Automatic processing system and processing method for guide sleeve of hydraulic tilting cylinder of forklift

Abstract

The invention provides a forklift hydraulic tilting cylinder guide sleeve automatic machining system which comprises a material supply frame, a feeding conveying line, a finished product material position, an air blowing station, a robot control cabinet, a safety protective fence, a machine tool, an automatic robot, a positioning overturning accompanying table and a detection station. And the automatic robot achieves transferring and automatic feeding of the workpieces on all the stations through the ground rail. The invention further provides a machining method of the automatic machining system for the forklift hydraulic tilting cylinder guide sleeve. The machining method comprises full-process automatic operation including blank feeding, automatic machining, air-blowing cleaning, sampling inspection and finished product discharging. According to the system, through the technologies of mistake proofing detection and the like, the problems of repeated sequence turning, low efficiency, high labor intensity and unstable product quality in a traditional machining mode are solved, the production efficiency and the consistency of the product quality are remarkably improved, the labor cost and the labor intensity are reduced, and the system is suitable for large-scale automatic production of the guide sleeves.

Description

Technical Field

[0001] The present invention relates to the field of mechanical manufacturing automation, and particularly to an automated processing system for a forklift hydraulic tilt cylinder guide sleeve.

[0002] The present invention also relates to a processing method for a forklift hydraulic tilt cylinder guide sleeve using the automated processing system for the forklift hydraulic tilt cylinder guide sleeve, which is suitable for realizing continuous, efficient, and highly consistent automated production of the workpiece from blank to finished product. Background Art

[0003] As Figures 1 to 2 shown, the forklift hydraulic tilt cylinder guide sleeve is one of the main components of the forklift hydraulic tilt cylinder. It mainly serves as a guide during the reciprocating movement of the piston rod during the operation of the hydraulic cylinder and bears a certain radial pressure, as well as the sealing and dust prevention of the hydraulic oil in the hydraulic cylinder. Since the quality of the forklift hydraulic tilt cylinder guide sleeve is crucial for the life of the entire forklift hydraulic cylinder, there are relatively high requirements for the machining dimensional accuracy, geometric tolerances, and quality consistency of the forklift hydraulic tilt cylinder guide sleeve product after machining.

[0004] The common machining method for forklift hydraulic tilt guide sleeves in the industry at present is as follows: An economy lathe is used as the machining equipment, and the machining process is: Manual loading → The hard jaws of the three-jaw chuck at the spindle end clamp the outer circle of one end of the blank guide sleeve → After manually closing the machine door, press the start button to machine the flat end face, outer circle, groove, and chamfer of the guide sleeve blank → After machining; the operator turns the workpiece around → The soft jaws of the three-jaw chuck at the spindle end clamp the outer circle → After manually closing the machine door, press the start button to machine the end face to obtain the total length, inner and outer grooves, and chamfer. After machining, it is manually placed in the material box, and when the material box is full, it is batch-transported to the milling station: Manual loading → The standard three-jaw chuck at the milling station vertically clamps the workpiece → After manually closing the machine door, press the start button to machine the evenly distributed wrench grooves on the workpiece end face → After machining; the operator uses a manual deburring tool to deburr the workpiece.

[0005] However, the traditional machining method has significant defects: (1) The processes are scattered and the process transfer is frequent. It requires multiple manual loading, unloading, transportation, and turning around, and the process is cumbersome. (2) There is backlog of work-in-progress, long waiting time between processes, and a large number of work-in-progress. (3) The production rhythm is unbalanced, and it is difficult to coordinate the machining times of each process, affecting the overall efficiency. (4) High dependence on manual labor and high labor intensity. A large amount of manual operation is required, especially frequent clamping, turning around, and transportation, with high labor intensity. (5) It is difficult to ensure quality consistency. Multiple manual clampings are likely to introduce errors, and the quality fluctuates greatly in links such as manual deburring. (6) Low efficiency. There are many manual operation links, and the overall production efficiency is low.

[0006] There is an urgent need in the industry for an automated processing solution for the forklift hydraulic tilt cylinder guide sleeve that can solve the above problems and achieve high efficiency, high reliability, high consistency, and low labor intensity. Summary of the Invention

[0007] The purpose of the present invention is to provide an automated processing system for forklift hydraulic tilt cylinder guide sleeves to solve the problems raised in the above background technology:

[0008] (1) How to optimize the existing processing equipment for forklift hydraulic tilt cylinder guide sleeves and change the spatial layout of the existing processing equipment for forklift hydraulic tilt cylinder guide sleeves.

[0009] (2) How to solve the many problems of traditional processing methods and achieve automated processing that is efficient, reliable, stable, and ensures product quality consistency.

[0010] The purpose of the present invention is also to provide a processing method for forklift hydraulic tilt cylinder guide sleeves using the automated processing system for forklift hydraulic tilt cylinder guide sleeves to solve the problems raised in the above background technology:

[0011] (1) How to achieve fully automated continuous production of workpieces from blanks to finished products, reducing the number of manual interventions and labor intensity.

[0012] (2) How to eliminate transfer waiting between processes and reduce the backlog of work-in-progress.

[0013] (3) How to ensure the machining dimensional accuracy and batch consistency of products.

[0014] To achieve the above object, the present invention provides the following technical solutions:

[0015] An automated processing system for forklift hydraulic tilt cylinder guide sleeves;

[0016] It includes a raw material rack, a feeding conveyor line, a ground rail, a finished product storage position, a positioning and flipping transfer table, an automated robot, and several machine tools;

[0017] The raw material rack is used to receive and temporarily store the material boxes containing blank guide sleeves;

[0018] The feeding conveyor line is connected to the raw material rack and is used to store a certain number of blanks to ensure the continuous operation of the production line;

[0019] The finished product storage position is used to store the processed finished guide sleeves;

[0020] The automated robot is installed on the ground rail to enable the automated robot to move between the various workstations in the system. The automated robot is responsible for performing tasks such as blank grasping, workpiece transfer between workstations, and finished product unloading and stacking;

[0021] The machine tool is an efficient CNC lathe with automatic door and automatic tool change functions, capable of completing the main turning processes in one clamping or with the assistance of an automated robot, and can integrate milling functions or include an independent milling unit. A number of machine tools are arranged beside the automated robot, and a number of machine tools are within the clamping range of the automated robot;

[0022] The positioning and flipping pallet is used by the automated robot to receive the blank workpiece taken from the loading conveyor line, accurately position and adjust its posture, and identify key dimensions to achieve anti-mistake judgment of the blank.

[0023] Based on the above technical solutions, the present invention can also be improved as follows.

[0024] Furthermore, it also includes an air blowing station, which is used to remove residues such as cutting fluid and iron filings on the workpiece surface after key processes.

[0025] Furthermore, it also includes a safety fence, which is set around the working area of the automated robot to provide safety protection.

[0026] Furthermore, it also includes an inspection station, which is used to conduct spot checks on the workpieces or finished products during the processing.

[0027] Furthermore, it also includes a robot control cabinet, which is used to control the operation of the automated robot.

[0028] After adopting such a structure, the automated processing system for the forklift hydraulic tilt cylinder guide sleeve of the present invention has anti-mistake detection technology, which is applied to blank identification, anti-mixing, and clamping-in-place detection. It has floating compensation technology, which is applied to the grasping of the automated robot or the clamping of the machine tool to compensate for the slight deviation of the blank size and ensure the reliability of clamping and the machining accuracy. After the workpiece is loaded onto the machine tool, it is judged whether the workpiece is installed in place and fits well through air pressure detection to prevent processing accidents.

[0029] The automated processing system for the forklift hydraulic tilt cylinder guide sleeve of the present invention can be linked with the production line-level MES information system, responsible for production plan scheduling, material tracking, equipment status monitoring, data collection and analysis, quality information management, AGV scheduling, etc., to achieve transparent and information-based production management. The automatic AGV logistics system is docked with the incoming material rack and the finished product storage location to realize automatic warehousing of blanks and automatic outbound of finished products, connecting the warehouse and the production line.

[0030] To achieve the above object, the present invention also provides the following technical solutions:

[0031] A processing method for the forklift hydraulic tilt cylinder guide sleeve using the automated processing system for the forklift hydraulic tilt cylinder guide sleeve as described above, including the following steps:

[0032] a) The blanks of the guide sleeves for the hydraulic tilt cylinders of forklifts are delivered to the incoming material rack by AGV, and the blanks are taken out from the incoming material box manually and stacked on the loading conveyor line;

[0033] b) The automated robot takes the material from the loading conveyor line and places it on the positioning and flipping accompanying platform, where it positions the workpiece, identifies the outer diameter and length, and completes error-proofing of the blank;

[0034] c) The automated robot automatically completes the loading of materials into the machine tool, and the machine tool processes the outer circle, inner hole and chamfer of the workpiece end face;

[0035] d) The automated robot transfers and automatically completes the secondary loading of the machine tool, and the machine tool further processes the workpiece end face outer circle, inner hole, chamfer, thread, outer groove, etc.;

[0036] e) After processing, the workpiece is transferred to the air blowing station to remove iron chips and residual liquid;

[0037] f) After the workpiece passes the random inspection, the automated robot places the finished product in the cleaning frame;

[0038] g) The cleaning frames are moved and stacked in multiple layers by an automated robot. After stacking, the system automatically binds the cleaning frames and pallets;

[0039] h) The system automatically calls the AGV to transport the finished product pallets to the warehouse.

[0040] The processing method of the forklift hydraulic tilt cylinder guide sleeve automated processing system has the following beneficial technical effects:

[0041] (1) High degree of automation and continuity, realizing the automation of the entire process from blank loading, identification and positioning, multi-process processing, cleaning, detection to finished product stacking and unloading, and reducing human intervention to a minimum.

[0042] (2) Significantly improve efficiency, eliminate manual turning, multiple clamping, waiting time between processes and transfer time, optimize the cycle time, significantly improve production efficiency and equipment utilization, and significantly increase per capita output.

[0043] (3) Ensure quality consistency by using key technologies such as automatic clamping, precision machine tool processing, and online detection (error prevention, gas detection, and random inspection) to effectively reduce human errors and ensure high consistency in product dimensional accuracy, form and position tolerances, and batches.

[0044] (4) Reduce labor intensity and labor costs. Automate the clamping, turning, transporting, and deburring processes, and significantly reduce the number of workers required.

[0045] (5) Reduce work-in-progress and site occupancy. Assembly line production greatly reduces the backlog of work-in-progress between processes, shortens the production cycle, and saves site space.

[0046] (6) Solve the pain points of the industry, and effectively overcome the long-term unsolved problems existing in the traditional processing method, such as multiple reordering, unbalanced processes, high labor intensity, and quality fluctuations. Description of the Drawings

[0047] Figure 1 is a schematic structural diagram of a guide sleeve in the prior art.

[0048] Figure 2 is Figure 1 a sectional view of the left view of

[0049] Figure 3 is one of the perspective views of an embodiment of the automated processing system for the guide sleeve of the forklift hydraulic tilt cylinder.

[0050] Figure 4 is the second perspective view of an embodiment of the automated processing system for the guide sleeve of the forklift hydraulic tilt cylinder.

[0051] Figure 5 is a flowchart of an embodiment of the processing method for the guide sleeve of the forklift hydraulic tilt cylinder.

[0052] Description of the reference numerals in the drawings:

[0053] rack - 1; loading conveyor - 2; finished product level - 3; air blowing station - 4; robot control cabinet - 5; safety fence - 6; machine tool - 7; automated robot - 8; positioning and flipping traveling platform - 9; inspection station - 10; guide sleeve - 11; ground rail 12. Detailed Embodiments

[0054] To make the above objects, features, and advantages of the present invention more apparent and understandable, the following detailed description of the specific embodiments of the present invention will be given with reference to the accompanying drawings. Many specific details are set forth in the following description in order to fully understand the present invention. However, the present invention can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without departing from the connotation of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed below.

[0055] The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only and do not represent the only embodiment.

[0056] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art belonging to the technical field of the present invention. The terms used in the description of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more of the related listed items.

[0057] Please refer toFigures 3 to 4 。

[0058] This automatic processing system for the guide sleeve of the forklift hydraulic tilt cylinder includes a blank loading rack 1, a feeding conveyor line 2, a ground rail 12, a finished product storage position 3, a positioning and flipping follower table 9, an air blowing station 4, a safety protection fence 6, a robot control cabinet 5, an inspection station 10, an automatic robot 8, and three machine tools 7.

[0059] The blank loading rack 1 is used to receive and temporarily store the material box containing the blank guide sleeve 11, which is delivered by an AGV or other logistics equipment.

[0060] The feeding conveyor line 2 is connected to the blank loading rack 1 and is used to store a certain number of blanks to ensure the continuous operation of the production line. The feeding conveyor line 2 has sorting or buffering functions.

[0061] The finished product storage position 3 is used to store the processed finished guide sleeve 11, and the finished guide sleeve 11 is usually placed in a cleaning box or tray.

[0062] The automatic robot 8 is installed on the ground rail 12. The automatic robot 8 is the core handling equipment of the system and is usually a joint automatic robot 8. The automatic robot 8 is installed on the ground rail 12 so that it can move between the various workstations of the system. The automatic robot 8 is responsible for performing tasks such as blank grabbing, workpiece transfer between workstations (including loading onto the machine tool 7, transferring from the air blowing station 4 to the inspection station 10, etc.), and finished product unloading and stacking.

[0063] The machine tool 7 is a high-efficiency CNC lathe with an automatic door and automatic tool change function. It is preferably configured with a double spindle or a machine tool 7 with an automatic turning function to complete the main turning operations on both ends in one clamping or with the assistance of the automatic robot 8, replacing the traditional two clamps that require manual turning. It can integrate milling functions or include an independent milling unit. Several machine tools 7 are arranged beside the automatic robot 8, and several machine tools 7 are within the clamping range of the automatic robot 8.

[0064] The positioning and flipping follower table 9 is used by the automatic robot 8 to receive the blank workpiece taken from the feeding conveyor line 2, accurately position and adjust its posture, such as flipping, and identify key dimensions to achieve blank anti-mistake judgment, especially to prevent mixed materials or unqualified blanks from entering the processing.

[0065] The air blowing station 4 is used to remove residues such as cutting fluid and iron chips on the workpiece surface after key processes (such as after machining).

[0066] The safety protection fence 6 is set around the working area of the automatic robot 8 to provide safety protection.

[0067] The inspection station 10 is used to conduct automatic or semi-automatic spot checks on workpieces or finished products during the processing, and monitor the processing quality. Functions such as dimensional inspection and vision inspection can be integrated.

[0068] The robot control cabinet 5 is used to control the operation of the automated robot 8.

[0069] For this automated processing system of the forklift hydraulic tilt cylinder guide sleeve, first install the safety guardrail 6 to delimit the working area. Install the fixed incoming material rack 1, the feeding conveyor line 2, the finished product storage position 3, the air blowing station 4, the positioning and flipping follower table 9, and the inspection station 10 within the area. Install the high-efficiency CNC turning center as the machine tool 7 in place. The high-efficiency CNC turning center has double spindles, automatic tool change, and a power turret, and can complete turning and milling grooves. Install the automated robot 8 on the ground rail 12 to ensure that its working range can cover all the workstations that need to be operated. Connect the robot control cabinet 5, the control system of the machine tool 7, the inspection equipment, the pneumatic system, and the MES upper management system.

[0070] Integrate a non-contact laser distance sensor or a vision system on the positioning and flipping follower table 9 to measure the outer diameter and length of the blank. Integrate sensors on the fixture of the machine tool 7 to detect whether the workpiece is properly clamped (end face fitting). The end effector gripper of the automated robot 8 is designed to adapt to the shape of the guide sleeve 11 and may integrate a floating mechanism to compensate for minor dimensional deviations. The inspection station 10 is equipped with a pneumatic gauge or optical measurement equipment for spot checks of key dimensions. This automated processing system of the forklift hydraulic tilt cylinder guide sleeve deploys SPC software to receive and analyze the data of the inspection station 10 in real time. This automated processing system of the forklift hydraulic tilt cylinder guide sleeve also deploys an MES system to manage production orders, material information, equipment status, and quality data. The AGV system is configured to be docked with the warehouse management system, and the material information can be linked with the AGV system.

[0071] Please refer to Figure 5 , for the processing method of the forklift hydraulic tilt cylinder guide sleeve using the above-mentioned automated processing system of the forklift hydraulic tilt cylinder guide sleeve, including the following steps:

[0072] a) The blank of the forklift hydraulic tilt cylinder guide sleeve 11 is sent to the incoming material rack 1 by the AGV, and the operator takes the blank from the incoming material box and stacks it on the feeding conveyor line 2;

[0073] b) The automated robot 8 picks up the workpiece from the feeding conveyor line 2 and places it on the positioning and flipping follower table 9, positions the workpiece, identifies the outer diameter and length, and completes the blank anti-mistake judgment;

[0074] During the process, the positioning and flipping follower table 9 accurately positions and adjusts the posture of the workpiece, automatically identifies key dimensions such as its outer diameter and length, and conducts blank anti-mistake judgment. If it is qualified, continue; if it is unqualified, alarm or reject.

[0075] c) The automated robot 8 takes out the qualified blanks from the positioning and tilting pallet 9 and loads them onto the machining station of the machine tool 7 for the first automatic machining:

[0076] The machine tool 7 automatically closes the safety door and starts the machining program. The machining content for the first end of the workpiece includes: turning the end face, turning the outer diameter, boring the inner hole, chamfering, etc. The machine tool 7 automatically changes tools during the machining process.

[0077] d) Transfer and secondary machining of the workpiece according to the configuration of the machine tool 7;

[0078] The automated robot 8 opens the door of the machine tool 7, takes out the workpiece that has completed the machining of the first end. After the transfer operation, the automated robot 8 places the workpiece into the positioning and tilting pallet 9 for turning. Then, the automated robot 8 feeds the turned workpiece onto the main spindle of the machine tool 7 again for the machining of the second end. The machine tool 7 further machines the end face, outer diameter, inner hole, chamfer, thread, outer groove, etc. of the workpiece, and the machining is completed.

[0079] e) After the machining is completed, the automated robot 8 takes out the workpiece from the machine tool 7 (if independent milling is required, the automated robot 8 transfers the turned workpiece to the milling unit for loading, completes the milling of the evenly distributed wrench grooves on the end face, and then the automated robot 8 unloads the workpiece).

[0080] The workpiece is transferred to the air-blowing station 4, and compressed air is used to remove the iron chips and residual cutting fluid on the surface of the workpiece.

[0081] f) The automated robot 8 transfers the cleaned workpiece to the inspection station 10 for automatic or semi-automatic quality sampling inspection of dimensions, appearance, etc.

[0082] g) The cleaning frames are shifted and stacked in multiple layers by the automated robot 8. After the stacking is completed, the system automatically binds and codes the cleaning frames and pallets;

[0083] h) When the cleaning frames and pallets are stacked, the system automatically binds and codes the full-load cleaning frames and pallets. The system automatically calls the AGV through the MES, transports the pallet with the bound and coded finished products away from the finished product storage location 3, and sends it to the warehouse or the next process.

[0084] The above is only one implementation mode of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the principle of the present invention, several variations and improvements can be made, and these should also be regarded as belonging to the protection scope of the present invention.

Claims

1. An automated processing system for the guide sleeve of a forklift hydraulic tilt cylinder, characterized in that: It includes a raw material rack (1), a feeding conveyor line (2), a ground rail (12), a finished product bin (3), a positioning and flipping follower table (9), an automated robot (8) and several machine tools (7); The raw material rack (1) is used to receive and temporarily store the material box containing the blank guide sleeve (11); The feeding conveyor line (2) is connected to the raw material rack (1) and is used to store a certain number of blanks to ensure the continuous operation of the production line; The finished product bin (3) is used to store the processed finished guide sleeve (11); The automated robot (8) is installed on the ground rail (12) to enable the automated robot (8) to move between the various workstations of the system. The automated robot (8) is responsible for performing tasks such as blank grasping, workpiece transfer between workstations, and finished product blanking and stacking; The machine tool (7) is a high-efficiency CNC lathe with automatic door and automatic tool change functions to complete the main turning processes in one clamping or with the assistance of the automated robot (8). It can integrate milling functions or include an independent milling unit. Several machine tools (7) are all arranged beside the automated robot (8), and several machine tools (7) are all within the clamping range of the automated robot (8); The positioning and flipping follower table (9) is used by the automated robot (8) to receive the blank workpiece taken from the feeding conveyor line (2), perform precise positioning and attitude adjustment on it, and perform key dimension identification to achieve blank anti-misoperation judgment.

2. The automated processing system for the guide sleeve of a forklift hydraulic tilt cylinder according to claim 1, characterized in that: It further includes an air blowing station (4), and the air blowing station (4) is used to remove residues such as cutting fluid and iron filings on the workpiece surface after key processes.

3. The automated processing system for the guide sleeve of a forklift hydraulic tilt cylinder according to claim 1, characterized in that: It further includes a safety guardrail (6), and the safety guardrail (6) is arranged around the working area of the automated robot (8) to provide safety protection.

4. The automated processing system for the guide sleeve of a forklift hydraulic tilt cylinder according to claim 1, characterized in that: It further includes an inspection station (10), and the inspection station (10) is used to conduct spot checks on the workpieces or finished products during the processing process.

5. The automated processing system for the guide sleeve of a forklift hydraulic tilt cylinder according to claim 1, characterized in that: It further includes a robot control cabinet (5), and the robot control cabinet (5) is used to control the operation of the automated robot (8).

6. A processing method for the guide sleeve of a forklift hydraulic tilt cylinder using the automated processing system for the guide sleeve of a forklift hydraulic tilt cylinder as described in claims 1 to 5, including the following steps: a) The blank of the guide sleeve (11) of the forklift hydraulic tilt cylinder is fed to the raw material rack (1) by an AGV, and the worker takes the blank from the incoming material box and stacks it on the feeding conveyor line (2); b) The automated robot (8) takes the material from the feeding conveyor line (2) and places it on the positioning and flipping follower table (9), positions the workpiece, identifies the outer diameter and length, and completes the blank anti-misoperation judgment; c) The automated robot (8) automatically feeds the machine tool (7), and the machine tool (7) processes the end face, outer circle, inner hole, and chamfer of the workpiece; d) The automated robot (8) transfers and automatically completes the secondary loading of the machine tool (7), and the machine tool (7) further processes the outer diameter, inner hole, chamfer, thread, outer groove, etc. of the workpiece end face; e) After processing is completed, the workpiece is transferred to the air-blowing station (4) to remove iron filings and residual liquid; f) After the workpiece passes the sampling inspection, the automated robot (8) places the finished product in the cleaning frame; g) The cleaning frames are shifted and stacked in multiple layers by the automated robot (8), and after stacking is completed, the system automatically binds and codes the cleaning frames and pallets; h) The system automatically calls the AGV to transport the finished product pallet to the warehouse.

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