Detection device for preventing forming machine sub-opening feeding frame guide rail from being separated from sliding block

Abstract

The invention relates to the technical field of forming machine feeding frame detection, in particular to a detection device for preventing a forming machine sub-opening feeding frame guide rail from being separated from a sliding block, which comprises a hydraulic buffer and a proximity switch alarm system. The hydraulic buffers are installed at the two ends of the rear side of the feeding frame and absorb vibration energy through hydraulic damping. The proximity switch alarm system is linked with the PLC through a non-contact inductance type proximity switch, and loosening early warning and shutdown protection are achieved. Looseness of the cylinder hoop can be monitored in real time, vibration impact is reduced, hard separation of the guide rail and the sliding block is avoided, the operation stability of equipment is improved, the fault shutdown time is shortened, and the production efficiency and economic benefits are remarkably improved.

Description

Technical Field

[0001] The invention belongs to the technical field of molding machine equipment, and in particular relates to a detection device for preventing a guide rail of a molding machine feeder frame from being disengaged from a slide block. Background Art

[0002] In the tire building machine production process, the feeder frame is a critical component, and its stable operation has a significant impact on the overall performance and production efficiency of the equipment. Existing building machine feeders are typically mounted at an angle and driven by a centrally located cylinder. However, in actual operation, due to adverse environmental factors such as high-frequency vibration and dust accumulation, the cylinder clamp fixing screws are prone to loosening. These screws are hidden within the mounting gap between the feeder frame and the cylinder, making initial signs of loosening difficult to detect during visual inspection, resulting in the problem often going undetected. When the cylinder clamp loosens, the overall stability of the cylinder decreases, and the inertial impact force generated by its telescopic movement is not effectively restrained. Vibration energy is directly transmitted to the feeder frame through the bracket. Test data shows that the vibration amplitude of the cylinder in the loose state increases by 30%-50% compared to the normal state, and the vibration frequency approaches the natural frequency of the feeder frame, which is highly likely to induce resonance. This continuous vibration causes the feeder frame to gradually move downward, widening the clearance between the bottom guide rail and the slider, and ultimately causing the guide rail and slider to disconnect. Under instantaneous impact loads, the slider exceeds the material's yield strength, causing fracture or severe wear. According to production records, this type of failure occurs on average once a month, with a single repair taking approximately 5-6 hours, severely impacting the continuity of the production line and overall productivity. Therefore, effectively monitoring cylinder clamp loosening and suppressing vibration transmission became a pressing technical challenge. Summary of the Invention

[0003] The present invention addresses a series of problems caused by loosening of the cylinder clamp fixing screws on the left and right feed racks of existing molding machines, including but not limited to defects such as vibration energy conduction, mechanical damage chain, and delayed fault warning. To this end, the present invention adopts the following technical solutions:

[0004] This invention provides a detection device for preventing the disengagement of the guide rail and slider of a forming machine's feeder rack. This device utilizes a dual mechanism of "buffered energy absorption + intelligent early warning" to provide real-time monitoring and early warning of cylinder clamp loosening, thereby improving equipment operational stability and reducing downtime. The detection device comprises a hydraulic buffer and a proximity switch alarm system, which are used to absorb vibration energy and trigger a warning signal in the event of loosening, respectively.

[0005] Furthermore, the hydraulic buffer is installed at both ends of the rear side of the left and right sub-mouth feed racks. The axis of the buffer piston rod is parallel to the direction of movement of the feed rack, its stroke is set to 20mm, and the maximum energy absorption is 500J. When the feed rack moves backward due to loosening of the cylinder clamp, the buffer first contacts the frame and absorbs the vibration energy through hydraulic damping, reducing the impact speed and avoiding hard collisions. The buffer design ensures that the vibration energy is fully absorbed when the displacement reaches within 20mm, and the energy is dissipated through the flow of hydraulic medium, controlling the impact force within the allowable range of the feed rack material.

[0006] Specifically, the proximity switch alarm system includes a non-contact inductive proximity switch, an alarm, a PLC control system, and an equipment operation interface. The proximity switch is mounted on the rear bracket of the feeder rack, with a detection distance set to 5mm, and the detection surface facing the metal sensor on the back of the feeder rack. When the feeder rack moves back more than 5mm, the proximity switch triggers a signal and interacts with the PLC control system to perform the following actions:

[0007] S1: Send a command to the alarm, light up the red alarm light and trigger the buzzer to continue the alarm;

[0008] S2: The warning message "The cylinder of the feed rack at the sub-mouth is loose and needs to be shut down for maintenance" is displayed on the equipment operation interface;

[0009] S3: After a delay of 5 seconds, the feeder drive motor is automatically paused to prevent the fault from escalating. The response time of the alarm system is set to ≤ 0.3 seconds, ensuring that loosening is detected and measures can be taken in the early stages.

[0010] Furthermore, the installation and commissioning of the hydraulic buffer and proximity switch alarm system must meet the following conditions:

[0011] The buffer positioning uses a laser rangefinder to ensure that the left and right buffers are installed at the same height, with an error of no more than 0.5mm, to prevent the feeder rack from tilting due to uneven force. The proximity switch calibration uses a standard gauge block to adjust the initial spacing between the sensor and the switch, simulating loose displacement to test the accuracy of the signal triggering and ensure reliable operation when the displacement reaches 5mm. In addition, the linkage test manually simulates the loose state of the cylinder clamp to observe the alarm system response time, the buffer's vibration absorption effect, and the reliability of the equipment's shutdown logic.

[0012] Furthermore, the vibration absorption effect of the buffer requires that the vibration amplitude be attenuated by ≥60%, and the peak vibration acceleration of the feeder rack be reduced from 15g to below 6g, which is lower than the allowable impact load of the slider material. This vibration absorption process is based on the compression and expansion characteristics of the hydraulic medium. The flow rate is adjusted through internal orifices to achieve precise control of the damping force, effectively suppressing the impact vibration of the feeder rack.

[0013] Specifically, the proximity switch's linkage mechanism with the PLC control system transmits the proximity switch's output signal to the PLC via a digital signal processing module. The PLC then determines whether to trigger an alarm and shut down the machine based on pre-set logic. The digital signal processing module's sampling frequency is 1kHz, ensuring real-time and accurate signal acquisition. Furthermore, the alarm system's linkage with the feeder's drive motor is achieved via a relay with a contact capacity of 10A / 250VAC, meeting the high reliability requirements of industrial environments.

[0014] Furthermore, the detection device addresses the vibration transmission mechanism caused by loose cylinder clamps. In conventional structures, when the cylinder clamps become loose, the inertial impact force generated by the cylinder's telescopic movement cannot be effectively restrained. Vibration energy is transmitted directly to the feed rack through the bracket, increasing the amplitude by 30%-50% and inducing a resonance effect. The present invention incorporates a buffer, which decomposes the impact force into the internal energy consumption of the hydraulic medium, significantly reducing the efficiency of vibration energy transmission.

[0015] In particular, the detection device also solves the problem of mechanical damage chains. In conventional structures, continuous vibration causes the feeder to gradually move downward, widening the clearance between the guide rail and the slider, ultimately leading to a hard disconnection. The present invention uses a proximity switch alarm system for real-time monitoring, issuing an early warning when the displacement reaches 5mm, prompting maintenance personnel to conduct repairs and preventing the slider from being subjected to instantaneous impact loads exceeding the material's yield strength, leading to breakage or severe wear.

[0016] Furthermore, the technical effects of the detection device are as follows:

[0017] The improved fault warning capability is demonstrated by the proximity switch and alarm system, which now enables real-time monitoring and early warning of loose cylinder clamps. This shortens fault detection time from traditional periodic inspections to immediate response, preventing slide damage caused by untimely detection of looseness. The enhanced operational stability of the equipment is demonstrated by the introduction of a buffer, which effectively suppresses the impact vibration of the feeder rack. Simulation calculations show that the peak vibration acceleration of the feeder rack has been reduced from 15g to below 6g, which is below the allowable impact load of the slide material. This significantly extends the service life of precision components such as the guide rails and slides, and significantly improves the equipment's mean time between failures (MTBF). The improved production efficiency is demonstrated by reducing downtime and maintenance frequency, increasing the effective operating time of a single production line by approximately 60-72 hours per year. Based on an hourly production capacity of 18 tire blanks, the annual production capacity can be increased by 1,080 to 1,296 tires per unit. Based on a net profit of 300 yuan per tire blank, the direct economic benefits are approximately 324,000 to 388,800 yuan per unit.

[0018] In particular, future development directions for this detection device include integrating vibration sensors with IoT technology to enable remote, real-time monitoring of equipment status. By deploying a vibration sensor array to collect vibration signals from the feeder rack and leveraging edge computing technology for real-time data analysis, the accuracy and efficiency of fault diagnosis can be further improved. Furthermore, a regular inspection and sensor calibration system will be established to ensure long-term, reliable system operation.

[0019] In summary, the present invention solves a series of problems caused by loose cylinder fixation of the feeding rack of the molding machine through the dual mechanism of "buffering energy absorption + intelligent early warning". It has both technical feasibility and economic rationality, and has significant application value and promotion prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 This is a schematic diagram of the installation position of the hydraulic buffer of the present invention;

[0021] Figure 2 This is a detailed diagram of the stroke setting of the hydraulic buffer of the present invention;

[0022] Figure 3 It is a schematic diagram of the overall structural layout of the present invention;

[0023] Figure 4 This is a schematic diagram of the installation position and detection distance of the proximity switch of the present invention;

[0024] Figure 5 This is a diagram illustrating the screw positions and maintenance difficulty of the present invention;

[0025] Figure 6 Schematic diagram of the linkage mechanism between the hydraulic buffer and the proximity switch of the present invention;

[0026] Figure 7 This is a schematic diagram of the installation position of the voice-controlled alarm light of the present invention;

[0027] Figure 8 This is a control logic flow chart of the present invention.

[0028] The reference numerals are as follows:

[0029] 1. Left and right feed racks; 2. Hydraulic buffer; 3. Proximity switch; 4. Voice-activated alarm light; 5. Metal sensor; 6. Cylinder; 7. Bracket; 8. Screws; 9. PLC control system; 10. Equipment operation interface; 11. Alarm; 12. Feed rack drive motor. DETAILED DESCRIPTION

[0030] This invention provides a detection device for preventing the disengagement of the guide rail and slider of a forming machine's feeder. Its core principle is to achieve real-time monitoring and early warning of cylinder clamp loosening through the dual mechanisms of a hydraulic buffer and a proximity switch alarm system. The following describes the technical solution of this invention in detail with reference to the accompanying drawings and specific embodiments.

[0031] exist Figure 1 The installation position of the hydraulic buffer 2 is shown in the figure, which is located at the rear ends of the left and right sub-mouth feed racks 1. The piston rod axis of the hydraulic buffer 2 remains parallel to the movement direction of the feed rack 1 to ensure that the buffering force is evenly distributed. The buffer stroke is set to 20mm, and the maximum absorbed energy is 500J. This parameter design is based on the maximum displacement of the feed rack 1 that may occur when the cylinder 6 is loose and the calculation results of the impact energy. The buffer is filled with hydraulic medium. When the feed rack 1 moves backward due to the loosening of the cylinder 6 clamp, the buffer 2 first contacts the frame and absorbs the vibration energy through hydraulic damping. The hydraulic medium forms a damping force under the action of the throttle hole, decomposing the impact force into internal energy consumption, thereby effectively reducing the impact speed of the feed rack 1 and avoiding hard collisions. Experimental data show that the buffer can reduce the peak vibration acceleration of the feed rack 1 from 15g to below 6g, which is significantly lower than the allowable impact load of the slider material.

[0032] Figure 3 The overall structural layout is further shown, in which the hydraulic buffer 2 and the proximity switch 3 together constitute the core components of the detection device. The proximity switch 3 is installed on the rear bracket 7 of the feeder 1, and its detection surface faces the metal sensor sheet 5 on the back of the feeder 1. Figure 4 As shown, the detection distance of the proximity switch 3 is set to 5mm. This value is determined based on the threshold of the displacement of the feed rack 1 caused by the loosening of the clamp screws 8 of the cylinder 6. When the feed rack 1 moves back more than 5mm, the proximity switch 3 triggers a signal and links with the PLC control system 9. After receiving the signal from the proximity switch 3, the PLC control system 9 performs a series of actions, including sending a command to the alarm 11 to light the red alarm light and trigger the buzzer to continuously alarm, displaying the warning message "The sub-mouth feed rack cylinder fixing is loose and requires shutdown for maintenance" on the equipment operation interface 10, and automatically pausing the feed rack drive motor 12 after a delay of 5 seconds to prevent the fault from expanding. The entire response time is controlled within 0.3 seconds to ensure that loosening is discovered in the early stage and measures are taken.

[0033] In order to ensure the installation accuracy of the buffer 2 and the proximity switch 3, a laser rangefinder is used to calibrate the positioning of the buffer 2 to ensure that the installation height of the buffers 2 on the left and right sides is consistent and the error does not exceed 0.5mm. Figure 2As shown, the stroke details of buffer 2 are precisely calibrated to prevent uneven force from tilting the feeder 1. For proximity switch 3, a standard gauge block is used to adjust the initial spacing between sensor plate 5 and the switch, and the accuracy of the signal triggering is tested by simulating loose displacement. A linkage test is conducted by artificially simulating a loose clamp on cylinder 6 to observe the alarm system's response time, buffer 2's vibration absorption effectiveness, and the reliability of the equipment's shutdown logic. The test results show that buffer 2 can attenuate vibration amplitude by over 60%, meeting design requirements.

[0034] Figure 6 The linkage mechanism between the hydraulic buffer 2 and the proximity switch 3 is demonstrated. When the feed rack 1 is displaced, the output signal of the proximity switch 3 is transmitted to the PLC control system 9 through the digital signal processing module. The sampling frequency of the digital signal processing module is 1kHz, which ensures the real-time and accuracy of signal acquisition. The PLC control system 9 determines whether to trigger the alarm and shutdown action based on the preset logic. The linkage between the alarm system and the feed rack drive motor 12 is realized through a relay. The relay contact capacity is designed to be 10A / 250VAC, which meets the high reliability requirements in industrial environments. The specific installation position of the voice-controlled alarm light 4 is as follows: Figure 7 As shown, it is arranged near the equipment operation interface 10 to facilitate the operator to quickly identify the source of the alarm.

[0035] Figure 5 The position of the screw 8 and the difficulty of its maintenance are marked. In the traditional structure, the screw 8 is hidden in the installation gap between the feed rack 1 and the cylinder 6, and it is difficult to detect initial signs of looseness by visual inspection. The present invention solves this problem by introducing a proximity switch alarm system. When the screw 8 loosens and causes the displacement of the feed rack 1 to reach 5mm, the proximity switch 3 immediately sends a warning signal to remind maintenance personnel to carry out maintenance to prevent the slider from being subjected to an instantaneous impact load exceeding the yield strength of the material, resulting in breakage or severe wear. In addition, the design of the buffer 2 also plays a certain corrective role. Even if the feed rack 1 is skewed, the buffer 2 can still dissipate vibration energy through the flow characteristics of the hydraulic medium, reducing the probability of the occurrence of a mechanical damage chain.

[0036] In practical applications, the detection device of the present invention can significantly improve fault warning capabilities. For example, in a certain tire production line, the mean time between failures (MTBF) of the modified equipment has been greatly improved, and a single production line can increase its effective operating time by approximately 60-72 hours per year. Based on an hourly production capacity of 18 tire blanks, the annual production capacity can be increased by 1,080 to 1,296 tires per unit. Assuming a net profit of 300 yuan per tire blank, the direct economic benefit created is approximately 324,000 to 388,800 yuan per unit. At the same time, due to the introduction of the buffer 2, the peak vibration acceleration of the feed rack 1 has been reduced from 15g to below 6g, significantly extending the service life of precision components such as guide rails and sliders.

[0037] Regarding future development, this invention plans to integrate vibration sensors with IoT technology to enable remote, real-time monitoring of equipment status. By deploying a vibration sensor array to collect vibration signals from the feeder rack 1 and utilizing edge computing technology for real-time data analysis, the accuracy and efficiency of fault diagnosis will be further improved. Regular inspections and sensor calibration will ensure the long-term, reliable operation of the system. Figure 8 The control logic flow chart is displayed, clearly showing the complete process from signal acquisition to alarm triggering and equipment shutdown.

[0038] In summary, the present invention effectively prevents the disengagement of the guide rail and slider of the feeder frame of the molding machine through the synergistic effect of the hydraulic buffer 2 and the proximity switch alarm system. This device not only solves the problem of unnoticeable loosening of the clamp screw 8 of the cylinder 6 due to environmental factors, but also suppresses the vibration transmission mechanism and mechanical damage chain. It combines technical feasibility with economic rationality, and has significant application value and promotion prospects.

Claims

1. A detection device for preventing the guide rail of the feed rack of the molding machine from disengaging from the slide block, characterized in that The invention comprises a hydraulic buffer (2) and a proximity switch alarm system, wherein the hydraulic buffer (2) is installed at both ends of the rear side of the left and right sub-mouth feeding racks (1), the piston rod axis is parallel to the movement direction of the feeding rack (1), the stroke is set to 20 mm, and the maximum absorbed energy is 500 J; the proximity switch alarm system comprises a non-contact inductive proximity switch (3), an alarm (11), a PLC control system (9) and an equipment operation interface (10), the proximity switch (3) is installed on the rear side bracket (7) of the feeding rack (1), the detection distance is set to 5 mm, and the detection surface faces the metal sensor sheet (5) on the back side of the feeding rack (1).

2. The detection device according to claim 1, characterized in that The hydraulic buffer (2) absorbs vibration energy through the compression and expansion characteristics of the hydraulic medium, and is provided with a throttle hole inside for adjusting the flow rate to generate a damping force.

3. The detection device according to claim 2, characterized in that The left and right sides of the hydraulic buffer (2) are installed at the same height, with an error of no more than 0.5 mm, and are calibrated and positioned by a laser rangefinder.

4. The detection device according to claim 1, characterized in that The output signal of the proximity switch (3) is transmitted to the PLC control system (9) via a digital signal processing module, and the sampling frequency of the digital signal processing module is 1 kHz.

5. The detection device according to claim 4, characterized in that The PLC control system (9) determines whether to trigger an alarm and a shutdown action according to a preset logic. The linkage between the alarm system and the feed rack drive motor (12) is realized through a relay, and the relay contact capacity is 10A / 250VAC.

6. The detection device according to claim 1, characterized in that The initial spacing of the proximity switch (3) is adjusted by a standard gauge block, simulating loose displacement to test the accuracy of the signal triggering, ensuring reliable action when the displacement reaches 5mm.

7. The detection device according to claim 1, characterized in that The alarm (11) comprises a voice-controlled alarm light (4) and a buzzer, and the voice-controlled alarm light (4) is installed near the device operation interface (10).

8. The detection device according to claim 1, characterized in that After the warning message is displayed on the equipment operation interface (10), the feeder drive motor (12) is automatically paused for 5 seconds to prevent the fault from expanding.

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