Torque distribution test system for screw gun

Abstract

The invention discloses a screw gun torque distribution test system, which comprises an electric gun, a torque test terminal, a data transmission network and a central processing platform, the electric gun is used for simulating a continuous screw driving process, the torque test terminal comprises a torque sensor, a microprocessor, a wireless communication module, a buffer, a terminal control cabinet and a support, the data transmission network is used for connecting the torque test terminal and the central processing platform and is also used for real-time transmission and sharing of data, the central processing platform is constructed based on cloud computing or a high-performance server and is used for receiving, storing, analyzing and processing torque data, and the electric gun is connected with the buffer and the torque sensor. The system can monitor the torque data of each station in real time and give out early warning immediately when abnormity is found, so that the product quality is remarkably improved. In conclusion, the scheme has the advantages of real-time monitoring and early warning, reduction of reject ratio, improvement of customer satisfaction, improvement of production efficiency and reduction of cost.

Description

Technical Field

[0001] The invention belongs to the technical field of mechanical equipment, and in particular relates to a screw gun torque distribution testing system. Background Art

[0002] In the current industrial field, screw guns, as the core equipment of fastening tools, have shown a steady growth in market size. For enterprises, screw gun torque supervision is an important link to ensure product quality and production safety.

[0003] At present, the commonly used torque monitoring methods mainly include torque wrenches, torque meters, torque sensors, etc. However, these monitoring methods have certain shortcomings. Torque wrenches need to be measured manually, there are subjective errors, and the measurement accuracy is affected by the quality and calibration status of the wrench itself; there are many types of torque meters, which need to be selected according to accuracy and measurement range, and the accuracy will decrease in the case of long-term use or improper maintenance; at the same time, the cost of torque sensors is high, and the installation and calibration process is complicated, which increases the detection cost, and the accuracy is easily affected by environmental interference. In addition, these methods require manual measurement, which is affected by the subjective consciousness of personnel, and it is easy to put the detection equipment on the shelf. Therefore, it is easy to cause inadequate torque supervision, unstable equipment quality, fastener failure and other product quality problems, which are easy to cause production safety hazards, affect equipment life and cost, and then affect the reputation of the enterprise, causing the competitiveness of the enterprise to decline.

[0004] Therefore, the present invention provides a screw gun torque distribution testing system for solving the problems raised by the above-mentioned background technology. Summary of the invention

[0005] In view of the problems raised by the above background technology, the purpose of the present invention is to provide a screw gun torque distribution test system, which has the advantages of real-time monitoring and early warning, reducing the failure rate, improving customer satisfaction, improving production efficiency and reducing costs.

[0006] In order to achieve the above technical objectives, the technical solution adopted by the present invention is as follows:

[0007] The screw gun torque distribution test system includes an electric gun, which is used to simulate the process of continuous screwing, and also includes a torque test terminal, a data transmission network and a central processing platform. The torque test terminal includes a torque sensor, a microprocessor, a wireless communication module, a buffer, a terminal control cabinet and a bracket. The data transmission network is used to connect the torque test terminal and the central processing platform, and is also used for real-time transmission and sharing of data. The central processing platform is built based on cloud computing or a high-performance server, and is used to receive, store, analyze and process torque data. The electric gun is connected to the buffer and the torque sensor.

[0008] It is further defined that the buffer also includes a ball screw, a spring, a guide shaft, an upper seat, an upper cover, a lower seat and a lower cover, the ball screw is arranged through the middle of the buffer, the upper cover is arranged at the top of the ball screw, the upper seat is arranged at the top of the upper cover, the lower cover is arranged at the bottom of the ball screw, the lower seat is arranged at the bottom of the lower cover, the spring is arranged around the periphery of the ball screw, the top of the spring is connected to the upper cover, and the bottom is connected to the lower cover, the two guide shafts are respectively arranged on both sides of the ball screw, the top of the guide shaft is connected to the upper cover, and the bottom is connected to the lower cover.

[0009] It is further defined that it also includes a nut plate, a limit sleeve, an oil-free bearing and a reinforcement strip, the nut plate is embedded in the ball screw and the guide shaft, the limit sleeve is arranged on the nut plate, the oil-free bearing is connected to the guide shaft, and the reinforcement strip is fixedly connected to the upper seat.

[0010] It is further defined that the terminal control cabinet includes a touch screen, a PLC controller, a wireless bridge and an alarm light.

[0011] It is further defined that the data transmission network uses a wireless bridge to receive data from the torque test terminal.

[0012] It is further defined that the torque sensor is a strain gauge torque sensor.

[0013] It is further defined that the buffer is made of stainless steel or alloy steel, and the spring is provided with a damping mechanism, and the damping mechanism is used to slow down the transmission speed of the shock wave and reduce the vibration amplitude.

[0014] It is further defined that both ends of the torque sensor are connected by flanges.

[0015] It is further defined that it also includes a data processing platform developed based on Python, and the data processing platform includes functional modules for system login, line management, workstation data, historical records and statistical data.

[0016] A design method for a screw gun torque distribution test system comprises the following steps:

[0017] S1: Design mechanical structure and buffer mechanism;

[0018] S2: Use wireless communication technology to ensure real-time and stable data upload;

[0019] S3: Collect data, filter and remove noise, clean the data, unify the format, and shield irrelevant signal interference;

[0020] S4: Data processing, real-time processing and storage of collected data for further analysis;

[0021] S5: Result push, generate result push for users to review and make decisions.

[0022] It is further defined that the mechanical structure of S1 specifically comprises the following steps:

[0023] S11: The mechanical structure is made of stainless steel or alloy steel to adapt to harsh production environment;

[0024] S12: The mechanical structure is designed with elastic elements and a damping structure to ensure the stability of the internal sensor and reduce damage caused by vibration;

[0025] S13: Flanges are designed on both sides of the sensor, taking full consideration of sealing and tightening force to ensure reliable connection without leakage;

[0026] The specific steps of the wireless communication technology of S2 are:

[0027] Step S21: Design a dedicated network communication module, which supports AP 2.4G network and Gigabit Ethernet communication modes, and can ensure real-time transmission and remote management of data;

[0028] The data processing in step S3 is specifically as follows:

[0029] Step S31: The guide shaft is equipped with multiple sets of strain gauges. When the elastic shaft is deformed, the strain gauges are stretched or compressed, causing their resistance values ​​to change. The torque is measured by calculating the linear relationship between the resistance change and the applied torque.

[0030] Step S32: Amplifying the signal through a precision operational amplifier to improve the signal-to-noise ratio of the signal, making it easier to be captured and processed by subsequent circuits;

[0031] Step S33: The A / D converter converts the continuous analog signal into a discrete digital signal to facilitate signal transmission and processing;

[0032] The data processing of step S4 is specifically as follows:

[0033] Step S41: the data processing and analysis module monitors the received torque data in real time and compares it with a preset threshold range;

[0034] Step S42: Statistical analysis, analyzing the change trend of the torque data by statistical analysis methods, including the average value, standard deviation, maximum value and minimum value, so as to understand the overall fluctuation of the torque;

[0035] The result push of step S5 is specifically as follows:

[0036] Step S51: Based on the data analysis results, the system can automatically generate various types of reports, including daily reports, weekly reports and monthly reports for viewing statistical results and abnormal records;

[0037] Step S52: Provide data visualization function to display the overall situation and change trend of torque data in the form of charts, dashboards and heat maps for easy viewing and analysis.

[0038] Beneficial effects of the present invention:

[0039] 1. Real-time monitoring and early warning: The system can monitor the torque data of each workstation in real time and issue an early warning immediately when an abnormality is found; this greatly reduces quality problems caused by improper torque control and improves product consistency and reliability.

[0040] 2. Reduce the unqualified rate: Before the application of this system, the unqualified rate of products was as high as 5% due to improper torque control. After the application of this system, through real-time monitoring and early warning, the unqualified rate was reduced to less than 1%, which significantly improved the product quality.

[0041] 3. Improve customer satisfaction: The improvement of product quality directly leads to the improvement of customer satisfaction. Customer feedback shows that the assembly quality and stability of the product have been significantly improved, reducing customer complaints and returns caused by quality problems.

[0042] 4. Improve production efficiency: The system can detect torque problems in time, avoiding time wasted on rework and waste disposal. Production efficiency has therefore increased by about 15%, saving the company a lot of manpower, material resources and time costs.

[0043] 5. Reduce costs: By reducing the cost of returns, repairs and compensation due to quality issues, companies can save millions of yuan each year. In addition, the system also reduces the time and labor costs of manual inspection, further reducing production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The present invention can be further illustrated by the non-limiting examples given in the accompanying drawings;

[0045] Figure 1 A system structure diagram of an embodiment of a screw gun torque distribution test system of the present invention;

[0046] Figure 2 It is a structural schematic diagram of an embodiment of a screw gun torque distribution testing system of the present invention;

[0047] Figure 3 It is a front view of an embodiment of a screw gun torque distribution testing system of the present invention;

[0048] Figure 4It is a schematic diagram of the overall structure of an embodiment of a screw gun torque distribution test system of the present invention;

[0049] Figure 5 This is a system interface diagram of an embodiment of a screw gun torque distribution test system of the present invention;

[0050] Figure 6 This is a diagram of the system background management interface of an embodiment of the screw gun torque distribution test system of the present invention.

[0051] The symbols of the main components are described as follows: ball screw 1, nut plate 2, limit sleeve 3, spring 4, oil-free bearing 5, guide shaft 6, upper seat 7, upper cover 8, lower seat 9, lower cover 10, reinforcement strip 11, buffer 12, torque sensor 13, terminal control cabinet 14, bracket 15. DETAILED DESCRIPTION

[0052] In order to enable those skilled in the art to better understand the present invention, the technical solution of the present invention is further described below in conjunction with the accompanying drawings and embodiments. The technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in the field without creative work are within the scope of protection of the present invention.

[0053] It should be noted that all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back, etc.) are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0054] In addition, the descriptions of "first", "second", etc. in the present invention are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in the field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0055] like Figure 1As shown, the screw gun torque distribution test system of the present invention includes an electric gun, which is used to simulate the process of continuous screwing, and also includes a torque test terminal, a data transmission network and a central processing platform. The torque test terminal includes a torque sensor 13, a microprocessor, a wireless communication module, a buffer 12, a terminal control cabinet 14 and a bracket 15. The data transmission network is used to connect the torque test terminal and the central processing platform, and is also used for real-time transmission and sharing of data. The central processing platform is built based on cloud computing or a high-performance server, and is used to receive, store, analyze and process torque data. The electric gun is connected to the buffer 12 and the torque sensor 13.

[0056] The system of the present invention mainly consists of three parts: torque test terminal, data transmission network and central processing platform. The torque test terminal is responsible for collecting the torque data of the electric gun, comparing it in real time, and uploading the data to the central processing platform through the data transmission network. The platform stores, analyzes and processes the data, and sends warnings and control instructions to relevant personnel. The following is a detailed introduction to these three parts:

[0057] ① Torque test terminal: It is the front-end sensing layer of the entire system, responsible for directly collecting the torque data of the electric gun. The terminal integrates a high-precision torque sensor, a microprocessor, a wireless communication module, and necessary buffer mechanisms to ensure the accuracy and real-time nature of data collection. The terminal can compare the torque parameters issued by the software in real time, and send the collected data to the central processing platform through the wireless communication module.

[0058] ②Data transmission network: It is a bridge connecting the torque test terminal and the central processing platform, responsible for real-time data transmission and sharing. Data from the terminal is received through a wireless bridge, which reduces network wiring, reduces the failure rate, and facilitates maintenance and repair.

[0059] ③ Central processing platform: It is the core of the whole system and is responsible for receiving, storing, analyzing and processing data. The platform is built on cloud computing or high-performance servers and has strong data processing capabilities. Through the developed data processing algorithm, the received torque data is deeply analyzed and mined to generate reports, early warning information and control instructions. The platform also provides a user-friendly visual interface to facilitate managers to monitor production data in real time and make remote decisions.

[0060] Preferably, the buffer 12 also includes a ball screw 1, a spring 4, a guide shaft 6, an upper seat 7, an upper cover 8, a lower seat 9 and a lower cover 10. The ball screw 1 is arranged through the middle of the buffer 12, the upper cover 8 is arranged at the top of the ball screw 1, the upper seat 7 is arranged at the top of the upper cover 8, the lower cover 10 is arranged at the bottom of the ball screw 1, and the lower seat 9 is arranged at the bottom of the lower cover 10. The spring 4 is arranged around the periphery of the ball screw 1, the top of the spring 4 is connected to the upper cover 8, and the bottom is connected to the lower cover 10. The two guide shafts 6 are respectively arranged on both sides of the ball screw 1, the top of the guide shaft 6 is connected to the upper cover 8, and the bottom is connected to the lower cover 10.

[0061] Preferably, it also includes a nut plate 2, a limit sleeve 3, an oil-free bearing 5 and a reinforcement strip 11, the nut plate 2 is embedded in the ball screw 1 and the guide shaft 6, the limit sleeve 3 is arranged on the nut plate 2, the oil-free bearing 5 is connected to the guide shaft, and the reinforcement strip 11 is fixedly connected to the upper seat 7.

[0062] Preferably, the terminal control cabinet 14 includes a touch screen, a PLC controller, a wireless bridge and an alarm light.

[0063] Preferably, the data transmission network uses a wireless bridge to receive data from the torque test terminal.

[0064] Preferably, the torque sensor adopts a strain gauge torque sensor. The sensor uses the American FNT-98A-50NM strain gauge torque sensor as the core measuring element. The sensor has high sensitivity, low linear error and good temperature stability, which can ensure high-precision torque measurement in various industrial environments. The core component inside the sensor is a high-precision elastic shaft, which will produce a small deformation when subjected to torque.

[0065] Preferably, the buffer is made of stainless steel or alloy steel, and a damping mechanism is provided on the spring 4, and the damping mechanism is used to slow down the transmission speed of the shock wave and reduce the vibration amplitude.

[0066] Preferably, both ends of the torque sensor 13 are connected by flanges.

[0067] Preferably, it also includes a data processing platform developed based on Python, which includes functional modules for system login, line management, workstation data, historical records and statistical data. Users can view production data in real time, receive warning information, adjust torque parameters, etc. through the interface to achieve interactive operations with the system. It also has data storage, analysis and visualization functions. The platform receives data from various terminals, performs real-time processing and analysis, and generates warnings and control instructions based on preset thresholds. The software system interface is shown in the figure below. Figure 5 As shown:

[0068] The backend management interface automatically generates various types of reports based on the data analysis results, such as daily reports, weekly reports, monthly reports, etc., to display the overall situation and change trend of torque data. It provides a variety of chart display forms to visualize the data, so that users can intuitively understand the information behind the data; it supports the export function of reports, and users can export reports in Excel, PDF and other formats for subsequent analysis and use.

[0069] Backend management interface such as Figure 5 and Figure 6 As shown: A design method for a screw gun torque distribution test system includes the following steps:

[0070] S1: Design mechanical structure and buffer mechanism;

[0071] S2: Use wireless communication technology to ensure real-time and stable data upload;

[0072] S3: Collect data, filter and remove noise, clean the data, unify the format, and shield irrelevant signal interference;

[0073] S4: Data processing, real-time processing and storage of collected data for further analysis;

[0074] S5: Result push, generate result push for users to review and make decisions.

[0075] Preferably, the mechanical structure of S1 specifically comprises the following steps:

[0076] S11: The mechanical structure is made of stainless steel or alloy steel to adapt to harsh production environment;

[0077] S12: The mechanical structure is designed with elastic elements and a damping structure to ensure the stability of the internal sensor and reduce damage caused by vibration;

[0078] S13: Flanges are designed on both sides of the sensor, taking full consideration of sealing and tightening force to ensure reliable connection without leakage;

[0079] The specific steps of the wireless communication technology of S2 are:

[0080] Step S21: Design a dedicated network communication module, which supports AP 2.4G network and Gigabit Ethernet communication modes, and can ensure real-time transmission and remote management of data;

[0081] The data processing in step S3 is specifically as follows:

[0082] Step S31: The guide shaft 6 is equipped with multiple sets of strain gauges. When the elastic shaft is deformed, the strain gauges are stretched or compressed, causing their resistance values ​​to change. The torque is measured by calculating the linear relationship between the resistance change and the applied torque.

[0083] Step S32: Amplifying the signal through a precision operational amplifier to improve the signal-to-noise ratio of the signal, making it easier to be captured and processed by subsequent circuits;

[0084] Step S33: The A / D converter converts the continuous analog signal into a discrete digital signal to facilitate signal transmission and processing;

[0085] The data processing of step S4 is specifically as follows:

[0086] Step S41: the data processing and analysis module monitors the received torque data in real time and compares it with a preset threshold range;

[0087] Step S42: Statistical analysis, analyzing the change trend of the torque data by statistical analysis methods, including the average value, standard deviation, maximum value and minimum value, so as to understand the overall fluctuation of the torque;

[0088] The result push of step S5 is specifically as follows:

[0089] Step S51: Based on the data analysis results, the system can automatically generate various types of reports, including daily reports, weekly reports and monthly reports for viewing statistical results and abnormal records;

[0090] Step S52: Provide data visualization function to display the overall situation and change trend of torque data in the form of charts, dashboards and heat maps for easy viewing and analysis.

[0091] The mechanical buffer structure is specifically as follows:

[0092] The design of the buffer takes the following aspects into consideration:

[0093] (1) Material selection:

[0094] High-strength and high-toughness stainless steel or alloy steel are used as the main materials. These materials not only have excellent mechanical properties, but also can maintain stable performance in harsh environments.

[0095] (2) Structural design:

[0096] Design elastic elements (springs) and place them between the core components of the sensor and the external environment as the first layer of buffering. When external impact force acts on the sensor, the elastic element deforms first, absorbing and dissipating part of the energy.

[0097] On the basis of elastic elements, damping mechanisms (rubber damping pads) are added to further slow down the transmission speed of shock waves and reduce the vibration amplitude. Ensure that the connection between all buffer elements and the sensor main structure is firm and reliable to prevent performance degradation or damage caused by loose connections.

[0098] Flange connection design, both ends of the sensor are connected with flanges, which is convenient for quick and accurate connection with the measurement object. The design of the flange takes into account factors such as sealing and uniform distribution of tightening force to ensure a firm connection without leakage.

[0099] The data processing modules are as follows:

[0100] Through a series of preprocessing, stable data is obtained. The data processing and analysis module monitors the received torque data in real time and compares it with the preset threshold range. Once the torque data is found to be beyond the normal range, the system will immediately trigger the alarm mechanism and send early warning information to relevant personnel through various means such as sound, SMS, and email. At the same time, the system will also record abnormal data to provide materials for subsequent analysis.

[0101] The above embodiments are merely illustrative of the principles and effects of the present invention, and are not intended to limit the present invention. Anyone familiar with the technology may modify or change the above embodiments without violating the spirit and scope of the present invention. Therefore, all equivalent modifications or changes made by those with ordinary knowledge in the technical field without departing from the spirit and technical ideas disclosed by the present invention should still be covered by the claims of the present invention.

Claims

1. A screw gun torque distribution test system, comprising an electric gun, which is used to simulate the process of continuous screwing, and is characterized by: It also includes a torque test terminal, a data transmission network and a central processing platform. The torque test terminal includes a torque sensor (13), a microprocessor, a wireless communication module, a buffer (12), a terminal control cabinet (14) and a bracket (15). The data transmission network is used to connect the torque test terminal and the central processing platform, and is also used for real-time transmission and sharing of data. The central processing platform is built based on cloud computing or a high-performance server and is used to receive, store, analyze and process torque data. The electric gun is connected to the buffer (12) and the torque sensor (13).

2. The screw gun torque distribution test system according to claim 1, characterized in that: The buffer (12) further comprises a ball screw (1), a spring (4), a guide shaft (6), an upper seat (7), an upper cover (8), a lower seat (9) and a lower cover (10); the ball screw (1) is arranged through the middle of the buffer (12); the upper cover (8) is arranged at the top of the ball screw (1); the upper seat (7) is arranged at the top of the upper cover (8); the lower cover (10) is arranged at the bottom of the ball screw (1); the lower seat (9) is arranged at the bottom of the lower cover (10); the spring (4) is arranged around the periphery of the ball screw (1); the top of the spring (4) is connected to the upper cover (8) and the bottom is connected to the lower cover (10); the two guide shafts (6) are respectively arranged on both sides of the ball screw (1); the top of the guide shaft (6) is connected to the upper cover (8) and the bottom is connected to the lower cover (10); It also includes a nut plate (2), a limiting sleeve (3), an oil-free bearing (5) and a reinforcement strip (11); the nut plate (2) is embedded in the ball screw (1) and the guide shaft (6); the limiting sleeve (3) is arranged on the nut plate (2); the oil-free bearing (5) is connected to the guide shaft; and the reinforcement strip (11) is fixedly connected to the upper seat (7).

3. The screw gun torque distribution test system according to claim 1, characterized in that: The terminal control cabinet (14) comprises a touch screen, a PLC controller, a wireless bridge and an alarm light, and the data transmission network uses a wireless bridge to receive data from the torque test terminal.

4. The screw gun torque distribution test system according to claim 1, characterized in that: The torque sensor is a strain gauge torque sensor.

5. The screw gun torque distribution test system according to claim 1, characterized in that: The buffer is made of stainless steel or alloy steel, and a damping mechanism is provided on the spring (4), and the damping mechanism is used to slow down the transmission speed of the shock wave and reduce the vibration amplitude.

6. The screw gun torque distribution test system according to claim 1, characterized in that: Both ends of the torque sensor (13) are connected by flanges.

7. The screw gun torque distribution test system according to claim 1, characterized in that: It also includes a data processing platform developed based on Python, which includes functional modules for system login, line management, workstation data, historical records and statistical data.

8. A design method for a screw gun torque distribution test system, characterized in that: The steps include: S1: Design mechanical structure and buffer mechanism; S2: Use wireless communication technology to ensure real-time and stable data upload; S3: Collect data, filter and remove noise, clean the data, unify the format, and shield irrelevant signal interference; S4: Data processing, real-time processing and storage of collected data for further analysis; S5: Result push, generate result push for users to review and make decisions.

9. The design method of the screw gun torque distribution test system according to claim 8, characterized in that: The specific steps of the mechanical structure of S1 are: S11: The mechanical structure is made of stainless steel or alloy steel; S12: Mechanical structure design elastic elements and add damping structure; S13: Flanges are designed on both sides of the sensor; The specific steps of the wireless communication technology of S2 are: Step S21: Design a dedicated network communication module, the network communication module supports AP 2.4G network and Gigabit Ethernet communication modes; The data processing in step S3 is specifically as follows: Step S31: The guide shaft (6) is equipped with multiple sets of strain gauges. When the elastic shaft is deformed, the strain gauges are stretched or compressed, causing their resistance values ​​to change. The torque is measured by calculating the linear relationship between the resistance change and the applied torque. Step S32: Amplifying the signal through a precision operational amplifier to improve the signal-to-noise ratio; Step S33: The A / D converter converts the continuous analog signal into a discrete digital signal; The data processing of step S4 is specifically as follows: Step S41: the data processing and analysis module monitors the received torque data in real time and compares it with a preset threshold range; Step S42: Statistical analysis, analyzing the change trend of the torque data by statistical analysis methods, including the mean value, standard deviation, maximum value and minimum value; The result push of step S5 is specifically as follows: Step S51: Based on the data analysis results, the system can automatically generate various types of reports, including daily reports, weekly reports and monthly reports; Step S52: Provide data visualization function to display the overall situation and change trend of torque data in the form of charts, dashboards and heat maps.

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