End plate flange porous integrated forming machine and using method

Abstract

The invention discloses an end plate flange multi-hole integrated forming machine and a using method, and belongs to the technical field of machining equipment, the end plate flange multi-hole integrated forming machine comprises a rack, a multi-station machining assembly distributed annularly, a numerical control hollow rotary mechanical arm located in the center and a control system; the multi-station machining assembly comprises a drilling station, a punching station, a turning station and a tapping station which are sequentially arranged in a surrounding mode, and the working procedures of drilling of a counter bore and a bottom hole, punching of a passage hole and a large hole, turning of the outer diameter and tapping of a workpiece are correspondingly completed through the drilling station, the punching station, the turning station and the tapping station respectively. And the numerical control hollow rotary manipulator is used for clamping the workpieces to circularly change positions among the stations, so that multi-process integrated machining of the end plate flange workpieces is realized. Through multi-procedure integrated design and automatic station circulation, efficient, high-precision and safe machining of the end plate flange workpiece is achieved, the production cost is reduced, and the production efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of mechanical processing equipment, and in particular to an end plate flange multi-hole integrated forming machine and a method of use, which is particularly suitable for multi-hole processing and multi-process integrated production of end plate flange workpieces. Background Art

[0002] In the field of mechanical processing, end plate flanges are important connecting components, and their processing quality and efficiency directly affect the assembly accuracy and production cycle of mechanical equipment. Traditional end plate flange processing technology adopts a decentralized single-machine operation mode, requiring multiple independent equipment such as drilling machines, punching machines, lathes, and tapping machines to complete multiple processes such as countersinking, bottom hole, punching, turning the outer diameter, and tapping. This process model has the following significant drawbacks: 1. Low production efficiency Each process requires separate equipment to be processed sequentially, and workpieces must be frequently disassembled and transferred from one machine to the next, resulting in a single processing cycle lasting several hours. For example, the traditional process for processing a typical end plate flange requires five setups and four transfers. Turnaround time alone accounts for over 30% of the total working time, severely hindering capacity expansion.

[0003] 2. High labor costs Decentralized processing relies heavily on manual labor, requiring at least one operator per machine and 5-6 workers collaborating on a single production line. With labor costs in the manufacturing industry increasing by an average of 8% to 10% annually, labor costs now account for 25% to 30% of total product costs. Furthermore, young workers are increasingly reluctant to engage in high-intensity, repetitive labor, making recruitment increasingly difficult.

[0004] 3. Unstable processing accuracy Multiple clamping operations can easily cause workpiece positioning datum offsets, with cumulative errors between processes reaching 0.1 to 0.3 mm, affecting hole coaxiality and outer diameter accuracy. For example, misalignment between tapping and drilling can lead to thread skew, requiring additional rework, with a rework rate as high as 5% to 8%, further wasting time and materials.

[0005] 4. Safety hazards and management costs Manual workpiece transfer requires frequent contact with mechanical equipment, posing a 4-6 times higher risk of injury than automated equipment. This is especially true during high-speed processes like punching and turning, where operators face multiple risks, including mechanical injuries and chip splashing. Furthermore, the multi-equipment layout requires significant workshop space (traditional production lines occupy 20-30 square meters), increasing rental costs and complicating logistics management.

[0006] 5. Environmental protection and energy consumption issues Running multiple devices simultaneously results in concentrated energy consumption. The cumulative standby power loss of a single device can reach 10-15 kWh per day, increasing annual energy costs by tens of thousands of yuan. The cost of disposing of waste, such as lubricants and cutting fluids, generated by equipment maintenance also rises with the increasing number of devices, which is inconsistent with the industry trend of green manufacturing.

[0007] As the high-end equipment manufacturing industry places increasingly stringent demands on "high precision, short delivery time, and low cost" in component processing, traditional decentralized processing models have become difficult to adapt to market competition. The market urgently needs integrated, automated equipment that can achieve efficient and precise processing of end plate flanges through multi-process linkage and less-manned operations. Based on the above-mentioned technical bottlenecks, the present invention proposes a forming equipment that integrates drilling, punching, turning, and tapping processes. Through automatic position adjustment of CNC manipulators and multi-axis collaborative processing, it fundamentally solves the efficiency, precision, and cost issues of traditional processes. Summary of the Invention

[0008] The purpose of the present invention is to provide an end plate flange multi-hole integrated forming machine and a method of use to overcome the above-mentioned technical problems. Through multi-process integrated design and automated workstation flow, efficient, high-precision and safe processing of end plate flange workpieces can be achieved, thereby reducing production costs and improving production efficiency.

[0009] The present invention solves the above technical problems through the following technical solutions: Provided is an end plate flange multi-hole integrated forming machine, comprising a frame, a ring-distributed multi-station processing assembly, a CNC hollow rotary manipulator located in the center, and a control system; the multi-station processing assembly comprises a drilling station, a punching station, a turning station, and a tapping station arranged in sequence.

[0010] Furthermore, the drilling station includes a multi-axis drilling head, a vertical guide rail slider mechanism and a drive motor; the multi-axis drilling head is slidingly connected to the vertical guide rail of the frame through the slider, and the drive motor drives the slider to move up and down through the screw nut mechanism.

[0011] Furthermore, the punching station includes a multi-axis hydraulic punching head, a punching cylinder and a punch fixing plate; the punching cylinder is fixed above the frame, the lower end of the cylinder rod is connected to the punch fixing plate, and the punching die corresponding to the hole position of the workpiece is installed on the punch fixing plate.

[0012] Furthermore, the turning station includes a driving spindle, a spindle positioning driving disk and a CNC tool holder; a positioning rod is provided at the lower end of the driving spindle, the positioning rod is adapted to the bottom hole of the workpiece tapping thread, and the driving spindle is driven to rotate by a motor to drive the workpiece to rotate; the CNC tool holder is installed on the frame through transverse and longitudinal guide rails.

[0013] Furthermore, the tapping station includes a multi-axis tapping head, a reduction gear box and a driving mechanism; the multi-axis tapping head is connected to the frame guide rail through a slider, and the driving mechanism is connected to the tapping head through the reduction gear box.

[0014] Furthermore, the CNC hollow rotary robot includes a turntable body, a workpiece fixture, a rotation drive mechanism and a translation drive mechanism; the turntable body is rotationally connected to the frame through bearings, and the workpiece fixtures are evenly distributed on the edge of the turntable; the rotation drive mechanism drives the turntable to rotate through gears or worm gear transmission, and the translation drive mechanism controls the lifting and lowering of the turntable.

[0015] Furthermore, the translation drive mechanism is a cylinder or a screw module.

[0016] Furthermore, the frame adopts a split frame structure, including an upper fixed plate, a lower fixed plate, 8 columns and 4 supporting legs. The upper fixed plate is arranged parallel to the lower fixed plate, and the 8 columns are evenly distributed between the two in a rectangular array. The upper and lower ends of each column are fastened to the upper fixed plate and the lower fixed plate by high-strength bolts to form a rigid frame structure; the 4 supporting legs are evenly distributed at the four corners of the lower fixed plate and fixed to the ground by anchor bolts.

[0017] Furthermore, the method for using the device comprises the following steps: (1) The workpiece is drilled with countersink and bottom hole at drilling station No. 1; (2) The CNC rotary table manipulator transfers the workpiece to the No. 2 punching station to complete the punching of the channel hole and the large hole; (3) The manipulator transfers the workpiece to turning station No. 3, drives the workpiece to rotate through the spindle positioning rod, and the CNC tool holder turns the outer diameter; (4) The robot transfers the workpiece to the No. 4 tapping station to complete multi-hole tapping; (5) After processing is completed, the workpiece exits with the robot and enters the next cycle. Beneficial effects

[0018] 1. Breaking the fragmented operation mode of "single machine, single process" in traditional processes, avoiding the frequent turnover of workpieces between multiple equipment such as drilling machines, punching machines, and lathes, and integrating five processes such as drilling, punching, turning, and tapping into a single device through a circular workstation layout and linkage with a CNC rotary table manipulator, achieving "one-time clamping and full-sequence forming", and increasing production efficiency to twice that of traditional processes.

[0019] 2. The entire machining process is controlled by the CNC system, and only one operator is required to complete loading and monitoring, reducing labor costs by 60%. Workpiece transfer, positioning, and machining are all automatically performed by mechanical devices, eliminating the safety hazards of manual contact with high-speed moving parts and reducing the risk of work-related injuries by more than 80%.

[0020] 3. The CNC turntable manipulator achieves a positioning accuracy of ±0.01mm, and the reference position of each station is unified, eliminating the accumulation of clamping errors. The turning station uses the spindle positioning rod to precisely match the workpiece bottom hole (positioning accuracy H7 / g6). Combined with the CNC tool holder's ±0.005mm repeatability, the outer diameter machining accuracy reaches IT7, with a surface roughness of Ra≤3.2. The tapping station's multi-axis device feeds synchronously, and a torque protection mechanism prevents tap breakage. The thread accuracy is stable at 6H level, and the first-time machining pass rate is increased to 99.8%.

[0021] 4. The circular layout reduces the equipment footprint to only 8-10 square meters, saving 60% of workshop space. The integrated design reduces the number of equipment in standby mode, reduces comprehensive energy consumption by 40%, and saves more than 50,000 yuan in electricity bills annually. At the same time, the number of maintenance points for a single device is reduced by 70% compared to traditional multi-machine systems, maintenance hours are shortened by 50%, and the cost of replacing wearing parts is reduced by 30%.

[0022] 5. The processing parameters of each workstation can be modified online through the CNC system, and the changeover time is compressed to less than 10 minutes, which can quickly respond to customer customized orders and increase production flexibility by 3 times.

[0023] In summary, the present invention systematically solves the multiple problems of traditional processing technology in terms of efficiency, cost, precision, safety, etc. through the three-dimensional innovation of "physical integration + logical coordination + digital control", provides a solution for the intelligent manufacturing of end plate flange components, and promotes the flange machining industry to upgrade towards less-manned, high-precision and green directions. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the main structure of the present invention; Figure 2 This is a schematic diagram of the frame structure of the present invention; Figure 3 This is a schematic structural diagram of the CNC hollow rotary manipulator of the present invention; Figure 4 This is a schematic diagram of the drilling station structure of the present invention; Figure 5 This is a schematic diagram of the punching station structure of the present invention; Figure 6 This is a schematic diagram of the turning station structure of the present invention; Figure 7 It is a schematic diagram of the tapping station structure of the present invention.

[0025] In the figure: 1. Frame; 11. Upper fixed plate; 12. Lower fixed plate; 13. Column; 14. Support leg; 2. CNC turntable manipulator; 21. Turntable body; 22. Workpiece fixture; 23. Rotation drive mechanism; 24. Translation drive mechanism; 3. Control system; 4. Drilling station; 41. Multi-axis drilling head; 42. Vertical guide rail slider mechanism; 43. Drive motor; 5. Punching station; 51. Multi-axis hydraulic punching head; 52. Punching cylinder; 53. Punch fixing plate; 6. Turning station; 61. Drive spindle; 62. Spindle positioning drive disk; 63. CNC tool holder; 7. Tapping station; 71. Multi-axis tapping head; 72. Reducer; 73. Column; 74. Drive mechanism. DETAILED DESCRIPTION

[0026] This invention utilizes a circular workstation design, comprising a machine frame, four surrounding machining stations (drilling, punching, turning, and tapping), a centrally located CNC hollow rotary manipulator, and a control system. The four stations are evenly distributed along the circumference of the frame, forming a circular machining area. The CNC hollow rotary manipulator, centrally located, rotates and lifts the workpiece between stations, achieving integrated machining of five steps: countersinking, bottom hole drilling, through-hole punching, oversize hole punching, outer diameter turning, and tapping.

[0027] Structure and connection relationship of each workstation 1. Drilling station (station 1) Structural composition: includes multi-axis drilling head, vertical guide rail slider mechanism, and drive motor.

[0028] Connections: The multi-axis drilling head slides into the vertical guide rails of the machine frame via a slider, which is in turn connected to the drive motor's screw-nut mechanism. The drive motor, mounted on the top of the frame, drives the slider up and down via a screw, driving the drilling head to countersink and tap the bottom hole. By integrating both a countersink drill bit and a bottom hole drill bit into the multi-axis head, dual-hole drilling can be completed simultaneously, reducing process switching time.

[0029] 2. Punching station (station 2) Structural composition: includes multi-axis hydraulic punching head, punching cylinder, and punch fixing plate.

[0030] Connections: The punching cylinder is fixed to the frame, with the lower end of the cylinder rod fixedly connected to the punch mounting plate. The punch mounting plate is mounted with the punching die corresponding to the workpiece hole position. The cylinder rod is hydraulically driven up and down, driving the punch to punch through-holes and large holes. Multi-axis hydraulic drive enables simultaneous punching of multiple holes, improving punching efficiency.

[0031] 3. Turning station (station 3) Structural composition: including driving spindle, spindle positioning driving plate, CNC tool holder and turning tool.

[0032] Connections: The drive spindle is vertically mounted above the machine frame, with a spindle positioning drive disc fixed at its lower end. A positioning rod is located in the center of the positioning disc and mates with the workpiece tapping hole. The drive spindle is connected to the machine frame by a motor via a belt or gear drive. The CNC toolholder is mounted to the machine frame via transverse and longitudinal guide rails. The turning tool is fixed to the toolholder and feeds via the guide rails. The positioning rod engages the workpiece bottom hole to rotate the workpiece, and the CNC toolholder precisely controls the turning trajectory, ensuring outer diameter machining accuracy.

[0033] 4. Tapping station (station No. 4) Structural composition: includes multi-axis tapping head, reduction box and drive mechanism.

[0034] Connection: The multi-axis tapping head slides into the machine frame guide rails via a slider, and the drive mechanism is connected to the tapping head via a reduction gearbox. The drive mechanism drives the reduction gearbox to reduce speed and increase torque, driving the tapping spindle to rotate and complete the tapping action. The multi-axis tapping head enables simultaneous tapping of multiple holes, significantly reducing the processing time for each hole.

[0035] 5. CNC hollow rotary robot Structural composition: includes turntable body, workpiece fixture, rotation drive mechanism, and translation drive mechanism.

[0036] Connections: The turntable is rotatably connected to the machine frame via bearings. Workpiece fixtures are evenly distributed around the turntable's edges, holding the workpiece. A rotary drive mechanism (servo motor + gear drive) is connected to the turntable's central axis, driving its rotation. A translational drive mechanism (pneumatic cylinder or screw module) is fixedly connected to the turntable's base, controlling its elevation and positioning, ensuring precise alignment of the workpiece at each workstation's reference position. The turntable's combined rotary indexing and elevation alignment capabilities ensure high positioning accuracy, ensuring precise alignment of the workpiece with each machining component.

[0037] 6. Rack Structural composition: includes upper fixed plate, lower fixed plate, 8 columns and 4 supporting legs.

[0038] Connection relationship: The rack adopts a split frame structure, which includes an upper fixing plate, a lower fixing plate, 8 columns and 4 supporting legs. The upper fixing plate and the lower fixing plate are arranged parallel to each other, and the 8 columns are evenly distributed between the two in a rectangular array. The upper and lower ends of each column are fastened to the upper and lower fixing plates by high-strength bolts to form a rigid frame structure; the 4 supporting legs are evenly distributed at the four corners of the lower fixing plate and fixed to the ground by anchor bolts.

[0039] How it works Loading and drilling: The workpiece is placed in the reference position of station No. 1, and the driving motor drives the multi-axis drilling head downward to drill countersinks and tap the bottom holes of the threads. After completion, the head retracts.

[0040] Punching position change: The CNC turntable manipulator rotates to transfer the workpiece to punching station No. 2, and the hydraulic punching head moves downward to punch the guide hole and the large hole. After completion, the head retracts.

[0041] Turning position change: The robot transfers the workpiece to turning station No. 3, drives the spindle downward, and the positioning rod is pushed into the bottom hole of the workpiece to drive the workpiece to rotate. The CNC tool holder feeds and turns the outer diameter. After completion, the spindle retracts.

[0042] Tapping position change: The robot moves the workpiece to tapping station No. 4, and the multi-axis tapping head moves downward to tap. After completion, the head retracts and the workpiece is processed.

[0043] Circular operation: The robot moves the finished product out and grabs a new workpiece to enter the next cycle.

[0044] The frame of this equipment is a high-strength cast iron base (size: diameter 2500mm × height 1800mm). The spacing accuracy between each workstation and the robot is controlled within ±0.1mm to ensure that there is no interference when the workpiece is replaced.

[0045] Installation steps Frame fixing: Fix the frame to the flat ground with anchor bolts and use a spirit level to calibrate the frame levelness (error ≤ 0.05mm / m).

[0046] Drilling station: Install the multi-axis drilling head on the vertical guide rail of the frame through the slider (guide rail straightness ≤ 0.02mm / m), connect the drive motor (servo motor, power 3kW) and the screw nut mechanism to ensure smooth up and down movement of the head.

[0047] Punching station: Fix the punching cylinder (stroke 100mm, maximum pressure 20MPa) on the top of the frame, the cylinder rod and the punch fixing plate are connected by bolts, and the vertical alignment accuracy of the punch and the workpiece reference position is ≤0.03mm.

[0048] Turning station: Install the drive spindle (speed range 0-2000r / min) above the frame, and connect the spindle positioning rod (diameter φ8mm, surface roughness Ra0.8) and the CNC tool holder (four-station electric tool holder, repeat positioning accuracy ±0.005mm) through a guide rail to ensure that the radial runout between the positioning rod and the tool holder is ≤0.02mm.

[0049] Tapping station: Fix the multi-axis tapping head (including 6-axis tapping multi-axis) on the frame guide rail, connect the reduction box (reduction ratio 1:5) and the drive mechanism (power 2.2kW), and ensure that the coaxiality of the tapping axis and the bottom hole of the workpiece is ≤0.03mm.

[0050] Robot installation: The CNC turntable robot (turntable diameter 800mm, load capacity 200kg) is installed on the central axis of the frame through a deep groove ball bearing. The workpiece fixture (pneumatic clamping jaws, clamping force adjustable 500~1000N) is evenly distributed on the edge of the turntable. The position accuracy of the fixture positioning surface and the reference position of each workstation is ≤0.01mm.

[0051] Equipped with Siemens S7-200 SMART PLC, it connects the drive motors, hydraulic valve groups and sensors (including work station origin sensors, workpiece arrival photoelectric switches, and tool wear detection sensors) of each work station via PROFINET bus.

[0052] Set the processing parameters for each station: Drilling station: drill speed 1500r / min, feed speed 0.5mm / s, countersink depth 5mm, bottom hole depth 15mm.

[0053] Punching station: hydraulic pressure 15MPa, punch downward speed 0.3m / s, punching holding time 0.5s.

[0054] Turning station: spindle speed 1200r / min, tool feed 0.3mm / r, outer diameter machining allowance 2mm.

[0055] Tapping station: tapping speed 400r / min, feed rate and pitch are synchronized (such as M10×1.5 pitch corresponds to feed speed 1.5mm / r).

[0056] Debug the CNC turntable manipulator: set the turntable rotation speed to 60° / s, the lifting stroke to 20mm, the positioning repeatability to ±0.01mm, and ensure that the workpiece transfer time between each station is ≤2s.

[0057] The equipment coordinates the linkage between the four major workstations and the robot through the CNC system, achieving multi-step continuous processing in a "fixed workstation, mobile workpiece" manner. The core principles are as follows: The principle of workstation integration: the four processing functions of drilling, punching, turning and tapping are integrated into the same equipment. The circular layout shortens the workpiece transfer path and eliminates the spatial discreteness of "equipment-workpiece" in traditional processes.

[0058] Robot coordination principle: The CNC turntable robot has both rotation indexing (to achieve workstation switching) and lifting and positioning (to compensate for workstation height differences) functions. Through the "rotation + lifting" compound movement, it ensures the precise docking of the workpiece with the processing components of each workstation.

[0059] Sequential control principle: The PLC program triggers the actions of each workstation according to the fixed timing of "drilling → punching → turning → tapping". At the same time, sensors monitor the processing status in real time (such as tool placement and workpiece clamping), forming a closed-loop control.

[0060] Operation process: During operation, the operator places the end plate flange workpiece to be machined into the fixture at drilling station No. 1. The operator manually presses the pneumatic clamping button on the fixture, and the jaws automatically tighten the workpiece (the clamping force is set to 800N by a pressure reducing valve). The fixture features a built-in dual-pin positioning mechanism (cylindrical pin + diamond pin) to ensure a positioning accuracy of ≤0.02mm in the XY plane. A spring-loaded ejector pin in the Z direction presses against the workpiece bottom surface, eliminating any play during clamping.

[0061] Subsequently, the CNC system triggers the drilling station drive motor to start, and the screw drives the multi-axis drilling head to descend at a speed of 0.5m / min. The drill bit cuts into the workpiece at the same time, and the countersink (diameter φ12mm, depth 5mm) and the bottom hole (diameter φ8mm, depth 15mm) are completed simultaneously.

[0062] After the processing is completed, the machine head returns to its original position at a speed of 1m / min. After the limit switch detects the machine head return signal, the PLC sends a "station 1 processing completed" command to the robot and enters the next process.

[0063] The CNC turntable manipulator's rotary drive motor starts, and the turntable rotates 90° clockwise (taking 1.5 seconds), moving the workpiece to punching station 2. Simultaneously, the translation drive cylinder actuates, raising the turntable 5mm to align the workpiece with the punch reference position (alignment error ≤ 0.05mm).

[0064] The solenoid valve of the punching cylinder is energized, and the cylinder rod pushes the punch downward at a speed of 0.3m / s. The φ20mm (aisle hole) and φ25mm (large hole) punches on the punch fixing plate complete punching synchronously. The hydraulic system pressure sensor monitors the pressure value in real time (the set threshold is 15MPa) and automatically unloads to protect the mold when overpressure occurs.

[0065] After punching is completed, the cylinder rod retracts, the turntable drops and resets, and the PLC triggers the robot to enter the next process.

[0066] The robot rotates 180° (relative to its initial position) and transfers the workpiece to turning station 3. The spindle motor is started, rotating at 1200 rpm. Simultaneously, the spindle slide descends, and the positioning rod pushes into the bottom hole of the workpiece (with a clearance of 0.01 to 0.02 mm), driving the workpiece to rotate synchronously.

[0067] According to a preset program, the CNC tool holder controls the 90° external cylindrical turning tool's lateral feed along the X-axis (feed rate 0.3mm / r), turning the workpiece's outer diameter to the specified size (e.g., φ100mm±0.05mm). During the turning process, the coolant pump activates, spraying high-pressure coolant (3MPa) into the machining area to reduce the workpiece's temperature rise (to within 15°C).

[0068] After turning is completed, the spindle stops rotating and retracts, the tool holder resets, and the PLC sends a "turning completed" signal to enter the next process.

[0069] The robot rotates 270° and transfers the workpiece to tapping station No. 4. The multi-axis tapping head descends at 0.2 m / s. The tap (M10 x 1.5) is aligned with the workpiece bottom hole. The drive mechanism drives the tapping spindle through the reduction gearbox at 400 r / min, while simultaneously feeding along the Z axis until the tapping depth reaches 10 mm.

[0070] During tapping, a torque sensor monitors the tapping torque in real time. When the torque exceeds the set value (8 N·m), the friction clutch automatically slips to prevent the tap from breaking. After tapping is completed, the machine head retracts and the PLC records the number of completed processes.

[0071] The finished workpiece rotates with the robot to the opposite side of its initial position (the discharge station). The clamp automatically releases, and the workpiece falls into the discharge chute, where it is transported by a conveyor belt to the finished product area. The operator then loads a new workpiece into station 1, and the machine automatically enters the next processing cycle.

[0072] Daily maintenance Lubrication and maintenance: Add lithium-based grease (NLGI grade 2) to the guide rails, screw rods, and manipulator turntable bearings of each workstation every week to ensure that the friction coefficient of moving parts is ≤0.005.

[0073] Tool inspection: Check the wear of drills, punches, turning tools, and taps before starting work every day. Replace drills when the wear on the cutting edge exceeds 0.2mm, and regrind turning tools when the wear on the tip radius exceeds 0.1mm.

[0074] Electrical inspection: Check the tightness of PLC terminals and motor encoder connection wires every month, and test the reliability of emergency stop buttons and safety door locks.

[0075] Common troubleshooting Workpiece positioning deviation: If the drilling position offset exceeds 0.1mm, adjust the rotation indexing parameters of the manipulator turntable through the CNC system (such as correcting the pulse equivalent), or calibrate the position of the fixture locating pin.

[0076] Abnormal punching noise: If abnormal noise occurs when the punch moves downward, stop the machine to check the clearance between the punch and the die (normal clearance is 0.03-0.05mm), clean the iron filings on the punch surface or replace the worn disc spring.

[0077] Abnormal tapping torque: If the torque is continuously too high during tapping, it may be that the bottom hole diameter is too small or the tap is worn. You need to recalibrate the drilling depth or replace the tap.

[0078] Key technical parameters: project Parameter value Accuracy index Processing workpiece diameter φ50-φ150mm — Maximum workpiece thickness 10mm — Drilling depth Countersink 5mm, bottom hole 15mm Depth error ±0.1mm Punching diameter φ20mm, φ25mm Diameter error ±0.08mm Turning outer diameter accuracy IT7 Surface roughness Ra3.2 Tapping accuracy Level 6H Pitch error ±0.02mm Single workpiece processing cycle 45-60 seconds — This implementation fully demonstrates the "full-process integration" and "CNC automation" features of the end plate flange multi-hole integrated forming machine through a detailed description of the equipment's principles, component layout, installation and commissioning, workflow, and maintenance strategies. Through the precise linkage of the CNC rotary table manipulator and the collaborative operation of each workstation, unmanned operation is achieved throughout the entire process, from workpiece clamping to multi-step processing. This significantly improves production efficiency and processing accuracy, meeting the modern manufacturing industry's demand for intelligent and efficient equipment.

[0079] In the description of the present invention, it should be understood that the terms "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship of the device or component when it is normally used. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, be constructed and operate in a specific orientation at all times, unless otherwise specified herein.

[0080] Although specific embodiments of the present invention have been described above, those skilled in the art will appreciate that these are merely illustrative and that the scope of the present invention is defined by the appended claims. Those skilled in the art may make various changes or modifications to these embodiments without departing from the principles and essence of the present invention, and such changes and modifications are intended to fall within the scope of the present invention.

Claims

1. An end plate flange multi-hole integrated forming machine, characterized in that: It includes a frame, a ring-shaped multi-station processing component, a CNC hollow rotary manipulator located in the center, and a control system; the multi-station processing component includes a drilling station, a punching station, a turning station, and a tapping station arranged in sequence.

2. The end plate flange multi-hole integrated forming machine according to claim 1, characterized in that: The drilling station includes a multi-axis drilling head, a vertical guide rail slider mechanism and a drive motor; the multi-axis drilling head is slidably connected to the vertical guide rail of the frame through the slider, and the drive motor drives the slider to move up and down through the screw nut mechanism.

3. The end plate flange multi-hole integrated forming machine according to claim 1, characterized in that: The punching station includes a multi-axis hydraulic punching head, a punching cylinder and a punch fixing plate; the punching cylinder is fixed above the frame, the lower end of the cylinder rod is connected to the punch fixing plate, and the punching die corresponding to the hole position of the workpiece is installed on the punch fixing plate.

4. The end plate flange multi-hole integrated forming machine according to claim 1, characterized in that: The turning station includes a driving spindle, a spindle positioning driving disk and a CNC tool holder; a positioning rod is provided at the lower end of the driving spindle, which is adapted to the bottom hole of the workpiece tapping thread, and the driving spindle is driven to rotate by a motor to drive the workpiece to rotate; the CNC tool holder is installed on the frame through transverse and longitudinal guide rails.

5. The end plate flange multi-hole integrated forming machine according to claim 1, characterized in that: The tapping station includes a multi-axis tapping head, a reduction box and a driving mechanism; the multi-axis tapping head is connected to the frame guide rail through a slider, and the driving mechanism is transmission-connected to the tapping head through the reduction box.

6. The end plate flange multi-hole integrated forming machine according to claim 1, characterized in that: The CNC hollow rotary manipulator includes a turntable body, a workpiece fixture, a rotation drive mechanism and a translation drive mechanism; the turntable body is rotationally connected to the frame through a bearing, and the workpiece fixture is evenly distributed on the edge of the turntable; the rotation drive mechanism drives the turntable to rotate through gears or worm gear transmission, and the translation drive mechanism controls the turntable to rise and fall.

7. The end plate flange multi-hole integrated forming machine according to claim 6, characterized in that: The translation drive mechanism is a cylinder or a screw module.

8. The end plate flange multi-hole integrated forming machine according to claim 1, characterized in that: The frame adopts a split frame structure, including an upper fixed plate, a lower fixed plate, 8 columns and 4 supporting legs. The upper fixed plate is arranged parallel to the lower fixed plate, and the 8 columns are evenly distributed between the two in a rectangular array. The upper and lower ends of each column are fastened to the upper fixed plate and the lower fixed plate by high-strength bolts to form a rigid frame structure; the 4 supporting legs are evenly distributed at the four corners of the lower fixed plate and fixed to the ground by anchor bolts.

9. The end plate flange multi-hole integrated forming machine according to any one of claims 1 to 8, characterized in that: The method for using the device comprises the following steps: (1) The workpiece is drilled with countersink and bottom hole at drilling station No. 1; (2) The CNC rotary table manipulator transfers the workpiece to the No. 2 punching station to complete the punching of the channel hole and the large hole; (3) The manipulator transfers the workpiece to turning station No. 3, drives the workpiece to rotate through the spindle positioning rod, and the CNC tool holder turns the outer diameter; (4) The robot transfers the workpiece to the No. 4 tapping station to complete multi-hole tapping; (5) After processing is completed, the workpiece exits with the robot and enters the next cycle.

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