelligent alignment processing method is characterized by: The alignment adjustment plates are provided with four, and the evenly spaced parts are on the circumference of the base, and are used to realize the vertical alignment of the cylinder. The lifting and lowering of the alignment adjustment plates are driven by hydraulic cylinders.

4. According to claim 3, a large aluminum alloy cylinder off-machine intelligent alignment processing method is characterized by: Four hydraulic servo actuators are evenly arranged around the base, and the four hydraulic servo actuators realize the horizontal alignment of the cylinder.

5. According to claim 3, a large aluminum alloy cylinder off-machine intelligent alignment processing method is characterized by: The alignment adjustment plate is a universal ball platform structure.

6. The method for intelligent alignment of a large aluminum alloy cylinder outside the machine according to claim 1 is characterized in that: The movable positioning plates are provided in multiple sets.

7. According to claim 4, a large aluminum alloy cylinder off-machine intelligent alignment processing method is characterized by: In step S2, the steps of adjusting the cylinder in the vertical and horizontal directions by using the intelligent alignment device are as follows: First, the vertical alignment of the cylinder is achieved through four alignment adjustment plates of the universal ball platform structure, and then four hydraulic servo actuators are used to directly push the cylinder to achieve horizontal alignment of the cylinder.

8. The method for intelligent alignment of a large aluminum alloy cylinder outside the machine according to claim 1 is characterized in that: In step S4, the cylinder reference conversion is realized by a cylinder quick-change structure, wherein the cylinder quick-change structure includes a base plate and a movable positioning plate having the same structure as that in the intelligent alignment device, and the base plate and the movable positioning plate are placed in the vertical lathe and the adjustment device respectively.

9. The method for intelligent alignment of a large aluminum alloy cylinder outside the machine according to claim 7, characterized in that: The laser sensor in step S1 is installed on the linear guide rail of the intelligent alignment device, and the laser sensor fully scans the inner wall of the cylinder through the movement of the vertical lathe turret and the linear guide rail.

10. The method for intelligent alignment of a large aluminum alloy cylinder outside the machine according to claim 9, characterized in that: The data twin system converts the posture difference into the coordinate value of the control system of the intelligent alignment device, controls the horizontal and vertical adjustment devices through the control system, and adjusts the horizontal and vertical postures through hydraulic drive, ultimately controlling the inner circular axis of the cylinder and the theoretical axis within the error range required by the technology.

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