Intelligent production line for frame cross member parts and production method thereof

Abstract

The invention discloses an intelligent production line for vehicle frame cross member parts and a production method thereof. The automatic sorting and stacking system comprises a frame cross beam steel plate punching area, a frame cross beam steel plate cutting area, a frame cross beam automatic sorting and stacking area and an automatic conveying system penetrating through the frame cross beam steel plate punching area, the frame cross beam steel plate cutting area and the frame cross beam automatic sorting and stacking area. According to the intelligent production line for the frame cross beam parts, a punching system, a cutting system, an automatic cross beam sorting and stacking system and an automatic conveying system are integrated, full-automatic production of the frame cross beam parts is achieved through informatization control of the production line, the production efficiency and the intelligent level of frame cross beams are improved, and the manufacturing cost of a workshop is reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of automobile manufacturing, and in particular relates to an intelligent production line for frame crossbeam parts and a production method thereof. Background Art

[0002] As an important equipment for logistics transportation and engineering construction, the structural strength and stability of commercial vehicles are of vital importance. The frame crossbeam is an important component of the frame, and its processing quality and precision have a decisive influence on the performance of the entire frame.

[0003] Traditionally, the production of frame crossbeam parts mainly adopts a single-machine production method. Each process is independent of each other, and manual material transfer and loading and unloading operations are required. Specifically, the punching, cutting, and sorting of frame crossbeam steel plates are usually completed independently by different equipment. The workpieces need to be transferred between the processes manually or by simple mechanical equipment. The following problems exist in the production process:

[0004] 1. Low production efficiency: The material transfer between processes requires a lot of manpower and material resources, the process switching time is long, and the overall production efficiency is low;

[0005] 2. High labor intensity: Operations such as loading and unloading and transportation of workpieces require manual participation, especially for the handling of large steel plates, which is labor-intensive and poses safety hazards;

[0006] 3. Poor product quality consistency: The uncertainty of manual operation makes it difficult to ensure the consistency of product quality, which easily leads to waste and rework;

[0007] 4. Difficulty in executing production plans: Due to the lack of effective information connection between various processes, it is difficult to execute and adjust production plans, and it is difficult to achieve flexible production;

[0008] 5. Difficulty in information traceability during the production process: lack of effective production information collection and feedback mechanism, long cycle for tracing and solving product quality problems;

[0009] 6. Low space utilization: The layout of various production equipment is scattered, occupying a large amount of workshop area, and the space utilization rate is low.

[0010] Therefore, how to overcome the problems of low efficiency, high labor intensity, poor quality consistency, and insufficient flexibility in the traditional production process of frame crossbeam components, and realize the automation, intelligent, and integrated production of punching, cutting, sorting, and transportation processes, is a technical problem that needs to be urgently solved in this field. Summary of the invention

[0011] The object of the present invention is to overcome the deficiencies of the prior art and provide an intelligent production line for frame crossbeam parts and its production method, aiming to solve the problems of low automation degree, low production efficiency, high manual labor intensity, poor product quality consistency, and scattered production processes in the production of commercial vehicle frame crossbeam parts.

[0012] To achieve the above object, the present invention provides the following technical solutions:

[0013] In the first aspect, the present invention provides an intelligent production line for frame crossbeam parts, including:

[0014] A frame crossbeam steel plate punching area, arranged at the front end of the production line, for punching the input frame crossbeam steel plate;

[0015] A frame crossbeam steel plate cutting area, arranged in the next area of the frame crossbeam steel plate punching area, for cutting the punched frame crossbeam steel plate;

[0016] A frame crossbeam automatic sorting and palletizing area, arranged in the next area of the frame crossbeam steel plate cutting area, for sorting and palletizing the cut frame crossbeam parts; and

[0017] An automated conveying system, running through part or all of the areas of the frame crossbeam steel plate punching area, the frame crossbeam steel plate cutting area, and the frame crossbeam automatic sorting and palletizing area, and arranged above the running-through areas, for automatically conveying frame crossbeam steel plates or parts between and within each area.

[0018] In some alternative embodiments of the present invention, the frame crossbeam steel plate punching area includes a frame crossbeam steel plate AGV loading trolley, a feeding conveying mechanism, a punching unit, a punching plate connecting table, a strip plate assembling device, a punching strip offline and a large plate online trolley; the frame crossbeam steel plate AGV loading trolley is located at the front end of the frame crossbeam steel plate punching area, the feeding conveying mechanism is docked with the frame crossbeam steel plate AGV loading trolley, and the feeding conveying mechanism adopts a stepping motion mode; the punching unit includes six numerically controlled flat punching machines, arranged side by side in sequence at the rear end of the feeding conveying mechanism, divided into a punching loading area and a punching unloading area; there are two punching plate connecting tables, respectively located in the middle area of the punching unit, arranged in the punching loading area and the punching unloading area respectively; the strip plate assembling device is located at the rear end of the punching unit, running in a stepping manner, for assembling the punched crossbeam steel plates into groups of two; the punching strip offline and the large plate online trolley are located at the rear end of the strip plate assembling device.

[0019] The two punching plate connecting tables are transfer buffer stations for loading and unloading the crossbeam steel plates during punching.

[0020] The under-line trolley for the punched strip plate and the on-line trolley for the large plate material are for off-line under-line after punching the crossbeam steel plate (in case of non-conforming products or equipment failures in subsequent processes), or for on-line of other large plate materials that do not require punching (for trial production).

[0021] In some alternative embodiments of the present invention, the automated conveying system running above the punching area of the crossbeam steel plate of the vehicle frame includes a punching loading electromagnetic crane group and a punching unloading electromagnetic crane group; the punching loading electromagnetic crane group runs above the punching loading area of the punching unit; the punching unloading electromagnetic crane group runs above the punching unloading area of the punching unit, the strip plate assembly device, the under-line trolley for the punched strip plate and the on-line trolley for the large plate material.

[0022] The punching loading electromagnetic crane group is arranged in sequence and includes a first and a second electromagnetic crane, and the first and second electromagnetic cranes run on the same rail; the punching unloading electromagnetic crane group is arranged in sequence and includes a third and a fourth electromagnetic crane, and the third and fourth electromagnetic cranes run on the same rail.

[0023] In some alternative embodiments of the present invention, the cutting area of the crossbeam steel plate of the vehicle frame includes a laser cutting unit, a cutting plate buffer mechanism, a cutting plate off-line trolley, and a waste collection trolley; the laser cutting unit includes four laser cutting machines, which are arranged side by side in sequence at the rear end of the punching area of the crossbeam steel plate of the vehicle frame; the cutting plate buffer mechanism is located in the middle area of the laser cutting unit and operates in a step-by-step manner, and is used for the transfer buffer station during loading and unloading when cutting the crossbeam steel plate. The cutting plate off-line trolley is located at the rear end of the laser cutting unit and is used for off-line under-line of the cut plate (in case of non-conforming products or equipment failures in subsequent processes); the waste collection trolley is located at the rear end of the cutting plate off-line trolley, and a waste bin is placed on the trolley for collecting the waste after cutting.

[0024] In some alternative embodiments of the present invention, the automated conveying system running above the cutting area of the crossbeam steel plate of the vehicle frame and the automatic sorting and stacking area of the crossbeam of the vehicle frame includes a cutting loading electromagnetic crane, a cutting transfer electromagnetic crane, and a cutting unloading electromagnetic crane; the cutting loading electromagnetic crane is the fifth electromagnetic crane, the cutting transfer electromagnetic crane is the sixth electromagnetic crane, and the cutting unloading electromagnetic crane is the seventh electromagnetic crane; the fifth, sixth, and seventh electromagnetic cranes are arranged in sequence and run above the cutting area of the crossbeam steel plate of the vehicle frame and the automatic sorting and stacking area of the crossbeam of the vehicle frame, and are on the same rail as the third and fourth electromagnetic cranes.

[0025] In some alternative embodiments of the present invention, the automatic sorting and palletizing area of the frame crossbeam includes a belt conveyor, an AGV empty pallet loading trolley, an empty pallet conveyor roller path, a pallet transfer trolley, an empty pallet accumulation system, a full pallet conveyor roller path, a crossbeam automatic sorting system, and an AGV full pallet unloading trolley; the belt conveyor is arranged at the rear end of the frame crossbeam steel plate cutting area, the transverse mechanism of the belt conveyor runs below the fifth, sixth, and seventh electromagnetic cranes, and the longitudinal mechanism of the belt conveyor is located within the crossbeam automatic sorting system for the transportation and transfer of the cut crossbeams; the crossbeam automatic sorting system is docked with the longitudinal mechanism of the belt conveyor to automatically grab and sort the transported crossbeams; the AGV empty pallet loading trolley, the empty pallet conveyor roller path, the pallet transfer trolley, the full pallet conveyor roller path, and the AGV full pallet unloading trolley are sequentially arranged in a C-shaped series layout and run below the belt conveyor and the crossbeam automatic sorting system for the automatic loading of empty pallets and the automatic unloading and transfer of full pallets after grabbing and sorting crossbeam parts; the empty pallet accumulation system is arranged in a C-shaped layout, is docked with the pallet transfer trolley, and is arranged on its left side for the accumulation and caching of empty pallets.

[0026] The crossbeam automatic sorting system includes fixed sorting robots and sorting platforms; there are four fixed sorting robots and two sets of sorting platforms; the fixed sorting robots and the sorting platforms are arranged symmetrically left and right on both sides of the longitudinal mechanism of the belt conveyor, and the fixed sorting robots are arranged overhead on the sorting platforms for the automatic grabbing and sorting of crossbeam parts.

[0027] The full pallet conveyor roller path includes two palletizing lifting roller paths and a full pallet transverse conveyor roller path; there are two palletizing lifting roller paths; the palletizing lifting roller paths are located below the crossbeam automatic sorting system, are arranged symmetrically left and right on both sides of the longitudinal mechanism of the belt conveyor, and lift the empty pallet to the set position during sorting for the robot to place the grabbed crossbeam parts into the empty pallet; the full pallet transverse conveyor roller path is located at the rear end of the two palletizing lifting roller paths and is docked with the full pallet on the lowered palletizing lifting roller path for off-line transfer.

[0028] In a second aspect, the present invention provides a production method using the intelligent production line for frame crossbeam parts described in the first aspect, which includes an intelligent production method for punching, cutting, automatic sorting, and automatic transfer of frame crossbeam parts.

[0029] The steel plate stack is transported to the feeding conveyor mechanism by the frame crossbeam steel plate AGV loading trolley.

[0030] The steel plate is lifted by the punching loading electromagnetic crane group and transported to the punching unit for punching.

[0031] The punched crossbeam steel plate is lifted by the punching unloading electromagnetic crane group and transported to the punching sheet metal connection platform for transfer and caching.

[0032] The crossbeam steel plates after punching are assembled into groups of two by the strip board assembling device;

[0033] The assembled steel plates are lifted by the cutting loading electromagnetic crane and transported to the laser cutting machine set for cutting;

[0034] The cut crossbeam steel plates are lifted by the cutting transfer electromagnetic crane or the cutting unloading electromagnetic crane and transported to the waste collection trolley for waste collection;

[0035] The crossbeam parts after waste treatment are lifted by the cutting unloading electromagnetic crane and transported onto the belt conveyor;

[0036] The crossbeam parts are transported to the crossbeam automatic sorting system by the belt conveyor;

[0037] The crossbeam parts are grabbed and sorted into empty trays by the fixed sorting robots of the crossbeam automatic sorting system;

[0038] The full tray filled with crossbeam parts is taken offline by the AGV full tray offline trolley.

[0039] In some alternative embodiments of the present invention, the following steps are specifically included:

[0040] Step 1: According to the product characteristics of the vehicle frame crossbeam, nesting of the developed materials of the crossbeam parts is carried out on the sizing sheet metal. The AGV loading trolley for the vehicle frame crossbeam steel plates is used for automatic loading. The electromagnetic crane automatically transfers the crossbeam steel plates to the punching machine set. According to the nesting information fed back by the information system, the punching machine set completes the punching process, and the strip board assembling device assembles the punched crossbeam steel plates into groups of two;

[0041] Step 2: The electromagnetic crane automatically transfers the assembled crossbeam steel plates to the laser cutting machine set. According to the nesting information fed back by the information system, the laser cutting machine set completes the cutting process. The electromagnetic crane transfers the cut crossbeam steel plates to the waste collection trolley, and the waste is demagnetized by controlling the dot matrix electromagnetic chuck through the information system to complete the collection and treatment of the waste;

[0042] Step 3: The electromagnetic crane transfers the crossbeam sheet materials after waste treatment to the belt conveyor. The belt conveyor transports the crossbeam sheet materials to the crossbeam automatic sorting system. According to the nesting information fed back by the information system, four fixed sorting robots automatically grab the crossbeams according to their sizes and place them into the empty trays on two palletizing lifting roller tracks. After being full, they are transported through the full tray horizontal conveying roller track to be docked with the AGV full tray offline trolley to complete the offline operation.

[0043] In Step 1, Step 2, and Step 3, the punching, cutting, and automatic sorting process beats need to match each other to ensure the line balance of the production line, and there will be no waiting situations for the punching machine set, the laser cutting machine set, and the crossbeam automatic sorting system.

[0044] Preferably, in the sorting step of the crossbeam parts, the empty pallet is lifted to the set position height by the palletizing lifting roller conveyor, and the fixed sorting robot puts the grabbed crossbeam parts into the empty pallet. After the pallet is full, the palletizing lifting roller conveyor descends and docks with the full pallet horizontal conveyor to complete the conveying and transfer.

[0045] The intelligent production line for the frame crossbeam parts of the present invention has the following advantageous effects:

[0046] 1. The present invention creatively designs an intelligent punching and cutting integrated production line for the production of frame crossbeam steel plate parts, which innovates the traditional single-machine production process and solves the problems of low production efficiency, high manual labor intensity, and poor product quality consistency in the punching, cutting, sorting, and transfer processes of commercial vehicle frame crossbeam parts. Through reasonable layout, the whole line body is flexible and compact, realizing fully automated production of the whole process. The workpiece transfer does not touch the ground throughout the process, greatly improving the automation degree and production efficiency, which is a first in the production of frame crossbeam parts in the commercial vehicle industry.

[0047] 2. The present invention adopts intelligent equipment such as electromagnetic crane automatic conveying, punching unit, laser cutting unit, strip plate assembly device, belt conveyor, crossbeam automatic sorting system, pallet conveyor roller, and AGV trolley to connect the whole production process of the frame crossbeam steel plate, and applies the information-connected MES system for the whole line control to realize intelligent production.

[0048] 3. In the design of the present invention, the rhythm problem in the electromagnetic crane conveying process is fully considered. By setting up the punching sheet metal connection table and the cutting sheet metal buffer mechanism, the problem of affecting the rhythm due to the long conveying path of a single electromagnetic crane is solved. Through the setting of the buffer station, the upper and lower materials of the punched steel plate or the cut steel plate can be completed through the cooperation of the rear electromagnetic crane.

[0049] 4. The production method proposed by the present invention, according to the product characteristics of the frame crossbeam, adopts the method of nesting the crossbeam part steel plates, which is convenient for the real-time association between the production plan and the production line. Through the MES system, the production information of the workstations can be traced and fed back in a timely manner.

[0050] 5. The present invention adopts a hierarchical layout of the electromagnetic crane, belt conveyor, crossbeam automatic sorting system, and pallet conveyor roller in space, which solves the difficulties in the conveying of crossbeam parts from cutting to sorting and boxing, and effectively saves the area occupied by the equipment in the workshop.

[0051] 6. The present invention sets up an online detection system in the punching and cutting processes of the production line to conduct online detection after each process is completed, and sets up offline workstations: the punching strip offline and the large sheet material online trolley and the cutting sheet material offline trolley to transfer the unqualified products out of the line offline. At the same time, the punching strip offline and the large sheet material online trolley can also be used for the online of trial products, increasing the flexibility of the production line.

[0052] 7. In the crossbeam automatic sorting system of the present invention, the fixed sorting robot is arranged overhead on the sorting platform. The empty pallet is lifted to a set position by the palletizing lifting roller table for sorting and grasping onto the empty pallet. Different types of electromagnetic end effectors are set on the sorting platform, which are applicable to all types of crossbeam parts, greatly improving the flexibility.

[0053] 8. In the present invention, the dot matrix electromagnetic lifting dot matrix group control technology is used to perform electromagnetic demagnetization treatment on the cutting waste, solving the problem of online collection of waste. And the waste collection trolley is driven out in time to ensure the whole line beat, enabling the production line to operate stably and efficiently. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] In order to more clearly illustrate the technical solutions of the disclosed embodiments of the present invention, the accompanying drawings of the embodiments will be briefly introduced below. These drawings are only for illustrative purposes and are not intended to limit the protection scope of the present invention.

[0055] Figure 1 It is a schematic structural diagram of the intelligent production line for the frame crossbeam parts of the present invention.

[0056] In the figure:

[0057] 1. Frame crossbeam steel plate punching area; 1.1 Frame crossbeam steel plate AGV loading trolley; 1.2 Feeding conveying mechanism; 1.3 Punching unit; 1.3.1 Punching loading area; 1.3.2 Punching unloading area; 1.4 Punching sheet metal connection table; 1.5 Strip board assembly device; 1.6 Punching strip board offline and large sheet metal online trolley;

[0058] 2. Automatic conveying system; 2.1 First electromagnetic crane; 2.2 Second electromagnetic crane; 2.3 Third electromagnetic crane; 2.4 Fourth electromagnetic crane; 2.5 Fifth electromagnetic crane; 2.6 Sixth electromagnetic crane; 2.7 Seventh electromagnetic crane;

[0059] 3. Frame crossbeam steel plate cutting area; 3.1 Laser cutting unit; 3.2 Cutting sheet metal buffer mechanism; 3.3 Cutting sheet metal offline trolley; 3.4 Waste collection trolley;

[0060] 4. Frame crossbeam automatic sorting and palletizing area; 4.1 Belt conveyor; 4.1.1 Transverse mechanism of belt conveyor; 4.1.2 Longitudinal mechanism of belt conveyor; 4.2 AGV empty pallet loading trolley; 4.3 Empty pallet conveyor roller table; 4.4 Pallet transfer trolley; 4.5 Empty pallet accumulation system; 4.6 Full pallet conveyor roller table; 4.6.1 Palletizing lifting roller table; 4.6.2 Full pallet transverse conveyor roller table; 4.7 Crossbeam automatic sorting system; 4.7.1 Fixed sorting robot; 4.7.2 Sorting platform; 4.8 AGV full pallet unloading trolley. Detailed implementation manners

[0061] The technical solutions (including the preferred technical solutions) of the present invention will be further described in detail below by means of the accompanying drawings and by listing some optional embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the scope of protection of the present invention.

[0062] Embodiment 1

[0063] As Figure 1 shown, the intelligent production line for frame crossbeam parts of this embodiment includes, arranged in sequence: frame crossbeam steel plate punching area 1, automatic conveying system 2, frame crossbeam steel plate cutting area 3, and frame crossbeam automatic sorting and palletizing area 4.

[0064] The frame crossbeam steel plate punching area 1 is arranged at the front end of the production line. The frame crossbeam steel plate punching area 1 is successively composed of a frame crossbeam steel plate AGV loading trolley 1.1, a feeding conveying mechanism 1.2, a punching unit 1.3, a punched sheet material connection table 1.4, a strip board assembly device 1.5, and a punched strip board unloading and large sheet material loading trolley 1.6.

[0065] The steel plate of the frame crossbeam, the AGV loading trolley 1.1, is located at the front end of the punching area of the steel plate of the frame crossbeam and is docked with the feeding conveyor mechanism 1.2. The feeding conveyor mechanism adopts a stepping motion mode and is used for loading the incoming steel plates of the crossbeam. It can store multiple stacks of incoming steel plates. The AGV is of the back-mounted type and is equipped with a transverse conveying system, which can convey the steel plate stacks to the feeding conveyor mechanism 1.2; the punching unit 1.3 is arranged side by side in sequence at the rear end of the feeding conveyor mechanism. The punching unit 1.3 includes six numerically controlled flat punching machines, which are divided into a punching loading area 1.3.1 and a punching unloading area 1.3.2; there are two punching plate connecting tables 1.4, which are located in the middle area of the punching unit and are respectively arranged in the punching loading area 1.3.1 and the punching unloading area 1.3.2, and are used for the transfer and buffering stations during the punching loading and unloading of the steel plates of the frame crossbeam; the strip plate assembling device 1.5 is located at the rear end of the punching unit and operates in a stepping manner, and is used for assembling the punched steel plates of the frame crossbeam into groups of two; the punching strip plate offline and large plate material online trolley 1.6 is located at the rear end of the strip plate assembling device and is used for the offline unloading of the punched steel plates of the frame crossbeam (in the case of non-conforming products or equipment failures in subsequent processes), or the online loading of other large plate materials that do not require punching (for trial production).

[0066] The part of the automated conveying system 2 that runs through the punching area 1 of the steel plate of the frame crossbeam is successively composed of a first electromagnetic crane 2.1, a second electromagnetic crane 2.2, a third electromagnetic crane 2.3, and a fourth electromagnetic crane 2.4.

[0067] The first electromagnetic crane 2.1 and the second electromagnetic crane 2.2 are arranged in sequence to form a punching loading electromagnetic crane group, which runs on a common rail above the punching loading area 1.3.1 and is used for the hoisting of the steel plates during the punching loading of the steel plates of the frame crossbeam. When loading with the electromagnetic crane, two plates are hoisted at a time and placed at the loading end of the numerically controlled flat punching machine; the third electromagnetic crane 2.3 and the fourth electromagnetic crane 2.4 are arranged in sequence to form a punching unloading electromagnetic crane group, which runs on a common rail above the punching unloading area 1.3.2, the strip plate assembling device 1.5, and the punching strip plate offline and large plate material online trolley 1.6, and is used for the hoisting of the steel plates after punching during the punching unloading of the steel plates of the frame crossbeam.

[0068] The third electromagnetic crane 2.3 hoists the punched steel plates of the frame crossbeam to the transfer and buffering station of the punching plate connecting table 1.4 and waits for the subsequent fourth electromagnetic crane 2.4 to carry out the next hoisting. The fourth electromagnetic crane 2.4 hoists the punched steel plates of the frame crossbeam to the strip plate assembling device 1.5 and assembles the punched steel plates of the frame crossbeam into groups of two.

[0069] The numerically controlled flat punch is provided with an online detection system at the unloading end, which is used to detect the quantity and quality of the punched holes. When non-conforming products appear, the punching unloading electromagnetic crane hoists the non-conforming products to the punching strip plate offline and large plate material online trolley 1.6 and transfers them out of the line.

[0070] When loading and unloading the crossbeam steel plates by punching, the principle of first-in, first-out is satisfied. The conveying rhythm of the electromagnetic crane matches the rhythm of processing one crossbeam steel plate (6000mm * 850mm) on the whole line in 2.5 minutes. Since the single electromagnetic crane has a long conveying path and affects the rhythm, a punching sheet metal connection table (1.4) is set up to transfer and buffer the workstations, and the loading and unloading of the punched steel plates can be completed through the joint cooperation of the rear electromagnetic cranes.

[0071] The cutting area 3 of the frame crossbeam steel plates is set in the next area of the punching area 1 of the frame crossbeam steel plates, and is successively composed of a laser cutting machine group 3.1, a cutting sheet metal buffer mechanism 3.2, a cutting sheet metal offline trolley 3.3, and a waste collection trolley 3.4.

[0072] The laser cutting machine group 3.1 includes four laser cutting machines, which are arranged side by side in sequence at the rear end of the punching area 1 of the frame crossbeam steel plates and are used for cutting the crossbeam steel plates after punching, and two punched crossbeam steel plates are cut at one time; the cutting sheet metal buffer mechanism 3.2 is located in the middle area of the laser cutting machine group and operates in a stepping manner, and is used as a transfer and buffer workstation for loading and unloading during the cutting of the crossbeam steel plates; the cutting sheet metal offline trolley 3.3 is located at the rear end of the laser cutting machine group and is used for offline unloading of the cut sheet metal (in case of unqualified products or equipment failures in subsequent processes); the waste collection trolley 3.4 is located at the rear end of the cutting sheet metal offline trolley, and a waste bin is placed on the trolley for collecting the waste after cutting.

[0073] The part of the automatic conveying system 2 that runs through the cutting area 3 of the frame crossbeam steel plates and the automatic sorting and stacking area 4 of the frame crossbeam is successively composed of a fifth electromagnetic crane 2.5, a sixth electromagnetic crane 2.6, and a seventh electromagnetic crane 2.7.

[0074] The fifth electromagnetic crane 2.5 is a cutting loading electromagnetic crane, the sixth electromagnetic crane 2.6 is a cutting transfer electromagnetic crane, and the seventh electromagnetic crane 2.7 is a cutting unloading electromagnetic crane. The above three electromagnetic cranes are arranged in sequence and run above the cutting area 3 of the frame crossbeam steel plates and the automatic sorting and stacking area 4 of the frame crossbeam, and are on the same rail as the third electromagnetic crane 2.3 and the third electromagnetic crane 2.4.

[0075] The fifth electromagnetic crane 2.5 hoists the two punched crossbeam steel plates assembled on the strip plate assembly device 1.5 to the laser cutting machine group 3.1 for cutting. Since the single electromagnetic crane has a long conveying path and affects the rhythm, a cutting sheet metal buffer mechanism 3.2 is set up for the transfer and buffer workstations for loading and unloading during the cutting of the crossbeam steel plates, and the transfer and hoisting are carried out through the sixth electromagnetic crane 2.6. The seventh electromagnetic crane 2.7 hoists the cut crossbeam steel plates above the waste collection trolley 3.4, and uses the electromagnetic lattice group control technology to demagnetize the cutting waste magnetically, and collect the waste online. After the collection, the trolley drives out, and the waste bin is hoisted offline by the overhead crane.

[0076] An on-line detection system is set on the laser cutting unit 3.1 to detect the cutting quality. When defective products occur, the sixth electromagnetic crane 2.6 will lift the defective products to the cutting sheet metal off-line trolley 3.3 and transfer them out of the line.

[0077] The automatic sorting and palletizing area 4 of the frame crossbeam is set in the next area of the frame crossbeam steel plate cutting area 3, and is composed of a belt conveyor 4.1, an AGV empty pallet on-line trolley 4.2, an empty pallet conveying roller path 4.3, a pallet transfer trolley 4.4, an empty pallet accumulation system 4.5, a full pallet conveying roller path 4.6, a crossbeam automatic sorting system 4.7, and an AGV full pallet off-line trolley 4.8.

[0078] The belt conveyor 4.1 is set at the rear end of the frame crossbeam steel plate cutting area 3. Part of the belt conveyor transverse mechanism 4.1.1 runs under the seventh electromagnetic crane 2.7, and part of the belt conveyor longitudinal mechanism 4.1.2 is located within the crossbeam automatic sorting system for the conveying and transfer of the crossbeams after cutting; the seventh electromagnetic crane 2.7 lifts the crossbeam parts with waste removed onto the belt conveyor 4.1, and transfers them to the crossbeam automatic sorting system 4.7 through its transverse mechanism and longitudinal mechanism (4.1.1, 4.1.2).

[0079] The crossbeam automatic sorting system 4.7 is docked with the belt conveyor longitudinal mechanism 4.1.2 to automatically grab and sort the conveyed crossbeams. The crossbeam automatic sorting system 4.7 includes fixed sorting robots 4.7.1 (four fixed sorting robots) and sorting platforms 4.7.2 (two sets of sorting platforms); the four fixed sorting robots and the two sets of sorting platforms are arranged symmetrically left and right on both sides of the belt conveyor longitudinal mechanism 4.1.2, and the fixed sorting robots are arranged overhead on the sorting platforms to grab and sort the crossbeam parts through visual guidance and the nesting information fed back by the information system.

[0080] The AGV empty pallet on-line trolley 4.2, the empty pallet conveying roller path 4.3, the pallet transfer trolley 4.4, the full pallet conveying roller path 4.6, and the AGV full pallet off-line trolley 4.8 are successively arranged in a C-shaped series and run under the belt conveyor 4.1 and the crossbeam automatic sorting system 4.7 for the automatic on-line of empty pallets and the automatic off-line transfer of full pallets after grabbing and sorting crossbeam parts; the full pallet conveying roller path 4.6 includes a palletizing lifting roller path 4.6.1 and a full pallet transverse conveying roller path 4.6.2;

[0081] After the AGV empty pallet loading trolley 4.2 docks with the empty pallet conveying roller 4.3, the empty pallet is conveyed to the empty pallet conveying roller 4.3. The pallet transfer trolley 4.4 is a ferry trolley connecting the empty pallet conveying roller 4.3 and the full pallet conveying roller 4.6. The empty pallet is transferred by the pallet transfer trolley 4.4 to dock with the stacking lifting roller 4.6.1, and the empty pallet is conveyed to the stacking lifting roller 4.6.1. The palletizing lifting roller table 4.6.1 includes two palletizing lifting roller tables, which are located below the automatic beam sorting system and are symmetrically arranged on both sides of the longitudinal mechanism 4.1.2 of the belt conveyor. When the robot grabs the beam parts for sorting, the palletizing lifting roller table 4.6.1 lifts the empty pallet to the set height, and the robot puts the grabbed beam parts into the empty pallet. After the pallet is full, the two palletizing lifting roller tables 4.6.1 descend and dock with the full pallet transverse conveying roller table 4.6.2, and transport and transfer them to the AGV full pallet offline trolley 4.8 to complete the offline process.

[0082] The above AGV carts are backpack-type and all have their own conveying system to transport the pallet to the roller table.

[0083] The empty pallet accumulation system 4.5 is arranged in a C shape, docked with the pallet transfer trolley 4.4, and arranged on its left side for accumulating and caching empty pallets. When the beam parts are being sorted and framed, the empty pallet conveyor roller 4.3 can convey the empty pallets to the empty pallet accumulation system, increasing the number of empty pallets that can be stored online to improve production efficiency.

[0084] Example 2

[0085] The production method of the intelligent production line of frame crossbeam parts described above is characterized in that it includes an intelligent production method for punching, cutting, automatic sorting, and automatic transportation of frame crossbeam parts, including the following steps:

[0086] The steel plate stack is transported to the feeding and conveying mechanism through the frame crossbeam steel plate AGV loading trolley;

[0087] The steel plate is hoisted to the punching unit for punching by the punching feeding electromagnetic hoisting unit;

[0088] The punched beam steel plate is hoisted to the punching plate material connection platform for transfer and buffering by the punching material unloading electromagnetic hoisting group;

[0089] The punched beam steel plates are assembled into two groups by the strip assembly device;

[0090] The assembled steel plates are hoisted to the laser cutting unit for cutting by the cutting and loading electromagnetic crane;

[0091] The cut beam steel plate is hoisted to the waste collection trolley for waste collection by the cutting transfer electromagnetic crane or the cutting unloading electromagnetic crane;

[0092] The electromagnetic crane for cutting and blanking hoists the crossbeam parts after processing the waste materials onto the belt conveyor;

[0093] The belt conveyor transports the crossbeam parts to the crossbeam automatic sorting system;

[0094] The fixed sorting robot of the crossbeam automatic sorting system grabs and sorts the crossbeam parts into empty trays;

[0095] The full-tray offline trolley of the AGV takes the full tray filled with crossbeam parts offline.

[0096] Specifically, it includes the following steps:

[0097] Step 1: According to the product characteristics of the frame crossbeam, nesting of the developed materials of the crossbeam parts is carried out on the sizing sheet metal. The AGV feeding trolley for the frame crossbeam steel plate is used for automatic feeding. The electromagnetic crane automatically transfers the crossbeam steel plate to the punching unit. According to the nesting information fed back by the information system, the punching unit completes the punching process. The strip plate assembly device assembles the punched crossbeam steel plates into groups of two;

[0098] Step 2: The electromagnetic crane automatically transfers the assembled crossbeam steel plate to the laser cutting unit. According to the nesting information fed back by the information system, the laser cutting unit completes the cutting process. The electromagnetic crane transfers the cut crossbeam steel plate to the waste collection trolley, and the information system controls the dot matrix electromagnetic chuck to demagnetize the waste materials to complete the collection and treatment of the waste materials;

[0099] Step 3: The electromagnetic crane transfers the crossbeam sheet material after waste treatment to the belt conveyor. The belt conveyor transports the crossbeam sheet material to the crossbeam automatic sorting system. According to the nesting information fed back by the information system, four fixed sorting robots automatically grab the crossbeams according to their sizes and place them into the empty trays on two stacking lifting roller beds. After the trays are full, they are transported by the full-tray horizontal conveying roller bed to be docked with the AGV full-tray offline trolley to complete the offline process.

[0100] In the above Step 1, Step 2, and Step 3, the punching, cutting, and automatic sorting process beats need to match each other to ensure the line balance of the production line, and there will be no waiting situations for the punching unit, laser cutting unit, and crossbeam automatic sorting system.

[0101] Preferably, in the crossbeam part sorting step, the empty tray is lifted by the stacking lifting roller bed to the set position height, and the fixed sorting robot puts the grabbed crossbeam parts into the empty tray. After the tray is full, the stacking lifting roller bed descends to be docked with the full-tray horizontal conveying roller bed to complete the transportation and transfer.

[0102] Embodiment 3

[0103] This embodiment provides a production method using the above intelligent production system for frame crossbeam parts. This method makes full use of the various functions of the intelligent production system and realizes the fully automated production of frame crossbeam parts. The specific production method steps are as follows:

[0104] Step 1: Feeding the raw materials onto the production line

[0105] The steel plate AGV loading trolley 1.1 for the frame crossbeam automatically transports the steel plate stack to the feeding conveyor mechanism 1.2. The AGV loading trolley adopts a back-mounted structure and is equipped with a horizontal conveying system, which can accurately position and smoothly transport the steel plate stack in place. The feeding conveyor mechanism adopts a step-by-step motion mode and can store multiple stacks of steel plate raw materials to ensure the continuity of production.

[0106] Step 2: Punching feeding

[0107] The first electromagnetic crane 2.1 and the second electromagnetic crane 2.2 form a punching feeding electromagnetic crane group, which runs on a common rail above the punching feeding area 1.3.1 and hoists two steel plates at a time and places them at the feeding end of the numerical control flat punching machine. The electromagnetic crane adopts the principle of electromagnetic adsorption and can firmly adsorb the steel plate to avoid the risk of slipping.

[0108] Step 3: Punching processing

[0109] The punching machine group 1.3 composed of six numerical control flat punching machines accurately punches the crossbeam steel plate according to the processing instructions issued by the MES system. The punching machine adopts a numerical control system, which can accurately control the punching position, shape and size according to the design requirements of different crossbeam parts. At the same time, the online detection system at the discharging end of the numerical control flat punching machine detects the quantity and quality of the punching in real time.

[0110] Step 4: Punching discharging and quality inspection

[0111] After punching, the third electromagnetic crane 2.3 hoists the punched crossbeam steel plate to the punching plate material connection table 1.4 for transfer and buffering. If the online detection system detects unqualified products, the punching discharging electromagnetic crane hoists the unqualified products to the punching strip board offline and large board material online trolley 1.6 for offline transfer. The qualified products wait for the fourth electromagnetic crane 2.4 at the rear for the next hoisting.

[0112] Step 5: Strip board assembly

[0113] The fourth electromagnetic crane 2.4 hoists the qualified punched crossbeam steel plates to the strip board assembly device 1.5 and assembles the punched crossbeam steel plates into groups of two, preparing for the subsequent cutting process. The strip board assembly device adopts a step-by-step motion mode to ensure the accuracy and stability of the assembly.

[0114] Step 6: Cutting feeding

[0115] The fifth electromagnetic crane 2.5 hoists the two punched crossbeam steel plates assembled on the strip plate assembling device 1.5 to the laser cutting unit 3.1 for cutting. If the conveying path of the electromagnetic crane is too long and affects the production rhythm, the cutting sheet buffer mechanism 3.2 can be used as a transfer buffer station, and the sixth electromagnetic crane 2.6 is used for transfer hoisting to optimize the production rhythm.

[0116] Step Seven: Laser Cutting and Quality Inspection

[0117] The laser cutting unit 3.1 precisely cuts the crossbeam steel plates after punching to form the final crossbeam parts. Laser cutting technology has the advantages of non-contact, small deformation, high precision, and high efficiency, and can meet the high-precision cutting requirements of the frame crossbeam parts. At the same time, the on-line detection system set on the laser cutting unit conducts real-time detection of the cutting quality. If unqualified products are detected, the sixth electromagnetic crane 2.6 hoists the unqualified products to the cutting sheet offline trolley 3.3 and transfers them out for offline processing.

[0118] Step Eight: Scrap Collection

[0119] The seventh electromagnetic crane 2.7 hoists the crossbeam steel plates after cutting above the scrap collection trolley 3.4, and uses the dot matrix group control technology of the dot matrix electromagnetic crane to perform electromagnetic demagnetization treatment on the cutting scraps to realize the on-line automatic collection of the scraps. The collected scrap trolley can be automatically driven out, and the scrap box is hoisted offline by the overhead crane to realize the automation and cleanliness of scrap treatment.

[0120] Step Nine: Crossbeam Conveying

[0121] The seventh electromagnetic crane 2.7 hoists the qualified crossbeam parts after removing the scraps onto the transverse mechanism 4.1.1 of the belt conveyor 4.1, and then the transverse mechanism and the longitudinal mechanisms (4.1.1, 4.1.2) jointly transfer them to the crossbeam automatic sorting system 4.7. The belt conveyor is made of high-strength wear-resistant material and runs smoothly to ensure the safe conveyance of the crossbeam parts.

[0122] Step Ten: Empty Pallet Loading

[0123] The AGV empty pallet loading trolley 4.2 automatically conveys the empty pallets to the empty pallet conveying roller path 4.3, and the pallet transfer trolley 4.4 transfers the empty pallets to the palletizing lifting roller path 4.6.1. The palletizing lifting roller path lifts the empty pallets to the set position height to prepare for receiving the sorted crossbeam parts.

[0124] Step Eleven: Automatic Sorting and Palletizing

[0125] Four fixed sorting robots 4.7.1 in the crossbeam automatic sorting system 4.7 accurately grasp the crossbeam parts on the belt conveyor through the nesting information fed back by vision guidance and the MES system, and place them into the empty trays lifted by the palletizing lifting roller table 4.6.1. Different types of electromagnetic end effectors set on the sorting platform can meet the grasping requirements of various crossbeam parts, improving the flexibility of the system.

[0126] Step Twelve: Full pallet off-line

[0127] When the pallet is full of crossbeam parts, the palletizing lifting roller table 4.6.1 descends and docks with the full pallet horizontal conveying roller table 4.6.2 to convey the full pallet to the AGV full pallet off-line trolley 4.8. The AGV full pallet off-line trolley transports the full pallet filled with crossbeam parts out of the production system, completing the entire production process.

[0128] Those skilled in the art can easily understand that the above is only a preferred embodiment of the present invention and does not limit the present invention. Any modifications, combinations, substitutions, improvements, etc. made within the spirit and principle of the present invention are included in the protection scope of the present invention.

Claims

1. An intelligent production line for frame crossbeam parts, characterized in that: include: The frame crossbeam steel plate punching area is arranged at the front end of the production line and is used to punch the input frame crossbeam steel plate; A frame crossbeam steel plate cutting area is arranged in a region next to the frame crossbeam steel plate punching area and is used for cutting the punched frame crossbeam steel plate; The frame crossbeam automatic sorting and stacking area is arranged in the next area of ​​the frame crossbeam steel plate cutting area, and is used for sorting and stacking the cut frame crossbeam parts; as well as The automated conveying system runs through part or all of the frame crossbeam steel plate punching area, the frame crossbeam steel plate cutting area and the frame crossbeam automatic sorting and stacking area, and is arranged above the through-going area, for automatically conveying the frame crossbeam steel plates or parts between the areas and within the areas.

2. The intelligent production system for frame crossbeam parts according to claim 1 is characterized in that: The frame crossbeam steel plate punching area includes: frame crossbeam steel plate AGV loading trolley, feeding conveying mechanism, punching unit, punching plate material docking platform, strip assembly device, punching strip offline and large plate material online trolley; the frame crossbeam steel plate AGV loading trolley is located at the front end of the frame crossbeam steel plate punching area, the feeding conveying mechanism is connected to the frame crossbeam steel plate AGV loading trolley, and the feeding conveying mechanism adopts a step-by-step movement mode; the punching unit includes six The CNC flat-bed punching machine is located at the rear end of the feeding and conveying mechanism and is arranged side by side in sequence, and is divided into a punching loading area and a punching unloading area; there are two punching sheet material docking stations, which are located in the middle area of ​​the punching unit and are arranged in the punching loading area and the punching unloading area respectively; the strip plate assembly device is located at the rear end of the punching unit and operates in a step-by-step manner, and is used to assemble the punched beam steel plates into groups of two; the punching strip plate unloading line and the large plate material loading line trolley are located at the rear end of the strip plate assembly device.

3. The intelligent production line for frame crossbeam parts according to claim 1, characterized in that: The automated conveying system running through the punching area of ​​the frame cross beam steel plate includes a punching loading electromagnetic hoisting group and a punching unloading electromagnetic hoisting group; the punching loading electromagnetic hoisting group runs above the punching loading area; the punching unloading electromagnetic hoisting group runs above the punching unloading area, the strip assembly device, the punching strip unloading line and the large plate material loading trolley, and is used for offline unloading of the cross beam steel plate after punching, or loading of other large plates that do not need punching; The punching loading electromagnetic hoist group is arranged in sequence, including the first and second electromagnetic hoists, and the first and second electromagnetic hoists run on a common rail; the punching unloading electromagnetic hoist group is arranged in sequence, including the third and fourth electromagnetic hoists, and the third and fourth electromagnetic hoists run on a common rail.

4. The intelligent production line for frame crossbeam parts according to claim 1, characterized in that: The frame crossbeam steel plate cutting area includes a laser cutting unit, a cutting plate material buffer mechanism, a cutting plate material offline trolley, and a waste collection trolley; the laser cutting unit includes four laser cutting machines, which are located at the rear end of the frame crossbeam steel plate punching area and arranged side by side in sequence; the cutting plate material buffer mechanism is located in the middle area of ​​the laser cutting unit and operates in a step-by-step manner; the cutting plate material offline trolley is located at the rear end of the laser cutting unit and is used for offline removal of the plate after cutting; the waste collection trolley is located at the rear end of the cutting plate material offline trolley, and a waste frame is placed on the trolley for collecting waste after cutting.

5. The intelligent production line for frame crossbeam parts according to claim 1, characterized in that: The automated conveying system running through the frame crossbeam steel plate cutting area and the frame crossbeam automatic sorting and stacking area includes a cutting and loading electromagnetic crane, a cutting and switching electromagnetic crane, and a cutting and unloading electromagnetic crane; the cutting and loading electromagnetic crane is the fifth electromagnetic crane, the cutting and switching electromagnetic crane is the sixth electromagnetic crane, and the cutting and unloading electromagnetic crane is the seventh electromagnetic crane; the fifth, sixth, and seventh electromagnetic cranes are arranged in sequence, run above the frame crossbeam steel plate cutting area and the frame crossbeam automatic sorting and stacking area, and share the same track with the third and fourth electromagnetic cranes; The automatic sorting and stacking area of ​​the frame beams includes a belt conveyor, an AGV empty pallet on-line trolley, an empty pallet conveying roller, a pallet transfer trolley, an empty pallet accumulation system, a full pallet conveying roller, an automatic beam sorting system, and an AGV full pallet off-line trolley; the belt conveyor is arranged at the rear end of the frame beam steel plate cutting area, a part of the belt conveyor transverse mechanism is located under the fifth, sixth, and seventh electromagnetic cranes for operation, and a part of the belt conveyor longitudinal mechanism is located in the beam automatic sorting system for conveying and transferring the beams after cutting; the AGV empty pallet on-line trolley The trolley, empty pallet conveyor roller table, pallet transfer trolley, full pallet conveyor roller table, and AGV full pallet offline trolley are arranged in a C-shape in series, and are located below the belt conveyor and the automatic beam sorting system for operation. They are used for automatic online loading of empty pallets and automatic offline transfer of full pallets after grabbing and sorting beam parts; the empty pallet accumulation system is arranged in a C-shape, docked with the pallet transfer trolley, and arranged on its left side, for accumulation and caching of empty pallets; the automatic beam sorting system is docked with the longitudinal mechanism of the belt conveyor to automatically grab and sort the beams transferred.

6. The intelligent production line for frame crossbeam parts according to claim 5, characterized in that: The automatic beam sorting system includes a fixed sorting robot and a sorting platform; there are four fixed sorting robots and two sorting platforms; the fixed sorting robots and the sorting platforms are symmetrically arranged on both sides of the longitudinal mechanism of the belt conveyor, and the fixed sorting robots are overhead arranged on the sorting platform to complete the grabbing and sorting of the beam parts.

7. The intelligent production line for frame crossbeam parts according to claim 5, characterized in that: The full pallet conveying rollers include a stacking lifting roller and a full pallet transverse conveying roller. There are two stacking lifting rollers. The stacking lifting rollers are located in the automatic beam sorting system and are symmetrically arranged on both sides of the longitudinal mechanism of the belt conveyor. During sorting, the empty pallet is lifted to the set position, and the robot puts the grabbed beam parts into the empty pallet. The full pallet transverse conveying roller is located at the rear end of the two stacking lifting rollers, docked with the full pallet on the stacking lifting roller after it is lowered, and transferred off the line.

8. A production method using the intelligent production system for frame crossbeam parts according to any one of claims 1 to 7, characterized in that: The following steps are involved: The steel plate stack is transported to the feeding and conveying mechanism through the frame crossbeam steel plate AGV loading trolley; The steel plate is hoisted to the punching unit for punching by the punching feeding electromagnetic hoisting unit; The punched beam steel plate is hoisted to the punching plate material connection platform for transfer and buffering by the punching material unloading electromagnetic hoisting group; The punched beam steel plates are assembled into two groups by the strip assembly device; The assembled steel plates are hoisted to the laser cutting unit for cutting by the cutting and loading electromagnetic crane; The cut beam steel plate is hoisted to the waste collection trolley for waste collection by the cutting transfer electromagnetic crane or the cutting unloading electromagnetic crane; The beam parts after waste processing are hoisted onto the belt conveyor through the electromagnetic crane for cutting and unloading; The beam parts are transported to the beam automatic sorting system through the belt conveyor; The fixed sorting robot of the beam automatic sorting system grabs and sorts the beam parts into empty pallets; The full pallet filled with beam parts is unloaded from the production line by the AGV full pallet unloading trolley.

9. The production method according to claim 8, characterized in that: The specific steps include: Step 1: According to the product characteristics of the frame crossbeam, nest the unfolded materials of the crossbeam parts on the fixed-length sheet, use the frame crossbeam steel plate AGV loading trolley for automatic loading, and the electromagnetic crane automatically transfers the crossbeam steel plate to the punching unit. According to the nesting information fed back by the information system, the punching unit completes the punching process, and the strip assembly device assembles the punched crossbeam steel plates into groups of two; Step 2: The electromagnetic crane automatically transfers the assembled beam steel plate to the laser cutting unit. According to the nesting information fed back by the information system, the laser cutting unit completes the cutting process. The electromagnetic crane transfers the cut beam steel plate to the waste collection trolley. The information system controls the dot matrix electromagnetic suction cup to demagnetize the waste, completing the collection and processing of the waste. Step 3: The electromagnetic crane transfers the beam sheet after waste processing to the belt conveyor, and the belt conveyor transports the beam sheet to the beam automatic sorting system. According to the nesting information fed back by the information system, four fixed sorting robots automatically grab the beams according to size and put them into the empty pallets on the two stacking lifting rollers. After the frame is full, it is transported to the full pallet horizontal conveyor roller to dock with the AGV full pallet offline trolley to complete the offline process.

10. The production method according to claim 8 or 9, characterized in that: In the beam parts sorting step, the empty pallet is lifted to the set height by the palletizing lifting roller, and the fixed sorting robot places the grabbed beam parts into the empty pallet. After the pallet is full, the palletizing lifting roller descends and docks with the full pallet's horizontal conveying roller to complete the conveying and transfer.

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