An online intelligent detection method and system based on spring integrated stamping parts

Abstract

The present invention relates to the technical field of spring quality inspection, and more particularly to an online intelligent inspection method and system for integrated spring stamping parts. The method comprises: marking a plurality of reference points to prepare a tapered blank; determining whether the pre-pressed inner circle is qualified based on a first ring distance standard deviation, and determining whether the pre-pressed outer circle is qualified based on a second ring distance standard deviation; adjusting the pressure distribution of the punch during the main pressing process based on a determination result based on the consistent offset of the pre-pressed inner circle and the pre-pressed outer circle; preparing a semi-finished spring, determining a plurality of cone generatrixes, and compensating for die clearance based on the angular offset ratio of the cone generatrixes; preparing a finished spring, and optimizing the pressure distribution based on the thickness standard deviation of the finished spring. The system comprises a data acquisition module for acquiring data, a data preprocessing module for preprocessing the acquired data, and a detection control module for controlling the online inspection process. The present invention improves the production quality of the spring.

Description

Technical Field

[0001] The present invention relates to the technical field of spring quality detection, and in particular to an online intelligent detection method and system based on spring integrated stamping parts. Background Art

[0002] In the integrated spring stamping process, improving the forming quality is the core goal to ensure the spring performance. Currently, traditional stamping faces multiple quality challenges. First, integrated spring forming involves complex deformation in multiple stages, including pre-stressing, final pressing, and final pressing. Material flow is significantly affected by die clearance, process parameters, and lubrication conditions, making thickness deviations prone to occur, such as uneven thickness of tapered sections, shape distortion, or internal stress concentration. Second, existing inspection methods often rely on offline three-dimensional coordinate measurement or manual spot checks, which suffer from detection lag, low efficiency, and large subjective errors. This makes it difficult to provide real-time feedback on the impact of process fluctuations on quality, leading to frequent batch defects. An intelligent inspection method is urgently needed. By integrating multiple sensors to collect key parameters during the forming process in real time and combining digital twin technology to construct a "process-deformation-quality" mapping model, quality risks can be dynamically predicted and feedback can be provided to adjust parameters such as pre-stressing pressure, final pressing and holding time, and die clearance. This method can achieve an upgrade from "post-event inspection" to "pre-event prevention and in-event control." Through data-driven intelligent decision-making, this method can significantly improve the quality stability of integrated spring forming, reduce scrap rates, and shorten production cycles. This provides technical support for the large-scale manufacturing of high-precision springs, especially automotive suspension disc springs.

[0003] Chinese patent application publication number CN117805318A discloses a testing device for in-situ spring testing, comprising a mounting assembly, a first movable seat, a controller, and a scanning and testing assembly. The first movable seat is provided with an annular bracket, which is mounted on the mounting assembly and can move on the mounting assembly along a first linear direction perpendicular to the annular bracket's annular surface. The annular bracket is configured to fit over the spring. The scanning and testing assembly is mounted on the annular bracket and can move in an annular direction around the annular bracket. The controller is electrically connected to the first movable seat and the scanning and testing assembly, respectively. This invention implements comprehensive, automated scanning and testing of springs, effectively preventing missed inspections and eliminating the need for manual scanning control. This improves spring testing accuracy while also being convenient to deploy and easy to operate.

[0004] The existing technology also has the following problems: the existing technology lacks a staged online detection process during the spring integral molding process, which will cause a lag in the spring production quality detection, thereby resulting in poor spring production quality. Summary of the Invention

[0005] To this end, the present invention provides an online intelligent detection method and system based on spring one-piece stamping parts, which is used to overcome the lack of a stage-by-stage online detection process in the spring one-piece forming process in the prior art, which will cause a lag in the spring production quality detection and thus lead to poor spring production quality.

[0006] To achieve the above objectives, the present invention provides, on the one hand, an online intelligent detection method based on a spring integral stamping part, comprising:

[0007] Marking a number of reference points at corresponding positions on the edges of the initial inner circle and the initial outer circle of the flat sheet of the spring, and pre-pressing the flat sheet to prepare a tapered sheet;

[0008] connecting the plurality of reference points of the tapered blank in the horizontal direction to obtain a pre-pressed inner circle and a pre-pressed outer circle, determining whether the pre-pressed inner circle is qualified based on a first ring distance standard deviation of the pre-pressed inner circle, and determining whether the pre-pressed outer circle is qualified based on a second ring distance standard deviation of the pre-pressed outer circle;

[0009] Under the condition that both the pre-pressed inner circle and the pre-pressed outer circle are determined to be unqualified, adjusting the pressure distribution of the punch of the punching machine during the main pressing process based on the determination result that the offsets of the pre-pressed inner circle and the pre-pressed outer circle are consistent;

[0010] The conical blank is subjected to main pressing to prepare a semi-finished spring, a plurality of reference points at corresponding positions of the inner circle and the outer circle of the semi-finished spring are connected along the side surface of the semi-finished spring to form a plurality of conical generatrixes, and a plurality of gap adjustment coefficients are determined based on a comparison result of angular offset ratios of the plurality of conical generatrixes with preset ratios, so as to compensate for die clearance during the coining process based on the plurality of gap adjustment coefficients;

[0011] The semi-finished spring is precision pressed to prepare a finished spring, and whether the spring preparation process is qualified is determined based on the thickness standard deviation of the finished spring, so as to optimize the pressure distribution under the condition that the spring preparation process is determined to be unqualified.

[0012] Furthermore, the process of determining the first ring distance standard deviation includes:

[0013] Acquiring image information of the flat blank and the tapered blank to respectively extract the initial inner circle and the pre-pressed inner circle;

[0014] Using the center of the flat blank as a reference point, the pre-pressed inner circle and the initial inner circle are overlapped to obtain a first concentric ring;

[0015] determining a plurality of first ring distances of the first concentric rings;

[0016] The standard deviation of the plurality of first ring distances is determined as a first ring distance standard deviation.

[0017] Furthermore, the process of determining the second ring distance standard deviation includes:

[0018] Acquiring image information of the flat blank and the tapered blank to respectively extract the initial outer circle and the pre-pressed outer circle;

[0019] Using the center of the flat blank as a reference point, the pre-pressed outer circle is overlapped with the initial outer circle to obtain a second concentric ring;

[0020] determining a plurality of second ring distances of the second concentric rings;

[0021] The standard deviation of the plurality of second ring distances is determined as a second ring distance standard deviation.

[0022] Furthermore, the process of determining whether the pre-pressed inner circle is qualified based on the first ring distance standard deviation includes:

[0023] Comparing the first ring distance standard deviation with a first preset standard deviation;

[0024] The pre-pressed inner circle is determined to be unqualified based on a comparison result that the first ring distance standard deviation is greater than the first preset standard deviation.

[0025] Furthermore, the process of determining whether the pre-pressed outer circle is qualified based on the second ring distance standard deviation includes:

[0026] Comparing the second ring distance standard deviation with a second preset standard deviation;

[0027] The pre-pressed outer circle is determined to be unqualified based on the comparison result that the second ring distance standard deviation is greater than the second preset standard deviation.

[0028] Furthermore, under the condition that both the pre-pressed inner circle and the pre-pressed outer circle are determined to be unqualified, the process of determining whether the offsets of the pre-pressed inner circle and the pre-pressed outer circle are consistent includes:

[0029] Determining an inner circle polar angle of a geometric center of the preloaded inner circle relative to a geometric center of the initial inner circle;

[0030] Determining the outer circle polar angle of the geometric center of the preload outer circle relative to the geometric center of the initial outer circle;

[0031] Determine the absolute difference between the inner circle polar angle and the outer circle polar angle as the polar angle difference;

[0032] comparing the polar angle difference with a preset polar angle difference;

[0033] Based on the comparison result that the polar angle difference is less than or equal to the preset polar angle difference, it is determined that the offsets of the pre-loaded inner circle and the pre-loaded outer circle are consistent.

[0034] Furthermore, the process of adjusting the pressure distribution of the punch of the punching machine based on the determination result that the offsets of the pre-pressed inner circle and the pre-pressed outer circle are consistent includes:

[0035] Using the center of the flat blank as a reference point, the pre-pressed inner circle and the pre-pressed outer circle are overlapped to obtain a third concentric ring;

[0036] A plane perpendicular to the symmetry plane of the third concentric ring is used as a dividing interface;

[0037] Determining an axis of symmetry of the third concentric ring and determining a first ring distance and a second ring distance where the axis of symmetry intersects the third concentric ring;

[0038] Comparing the distance deviation between the first ring distance and the second ring distance with a preset deviation;

[0039] Based on the comparison result of the distance deviation and the preset deviation, it is determined to increase the pressure on the side with the smaller ring distance by a corresponding pressure adjustment coefficient.

[0040] Furthermore, the process of compensating the mold gap in the coining process based on the angle offset ratio includes:

[0041] Comparing the angle offset ratio with a preset ratio;

[0042] Based on the comparison result of the angle offset ratio and the preset ratio, corresponding gap compensation coefficients are determined to compensate the mold gap according to the gap compensation coefficients.

[0043] Furthermore, the process of optimizing the pressure distribution based on the thickness standard deviation includes:

[0044] comparing the thickness standard deviation with a preset thickness standard deviation;

[0045] Determining that the spring preparation process is unqualified based on a comparison result that the thickness standard deviation is greater than the preset thickness standard deviation;

[0046] Subtracting the thickness standard deviation from the preset thickness standard deviation to obtain a standard deviation value;

[0047] comparing the standard deviation value with a preset deviation value;

[0048] A plurality of pressure optimization coefficients are determined based on a comparison result between the standard deviation value and the preset difference value, so as to optimize the pressure adjustment coefficient according to the plurality of pressure optimization coefficients.

[0049] On the other hand, the present invention also provides an online intelligent detection system based on spring integrated stamping parts, comprising:

[0050] a data acquisition module comprising a plurality of image collectors for acquiring image information of the flat blank, the tapered blank, the semi-finished spring, and the finished spring, and an ultrasonic thickness gauge for measuring the thickness of the finished spring;

[0051] a data preprocessing module connected to the data acquisition module, for determining, based on the plurality of image information, an initial inner circle and an initial outer circle of the flat blank, a pre-pressed inner circle and a pre-pressed inner circle of the tapered blank, a plurality of cone generatrixes of the semi-finished spring, and a plurality of thicknesses of the finished spring;

[0052] A detection control module, connected to the data preprocessing module, includes:

[0053] a determination unit configured to determine whether the pre-pressed inner circle is qualified based on a first ring distance standard deviation of the pre-pressed inner circle, determine whether the pre-pressed outer circle is qualified based on a second ring distance standard deviation of the pre-pressed outer circle, determine whether a die clearance in a coining process is compensated based on a ratio of angular offsets of a plurality of cone generatrixes, and determine whether a spring manufacturing process is qualified based on a thickness standard deviation of the finished spring;

[0054] An adjustment unit is used to adjust the pressure distribution of the punch of the punch press during the main pressing process based on the judgment result that the offset of the pre-pressing inner circle and the pre-pressing outer circle are consistent, to compensate for the mold gap in the coining process based on the angle offset ratio, and to optimize the pressure distribution based on the thickness standard deviation.

[0055] Compared with the prior art, the beneficial effects of the present invention are: the present invention marks the reference points of the flat blank and the pre-pressed blank, extracts the image information of the initial inner circle / outer circle and the pre-pressed inner circle / outer circle, calculates the first and second ring distance standard deviations, and uses the shape deviation of the inner circle / outer circle to achieve accurate identification of pre-pressing defects. When it is determined that the pre-pressed inner circle and the outer circle are both unqualified, the polar angle difference between the geometric centers of the inner circle and the outer circle is calculated to determine whether the offset direction is consistent. If consistent, the ring distance deviation on both sides of the symmetry axis of the third concentric ring is further analyzed, and the pressure distribution of the next stamping process is adjusted according to the deviation to reduce the ring distance deviation, thereby ensuring the symmetry of the tapered blank and avoiding local stress concentration caused by offset during the main pressing, thereby improving the production quality of the spring.

[0056] Furthermore, after the main pressing is completed, the present invention forms a conical busbar by connecting the reference points of the inner circle / outer circle of the semi-finished spring, calculates the angle offset ratio, and determines the gap compensation coefficient based on the comparison result with the preset ratio. For defects such as busbar torsion and local thinning, the mold gap in the precision pressing process is accurately compensated to further correct the busbar straightness, significantly improve the geometric accuracy and stability of the spring, avoid assembly failure or fatigue life reduction due to busbar deviation, and thus further improve the production quality of the spring.

[0057] Furthermore, the precision stamping process of the present invention measures the thickness standard deviation of the finished spring and adjusts the stamping process of the next spring based on the feedback of real-time thickness data, thereby ensuring the uniformity of the thickness of the finished spring and avoiding batch deviations caused by material rebound or mold wear, thereby further improving the production quality of the spring. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] Figure 1 This is a flow chart of an online intelligent detection method based on a spring integrated stamping part according to an embodiment of the present invention;

[0059] Figure 2 A flowchart of determining whether the offsets of the pre-loaded inner circle and the pre-loaded outer circle are consistent according to an embodiment of the present invention;

[0060] Figure 3 A flow chart of determining whether a spring preparation process is qualified according to an embodiment of the present invention;

[0061] Figure 4 This is a structural block diagram of an online intelligent detection system based on spring integrated stamping parts according to an embodiment of the present invention. DETAILED DESCRIPTION

[0062] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention.

[0063] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0064] It should be noted that, in the description of the present invention, terms such as "up", "down", "left", "right", "inside", and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation on the present invention.

[0065] Furthermore, it should be noted that, in the description of the present invention, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0066] See also Figure 1-Figure 3 As shown, Figure 1 This is a flow chart of an online intelligent detection method based on a spring integrated stamping part according to an embodiment of the present invention; Figure 2 A flowchart of determining whether the offsets of the pre-loaded inner circle and the pre-loaded outer circle are consistent according to an embodiment of the present invention; Figure 3 The present invention is a flowchart for determining whether the spring preparation process is qualified.

[0067] The embodiment of the present invention is based on an online intelligent detection method for spring integrated stamping parts, comprising:

[0068] Step S1, marking a number of reference points at corresponding positions on the edges of the initial inner circle and the initial outer circle of the flat sheet of the spring, and pre-pressing the flat sheet to prepare a tapered sheet;

[0069] Step S2, connecting the plurality of reference points of the tapered blank in the horizontal direction to obtain a pre-pressed inner circle and a pre-pressed outer circle, determining whether the pre-pressed inner circle is qualified based on a first ring distance standard deviation of the pre-pressed inner circle, and determining whether the pre-pressed outer circle is qualified based on a second ring distance standard deviation of the pre-pressed outer circle;

[0070] Step S3, under the condition that both the pre-pressed inner circle and the pre-pressed outer circle are determined to be unqualified, adjusting the pressure distribution of the punch of the punch during the main pressing process based on the determination result that the offsets of the pre-pressed inner circle and the pre-pressed outer circle are consistent;

[0071] Step S4: performing a main pressing on the conical blank to produce a semi-finished spring, connecting a plurality of reference points at corresponding positions on the inner circle and outer circle of the semi-finished spring along the side of the semi-finished spring to form a plurality of conical generatrixes, and determining a plurality of gap adjustment coefficients based on a comparison result of angular offset ratios of the plurality of conical generatrixes with preset ratios, so as to compensate for die clearance during the coining process according to the plurality of gap adjustment coefficients;

[0072] Step S5, coining the semi-finished spring to prepare a finished spring, determining whether the spring preparation process is qualified based on the thickness standard deviation of the finished spring, and optimizing the pressure distribution under the condition that the spring preparation process is determined to be unqualified.

[0073] Specifically, during the integrated stamping and forming process of springs, especially disc springs, stamping is usually not performed in just one pass. Instead, the same set of dies is used to pressurize the flat blank in stages, with different pressures applied each time, to eventually form the blank. Because disc spring materials (such as 60Si2MnA, 50CrVA, etc.) must have high strength limits, elastic limits, and fatigue limits, a single high-pressure stamping will lead to uneven stress distribution within the material, forming local stress concentration areas, inducing microcracks or deepening of the decarburization layer. By gradually increasing the pressure, the plastic deformation of the material is more uniform, reducing the accumulation of residual stress and the risk of cracking. At the same time, disc springs have extremely high requirements for dimensional accuracy. After the metal sheet is unloaded under a single high pressure, the elastic recovery is more significant, causing the final shape to deviate from the design. The stepwise pressurization gradually consumes the elastic deformation energy through the intermediate stress release step, significantly reducing the amount of springback.

[0074] Specifically, the disc spring flat plate blank is a circular metal flat plate of equal thickness and concentricity, which is prepared by precision punching by a high-speed punch press.

[0075] It can be understood that several reference points are marked at corresponding positions on the edges of the initial inner circle and the initial outer circle of the flat blank. The corresponding positions refer to the alignment points of the initial inner circle and the outer circle edges of the flat blank in the same radial direction. Specifically, with the geometric center of the flat blank as the reference, a radial straight line is drawn along the radial direction from the center of the circle to a certain point on the edge of the inner circle. The intersection of this straight line to the edge of the outer circle and the edge of the inner circle is the reference point of the corresponding position of the inner circle and the outer circle.

[0076] Specifically, the reference points can be set at equal angular intervals along the circumference, for example, a reference point can be set every 30°. The reference points need to be marked at the vertex position of the edge of the blank. The marking method can be laser marking, which is not limited to a specific method, as long as the marking does not affect the processing accuracy of the disc spring.

[0077] It can be understood that the reference points are characteristic points marked on the surface of the flat blank, and their positions will change significantly due to the plastic deformation of the material during the stamping process of the flat blank. However, under ideal conditions, several reference points of the inner circle and the outer circle are still on the same horizontal plane, the connecting lines are still standard circles, and the connecting lines at corresponding positions are still along the same radial direction.

[0078] Specifically, the process of determining the first ring distance standard deviation includes:

[0079] Acquiring image information of the flat blank and the tapered blank to respectively extract the initial inner circle and the pre-pressed inner circle;

[0080] Using the center of the flat blank as a reference point, the pre-pressed inner circle and the initial inner circle are overlapped to obtain a first concentric ring;

[0081] determining a plurality of first ring distances of the first concentric rings;

[0082] The standard deviation of the plurality of first ring distances is determined as a first ring distance standard deviation.

[0083] Specifically, the process of determining the second ring distance standard deviation includes:

[0084] Acquiring image information of the flat blank and the tapered blank to respectively extract the initial outer circle and the pre-pressed outer circle;

[0085] Using the center of the flat blank as a reference point, the pre-pressed outer circle is overlapped with the initial outer circle to obtain a second concentric ring;

[0086] determining a plurality of second ring distances of the second concentric rings;

[0087] The standard deviation of the plurality of second ring distances is determined as a second ring distance standard deviation.

[0088] It can be understood that the first ring distance, the second ring distance and the third ring distance are all distances between the inner circle and the outer circle along the radial direction.

[0089] It can be understood that the process of extracting the initial inner circle, the initial outer circle, the pre-pressed inner circle and the pre-pressed outer circle according to the image information is as follows:

[0090] After the image information is processed by grayscale, denoising, enhancement and other processes, several dimensions of each circle are extracted and modeled. The modeling method is the existing technology and will not be described in detail here.

[0091] It can be understood that the comparison of the circles in the embodiment of the present invention is performed based on the established model.

[0092] Specifically, the process of determining whether the pre-pressed inner circle is qualified based on the first ring distance standard deviation includes:

[0093] Comparing the first ring distance standard deviation with a first preset standard deviation;

[0094] Determining that the preload inner circle is unqualified based on a comparison result that the first ring distance standard deviation is greater than the first preset standard deviation;

[0095] The pre-pressed inner circle is determined to be qualified based on a comparison result that the first ring distance standard deviation is less than or equal to the first preset standard deviation.

[0096] Specifically, the value range of the first preset standard deviation is set to [0.05 mm, 0.1 mm], and is preferably 0.08 mm in the embodiment of the present invention.

[0097] It can be understood that a larger standard deviation of the first ring distance indicates a greater degree of dispersion of the ring distances, a greater degree of deviation of the pre-pressed inner circle from the standard circle, and a greater degree of deviation of the state of the blank during the stamping process from the ideal state.

[0098] Specifically, the process of determining whether the pre-pressed outer circle is qualified based on the second ring distance standard deviation includes:

[0099] Comparing the second ring distance standard deviation with a second preset standard deviation;

[0100] Determining that the preloaded outer circle is unqualified based on a comparison result that the second ring distance standard deviation is greater than the second preset standard deviation;

[0101] The pre-pressed outer circle is determined to be qualified based on a comparison result that the second ring distance standard deviation is less than or equal to the second preset standard deviation.

[0102] Specifically, the value range of the second preset standard deviation is set to [0.08 mm, 0.12 mm], and 0.1 mm is preferred in the embodiment of the present invention.

[0103] It can be understood that a larger standard deviation of the second ring distance indicates a greater degree of dispersion of the ring distances, a greater degree of deviation of the pre-pressed outer circle from the standard circle, and a greater degree of deviation of the state of the blank during the stamping process from the ideal state.

[0104] Specifically, under the condition that both the pre-pressed inner circle and the pre-pressed outer circle are determined to be unqualified, the process of determining whether the offsets of the pre-pressed inner circle and the pre-pressed outer circle are consistent includes:

[0105] Determining an inner circle polar angle of a geometric center of the preloaded inner circle relative to a geometric center of the initial inner circle;

[0106] Determining the outer circle polar angle of the geometric center of the preload outer circle relative to the geometric center of the initial outer circle;

[0107] Determine the absolute difference between the inner circle polar angle and the outer circle polar angle as the polar angle difference;

[0108] comparing the polar angle difference with a preset polar angle difference;

[0109] Determining that the offsets of the preload inner circle and the preload outer circle are consistent based on a comparison result that the polar angle difference is less than or equal to the preset polar angle difference;

[0110] Based on the comparison result that the polar angle difference is greater than the preset polar angle difference, it is determined that the offsets of the pre-loaded inner circle and the pre-loaded outer circle are inconsistent.

[0111] Specifically, the polar angle refers to the angle between the line connecting the geometric center of the inner circle or outer circle after preloading and the initial center of the circle and the horizontal direction.

[0112] Specifically, the value range of the preset polar angle difference is set to [3°, 6°], and 5° is preferred in the embodiment of the present invention.

[0113] Specifically, during the stamping process of the blank, the material flow is constrained by the mold cavity, and the deformation of the inner circle and the outer circle must meet the symmetry requirements: the inner circle is radially offset due to axial compression (toward the center of the mold); the outer circle is radially expanded due to volume conservation (away from the center of the mold). Ideally, the deformation directions of the two should be strictly symmetrical (that is, the polar angles are the same), so the polar angle difference is 0°. If the polar angle difference exceeds 5°, it means that there is a directional deviation in the material flow or mold constraint, and the offset direction is not synchronized. For example, the inner circle offsets to the left and the outer circle offsets to the right. If the polar angle difference is less than or equal to 5°, the offset directions of the inner circle and the outer circle are synchronized, and both offset to the left or right or forward or backward.

[0114] Specifically, the process of adjusting the pressure distribution of the punch of the punching machine based on the result of determining that the offsets of the pre-pressed inner circle and the pre-pressed outer circle are consistent includes:

[0115] Using the center of the flat blank as a reference point, the pre-pressed inner circle and the pre-pressed outer circle are overlapped to obtain a third concentric ring;

[0116] Determining an axis of symmetry of the third concentric ring and determining a first ring distance and a second ring distance where the axis of symmetry intersects the third concentric ring;

[0117] Comparing the distance deviation between the first ring distance and the second ring distance with a preset deviation;

[0118] Based on the comparison result of the distance deviation and the preset deviation, determining to increase the pressure on the side with the smaller ring distance by a corresponding pressure adjustment coefficient;

[0119] Specifically, based on the comparison result that the distance deviation is greater than the preset deviation, it is determined that the pressure on the side with the smaller ring distance is increased by a first pressure adjustment coefficient;

[0120] Based on the comparison result that the distance deviation is less than or equal to the preset deviation, it is determined to increase the pressure on the side with the smaller ring distance by a second pressure adjustment coefficient.

[0121] Specifically, the value range of the preset deviation is set to [0.8mm, 1.5mm], and the embodiment of the present invention is preferably 1mm; the value range of the first pressure adjustment coefficient is set to [1.05, 1.07], and the embodiment of the present invention is preferably 1.06; the value range of the second pressure adjustment coefficient is set to [1.02, 1.04], and the embodiment of the present invention is preferably 1.03.

[0122] Specifically, the greater the stamping pressure, the greater the deformation of the material and the larger the ring distance.

[0123] Specifically, the process of determining the angle offset ratio includes:

[0124] For a single cone busbar, determining an offset angle between the single cone busbar and the corresponding initial busbar;

[0125] comparing the offset angle with a preset angle;

[0126] The percentage of the number of cone busbars whose offset angle is smaller than the preset angle to the total number of cone busbars is determined as the angle offset ratio.

[0127] It can be understood that the offset angle between a single cone busbar and the corresponding initial busbar is the angle between the extension lines of the two cone busbars.

[0128] Specifically, the value range of the preset angle is set to [10°, 20°], and 15° is preferred in the embodiment of the present invention.

[0129] Specifically, the process of compensating the mold gap during the coining process based on the angle offset ratio includes:

[0130] Comparing the angle offset ratio with a preset ratio;

[0131] Determining corresponding gap compensation coefficients based on a comparison result of the angle offset ratio and the preset ratio, so as to compensate the mold gap according to the gap compensation coefficients;

[0132] Specifically, based on a comparison result that the angle offset ratio is greater than the preset ratio, it is determined that the mold gap is increased by a first gap compensation coefficient;

[0133] Based on a comparison result that the angle offset ratio is less than or equal to the preset ratio, it is determined that the mold gap is increased by a second gap compensation coefficient.

[0134] Specifically, the value range of the preset proportion is set to [55%, 70%], and the preferred embodiment of the present invention is 60%; the value range of the first gap compensation coefficient is set to [1.12, 1.15], and the preferred embodiment of the present invention is 1.13; the value range of the second gap compensation coefficient is set to [1.08, 1.11], and the preferred embodiment of the present invention is 1.1.

[0135] Specifically, during the stamping process of disc springs, the angle of the cone busbar is offset. Its essence is the abnormal local plastic deformation caused by uneven material flow or mold constraints. Appropriately increasing the mold gap can adjust the geometric constraints of the mold cavity, optimize the material flow path, reduce deformation resistance, and ultimately achieve the linearization of the busbar.

[0136] Specifically, the process of optimizing the pressure distribution based on the thickness standard deviation includes:

[0137] comparing the thickness standard deviation with a preset thickness standard deviation;

[0138] Determining that the spring preparation process is unqualified based on a comparison result that the thickness standard deviation is greater than the preset thickness standard deviation;

[0139] Subtracting the thickness standard deviation from the preset thickness standard deviation to obtain a standard deviation value;

[0140] comparing the standard deviation value with a preset deviation value;

[0141] A plurality of pressure optimization coefficients are determined based on a comparison result between the standard deviation value and the preset difference value, so as to optimize the pressure adjustment coefficient according to the plurality of pressure optimization coefficients.

[0142] Specifically, based on the comparison result that the standard deviation value is greater than or equal to the preset difference value, it is determined to reduce the pressure adjustment coefficient by the first pressure optimization coefficient;

[0143] Based on a comparison result that the standard deviation is greater than or equal to the preset difference, it is determined to reduce the pressure adjustment coefficient by the first pressure optimization coefficient.

[0144] Specifically, the value range of the preset difference is set to [0.02mm, 0.04mm], and the embodiment of the present invention preferably prefers 0.03mm; the value range of the first pressure optimization coefficient is set to [0.88, 0.92], and the embodiment of the present invention preferably prefers 0.9; the value range of the second pressure optimization coefficient is set to [0.93, 0.96], and the embodiment of the present invention preferably prefers 0.95.

[0145] Specifically, the thickness standard deviation is the standard deviation of the thickness at several locations on the conical side of the disc spring.

[0146] See also Figure 4 As shown in FIG, it is a structural block diagram of an online intelligent detection system based on spring integrated stamping parts according to an embodiment of the present invention.

[0147] The embodiment of the present invention is based on an online intelligent detection system for spring integrated stamping parts, comprising:

[0148] a data acquisition module comprising a plurality of image collectors for acquiring image information of the flat blank, the tapered blank, the semi-finished spring, and the finished spring, and an ultrasonic thickness gauge for measuring the thickness of the finished spring;

[0149] a data preprocessing module connected to the data acquisition module, for determining, based on the plurality of image information, an initial inner circle and an initial outer circle of the flat blank, a pre-pressed inner circle and a pre-pressed inner circle of the tapered blank, a plurality of cone generatrixes of the semi-finished spring, and a plurality of thicknesses of the finished spring;

[0150] A detection control module, connected to the data preprocessing module, includes:

[0151] a determination unit configured to determine whether the pre-pressed inner circle is qualified based on a first ring distance standard deviation of the pre-pressed inner circle, determine whether the pre-pressed outer circle is qualified based on a second ring distance standard deviation of the pre-pressed outer circle, determine whether a die clearance in a coining process is compensated based on a ratio of angular offsets of a plurality of cone generatrixes, and determine whether a spring manufacturing process is qualified based on a thickness standard deviation of the finished spring;

[0152] An adjustment unit is used to adjust the pressure distribution of the punch of the punch press during the main pressing process based on the judgment result that the offset of the pre-pressing inner circle and the pre-pressing outer circle are consistent, to compensate for the mold gap in the coining process based on the angle offset ratio, and to optimize the pressure distribution based on the thickness standard deviation.

[0153] Specifically, the image collector is, for example, an industrial camera, and the specific model is not limited, as long as it meets the detection requirements.

[0154] Specifically, the ultrasonic thickness gauge is, for example, Olympus 38DLPLUS, and the specific model is not limited, as long as it meets the detection requirements.

[0155] Thus far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art may make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will fall within the scope of protection of the present invention.

Claims

1. An online intelligent detection method based on spring integrated stamping parts, characterized in that: include: Marking a number of reference points at corresponding positions on the edges of the initial inner circle and the initial outer circle of the flat sheet of the spring, and pre-pressing the flat sheet to prepare a tapered sheet; connecting the plurality of reference points of the tapered blank in the horizontal direction to obtain a pre-pressed inner circle and a pre-pressed outer circle, determining whether the pre-pressed inner circle is qualified based on a first ring distance standard deviation of the pre-pressed inner circle, and determining whether the pre-pressed outer circle is qualified based on a second ring distance standard deviation of the pre-pressed outer circle; Under the condition that both the pre-pressed inner circle and the pre-pressed outer circle are determined to be unqualified, adjusting the pressure distribution of the punch of the punching machine during the main pressing process based on the determination result that the offsets of the pre-pressed inner circle and the pre-pressed outer circle are consistent; The conical blank is subjected to main pressing to prepare a semi-finished spring, a plurality of reference points at corresponding positions of the inner circle and the outer circle of the semi-finished spring are connected along the side surface of the semi-finished spring to form a plurality of conical generatrixes, and a plurality of gap adjustment coefficients are determined based on a comparison result of angular offset ratios of the plurality of conical generatrixes with preset ratios, so as to compensate for die clearance during the coining process based on the plurality of gap adjustment coefficients; coining the semi-finished spring to prepare a finished spring, and determining whether the spring preparation process is qualified based on a thickness standard deviation of the finished spring, so as to optimize the pressure distribution if the spring preparation process is determined to be unqualified; The process of determining the first ring distance standard deviation includes: Acquiring image information of the flat blank and the tapered blank to respectively extract the initial inner circle and the pre-pressed inner circle; Using the center of the flat blank as a reference point, the pre-pressed inner circle and the initial inner circle are overlapped to obtain a first concentric ring; determining a plurality of first ring distances of the first concentric rings; Determine the standard deviation of the plurality of first ring distances as a first ring distance standard deviation; The process of determining the second ring distance standard deviation includes: Acquiring image information of the flat blank and the tapered blank to respectively extract the initial outer circle and the pre-pressed outer circle; Using the center of the flat blank as a reference point, the pre-pressed outer circle is overlapped with the initial outer circle to obtain a second concentric ring; determining a plurality of second ring distances of the second concentric rings; Determine the standard deviation of the plurality of second ring distances as a second ring distance standard deviation; The process of determining whether the pre-pressed inner circle is qualified based on the first ring distance standard deviation includes: Comparing the first ring distance standard deviation with a first preset standard deviation; Determining that the preload inner circle is unqualified based on a comparison result that the first ring distance standard deviation is greater than the first preset standard deviation; The process of determining whether the preloaded outer circle is qualified based on the second ring distance standard deviation includes: Comparing the second ring distance standard deviation with a second preset standard deviation; The pre-pressed outer circle is determined to be unqualified based on the comparison result that the second ring distance standard deviation is greater than the second preset standard deviation.

2. The online intelligent detection method based on spring integrated stamping parts according to claim 1 is characterized in that: Under the condition that both the pre-pressed inner circle and the pre-pressed outer circle are determined to be unqualified, the process of determining whether the offsets of the pre-pressed inner circle and the pre-pressed outer circle are consistent includes: Determining an inner circle polar angle of a geometric center of the preloaded inner circle relative to a geometric center of the initial inner circle; Determining the outer circle polar angle of the geometric center of the preload outer circle relative to the geometric center of the initial outer circle; Determine the absolute difference between the inner circle polar angle and the outer circle polar angle as the polar angle difference; comparing the polar angle difference with a preset polar angle difference; Based on the comparison result that the polar angle difference is less than or equal to the preset polar angle difference, it is determined that the offsets of the pre-loaded inner circle and the pre-loaded outer circle are consistent.

3. The online intelligent detection method based on spring integrated stamping parts according to claim 2 is characterized in that: The process of adjusting the pressure distribution of the punch of the punching machine based on the result of determining that the offsets of the pre-pressed inner circle and the pre-pressed outer circle are consistent includes: Using the center of the flat blank as a reference point, the pre-pressed inner circle and the pre-pressed outer circle are overlapped to obtain a third concentric ring; A plane perpendicular to the symmetry plane of the third concentric ring is used as a dividing interface; Determining an axis of symmetry of the third concentric ring and determining a first ring distance and a second ring distance where the axis of symmetry intersects the third concentric ring; Comparing the distance deviation between the first ring distance and the second ring distance with a preset deviation; Based on the comparison result of the distance deviation and the preset deviation, it is determined to increase the pressure on the side with the smaller ring distance by a corresponding pressure adjustment coefficient.

4. The online intelligent detection method based on spring integrated stamping parts according to claim 3 is characterized in that: The process of compensating the die gap during the coining process based on the angle offset ratio includes: Comparing the angle offset ratio with a preset ratio; Based on the comparison result of the angle offset ratio and the preset ratio, corresponding gap compensation coefficients are determined to compensate the mold gap according to the gap compensation coefficients.

5. The online intelligent detection method based on spring integrated stamping parts according to claim 4 is characterized in that: The process of optimizing the pressure distribution based on the thickness standard deviation includes: comparing the thickness standard deviation with a preset thickness standard deviation; Determining that the spring preparation process is unqualified based on a comparison result that the thickness standard deviation is greater than the preset thickness standard deviation; Subtracting the thickness standard deviation from the preset thickness standard deviation to obtain a standard deviation value; comparing the standard deviation value with a preset deviation value; A plurality of pressure optimization coefficients are determined based on a comparison result between the standard deviation value and the preset difference value, so as to optimize the pressure adjustment coefficient according to the plurality of pressure optimization coefficients.

6. An online intelligent detection system using the online intelligent detection method based on spring integrated stamping parts according to any one of claims 1 to 5, characterized in that: include: a data acquisition module comprising a plurality of image collectors for acquiring image information of the flat blank, the tapered blank, the semi-finished spring, and the finished spring, and an ultrasonic thickness gauge for measuring the thickness of the finished spring; a data preprocessing module connected to the data acquisition module, for determining, based on the plurality of image information, an initial inner circle and an initial outer circle of the flat blank, a pre-stressed inner circle and a pre-stressed outer circle of the tapered blank, a plurality of cone generatrixes of the semi-finished spring, and a plurality of thicknesses of the finished spring; A detection control module, which is connected to the data preprocessing module, include, a determination unit configured to determine whether the pre-pressed inner circle is qualified based on a first ring distance standard deviation of the pre-pressed inner circle, determine whether the pre-pressed outer circle is qualified based on a second ring distance standard deviation of the pre-pressed outer circle, determine whether a die clearance in a coining process is compensated based on a ratio of angular offsets of a plurality of cone generatrixes, and determine whether a spring manufacturing process is qualified based on a thickness standard deviation of the finished spring; An adjustment unit is used to adjust the pressure distribution of the punch of the punch press during the main pressing process based on the judgment result that the offset of the pre-pressing inner circle and the pre-pressing outer circle are consistent, to compensate for the mold gap in the coining process based on the angle offset ratio, and to optimize the pressure distribution based on the thickness standard deviation.

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