Intelligent production equipment for lower side door of open wagon of railway wagon

Abstract

The invention relates to intelligent production equipment for lower side doors, in particular to intelligent production equipment for lower side doors of open wagons of railway wagons. The problems that an existing railway train open wagon lower side door production device is low in production speed and needs a large number of operators are solved. The automatic assembly line comprises a manual feeding station, an automatic assembly station, a manual character pressing and hanging ring base spot welding station, an automatic full welding station, a manual polishing and pressing station, an automatic discharging station and a speed multiplication chain. The manual feeding station, the automatic assembling station, the manual character pressing and hanging ring base spot welding station, the automatic full welding station, the manual polishing and pressing station and the automatic discharging station are sequentially arranged along the speed chain from the starting end to the tail end of the speed chain. The invention belongs to the technical field of railway production equipment.

Description

Technical Field

[0001] The present invention relates to intelligent production equipment for lower side doors, belonging to the technical field of railway production equipment. Background Art

[0002] Gondolas are a type of railway freight car. They are characterized by being uncovered and having four side panels, two of which have retractable doors for easy unloading. They are primarily used to transport bulk goods such as coal and ballast, which are weatherproof. Gondolas are primarily used to transport bulk cargo such as coal, ore, mining and construction materials, lumber, and steel, as well as lightweight machinery. Covered with waterproof canvas or other coverings, they can replace covered cars in transporting rain-resistant goods. Therefore, gondolas are highly versatile and constitute the largest group of freight cars. The lower side door, a movable door installed at the cargo entrance and exit of a gondola, is a key feature of gondolas. Currently, these lower side doors are welded using conventional automatic welding machines, a method with low intelligence, requiring many operators, and resulting in slow production.

[0003] Utility model patent publication number CN2928357Y, filed on July 28, 2006, discloses an automatic welding device for the lower side doors of open railway freight cars. The device comprises a frame, four welding carriages, two welding gun clamping mechanisms, two feed mechanisms, a workpiece conveying mechanism, workpiece longitudinal and transverse positioning mechanisms, and an electrical control mechanism for coordinating the movement of the welding carriages, feed mechanisms, workpiece conveying mechanisms, and workpiece longitudinal and transverse positioning mechanisms. The frame is divided into pre-welding, welding, and post-welding zones. The welding carriage is mounted above the frame in the welding zone and is slidably connected to the frame. Two feed mechanisms are mounted parallel to the upper portion of the welding zone frame. The welding gun clamping mechanism is fixedly connected to the feed mechanisms, and the welding carriage's welding gun is secured in the clamping mechanism. However, this automatic welding device still has a relatively slow production speed and requires specialized operator operation and supervision. Summary of the Invention

[0004] The present invention aims to solve the problems of slow production speed and large number of operators required in existing railway train open car lower side door production equipment, and further proposes an intelligent production equipment for railway freight car lower side doors.

[0005] The technical solution adopted by the present invention to solve the above problems is as follows: the present invention includes a manual loading station, an automatic assembly station, a manual lettering and spot welding hanging ring seat station, an automatic full welding station, a manual grinding and pressing station, an automatic unloading station and a double-speed chain; Manual loading station, automatic assembly station, manual lettering and spot welding hanging ring seat station, automatic full welding station, manual grinding and pressing station and automatic unloading station are arranged along the speed chain from the starting end to the end.

[0006] Furthermore, the manual loading station includes a power-assisted manipulator, a loading workbench, and multiple electromagnets; The power-assisting manipulator is arranged on one side of the loading workbench, and a plurality of electromagnets are installed on the end effector of the power-assisting manipulator.

[0007] Furthermore, the automatic assembly station includes a truss manipulator, a spot welding robot, a door positioning fixture, and a folding positioning and pressing fixture; The door positioning fixture and the folding sheet positioning and pressing fixture are arranged side by side below the truss manipulator, and the spot welding robot is arranged on one side of the folding sheet positioning and pressing fixture.

[0008] Furthermore, the manual lettering and spot welding hanging ring seat station includes a lettering machine and a door positioning fixture; The door positioning fixture is arranged below the embossing machine.

[0009] Furthermore, the automatic full welding station includes a door positioning fixture, a door frame, four welding robots and four welding machines; The door positioning fixture is set under the door frame, and the door positioning fixture is installed on the speed chain. Two sets of welding robots are installed on the door frame. The two sets of welding robots are symmetrically set on both sides of the door positioning fixture. A welding machine is installed on the execution end of each welding robot.

[0010] Furthermore, the automatic full welding station also includes four sets of weld seam trackers; The weld seam tracker is installed at the execution end of the welding robot.

[0011] Furthermore, the manual grinding and pressing station includes a rotary clamping fixture and a grinder; The rotary clamping fixture is set on one side of the double-speed chain. The rotary clamping fixture is used to lift and clamp the lower side door of the open car on the double-speed chain. After grinding, the lower side door of the open car is rotated and placed on the double-speed chain. The grinder is used to grind the welds on the lower side doors of open cars.

[0012] Furthermore, the automatic unloading station includes an unloading robot and a plurality of electromagnets; The unloading robot is arranged on one side of the end of the double-speed chain, and a plurality of electromagnets are installed on the end effector of the unloading robot.

[0013] The beneficial effects of the present invention are: 1. This invention uses dual-gun dual-arc fillet welding for symmetrical welding. The dual welding guns are independently equipped with line laser sensors, with an adjustable time interval of 0 to 1 second. The pulse heat input of the welding machine is coordinated and controlled, and the arc swing operation is coordinated to achieve low-deformation forming welding of stamped carbon steel sheet metal and reinforced rib structures, and achieve flexible adaptation to different gaps. The composite truss achieves precise positioning of parts and realizes high-speed and precise structure in three axes. The high-precision rotation axis at the Z-axis end realizes precise rotation of long parts. At the same time, the composite structure is set in the Z-axis to provide precise positioning while achieving close fit between different parts. 2. The present invention simplifies the overall design structure, increases production speed, reduces the use of manpower, and improves production speed and weld quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 It is a structural diagram of the manual loading station; Figure 3 It is a structural diagram of the automatic assembly station; Figure 4 This is a structural diagram of the manual lettering and spot welding hanging ring seat station; Figure 5 This is a structural diagram of an automatic full welding station; Figure 6 It is a structural diagram of the manual grinding and pressing station; Figure 7 It is a structural diagram of the automatic unloading station; Figure 8 It is a schematic diagram of the folding material rack structure of the folding positioning and pressing fixture; Figures 1 to 7 Among them, 1-manual loading station, 101-power-assisted manipulator, 102-loading workbench, 103-electromagnet, 2-automatic assembly station, 201-truss manipulator, 202-spot welding robot, 203-door positioning fixture, 204-folding positioning and pressing fixture, 3-manual embossing and spot welding hanging ring seat station, 301-embossing machine, 302-door positioning fixture, 4-automatic full welding station, 402-gantry, 403-welding robot, 404-welding machine, 5-manual grinding and pressing station, 501-rotating clamping fixture, 6-automatic unloading station, 601-unloading manipulator, 602-electromagnet, 7-open car lower side door, 8-speed chain. DETAILED DESCRIPTION

[0015] Specific implementation method 1: Figure 1As shown, the intelligent production equipment for the lower side door of a railway freight car includes a manual loading station 1, an automatic assembly station 2, a manual lettering and spot welding hanging ring seat station 3, an automatic full welding station 4, a manual grinding and pressing station 5, an automatic unloading station 6 and a double-speed chain 8; The manual loading station 1, the automatic assembly station 2, the manual embossing and spot welding hanging ring seat station 3, the automatic full welding station 4, the manual grinding and pressing station 5 and the automatic unloading station 6 are arranged in sequence along the speed chain 8 from the starting end to the end of the speed chain 8.

[0016] Specific implementation method 2: Figure 2 As shown, the manual loading station 1 includes a power-assisted manipulator 101, a loading workbench 102, and a plurality of electromagnets 103; The power-assisting manipulator 101 is disposed on one side of the loading workbench 102 , and a plurality of electromagnets 103 are mounted on the end effector of the power-assisting manipulator 101 .

[0017] A gondola lower side door 7 is manually taken out from the stacked gondola lower side doors, and the electromagnet 103 on the end effector of the power-assisting manipulator 101 adsorbs the gondola lower side door 7, and then rotates it to above the starting end of the double-speed chain 8. Then the power-assisting manipulator 101 places the gondola lower side door 7 on the starting end of the double-speed chain 8, and the double-speed chain 8 drives the gondola lower side door 7 to the next workstation.

[0018] Among them, the height of the speed material strip 8 from the bottom surface is 800mm, which ensures that personnel can reduce bending when pressing and polishing.

[0019] The power manipulator 101 has two axes, a rotary axis and a lifting axis, and is manually controlled for loading; the electromagnet 103 is installed on the end effector of the power manipulator 101 through a spring, and the electromagnet absorbs the position of the four bosses of the lower side door 7 of the open car.

[0020] Specific implementation method three: Figure 3 As shown, the automatic assembly station 2 includes a truss manipulator 201, a spot welding robot 202, a door positioning fixture 203, and a folding positioning and pressing fixture 204; The door positioning fixture 203 and the folding leaf positioning and pressing fixture 204 are arranged side by side below the truss manipulator 201 , and the spot welding robot 202 is arranged on one side of the folding leaf positioning and pressing fixture 204 .

[0021] After the lower side door 7 of the open car is transferred to this workstation, the door positioning fixture 203 lifts and rotates the lower side door of the open car, and a truss robot 201 places the hinge. After the placement is completed, the hinge positioning and clamping fixture 204 positions and clamps the hinge, and the spot welding robot 202 spot welds the hinge. After the spot welding is completed, the double-speed chain 8 transfers the lower side door 7 of the open car to the next workstation.

[0022] Among them, the distance that the truss manipulator 201 grabs the folding sheet from the farthest side is expected to be 4500mm. According to the rated operating speed of 300mm / s of the truss manipulator 201, the movement time for grabbing one piece is 15s, plus the grabbing time of 5s and the welding time of 10s. In addition, when the lower side door 7 of the open car is being transported by the double-speed chain 8, the truss manipulator 201 can be prepared in advance.

[0023] Among them, the spot welding robot 202 is a QJR6-2000H model robot from Qianjiang Robotics; Among them, the folding positioning and clamping fixture 204 is positioned by means of a car door pin. After the truss manipulator 201 places the folding leaf, the cylinder passes the pins on both sides of the folding leaf hole. The pins are stepped shafts, which can position both sides of the folding leaf. When the lower side door 7 of the open car is running on the speed chain 8, the lower side door 7 of the open car is avoided by the lifting cylinder.

[0024] After the pinning is completed, the truss is used to press the hinge and the car door. The pressing force is estimated to be 500kg. After they are stuck together, the six-axis robot will spot weld the hinge on both sides to ensure the fit between the hinge and the car door.

[0025] The loading rack of the folding positioning and pressing fixture 204 is as follows Figure 8 As shown, it adopts a layered pull-out structure, which is divided into 8 layers in total, with 15 workpieces on each layer. A total of 120 workpieces can be installed, and the estimated usage time is 6000s. After using one layer, the loader will open the drawer to load the next layer.

[0026] Specific implementation method four: Figure 4 As shown, the manual lettering and spot welding hanging ring seat station 3 includes a lettering machine 301 and a door positioning fixture 302; The door positioning fixture 302 is arranged below the embossing machine 301 .

[0027] When the lower door 7 of the gondola car reaches the manual lettering and spot welding workstation 3, the door positioning fixture 302 lifts and clamps the lower door 7. The lettering machine 301 and welding machine are manually operated to emboss the lettering and spot weld the hanger. After the work is completed, the door positioning fixture 302 drops, and the double-speed chain 8 transports the lower door 7 to the next workstation. Specific implementation method five: Figure 5 As shown, the automatic full welding station 4 includes a door positioning fixture, a door frame 402, four sets of welding robots 403 and four sets of welding machines 404; The door positioning fixture is set below the door frame 402, and the door positioning fixture is installed on the speed chain 8. Two sets of welding robots 403 are installed on the door frame 402. The two sets of welding robots 403 are symmetrically set on both sides of the door positioning fixture. A set of welding machines 404 is installed on the execution end of each set of welding robots 403.

[0028] Among them, the automatic full welding station 4 also includes four sets of weld trackers; The weld seam tracker is installed at the execution end of the welding robot 403 .

[0029] After the lower side door 7 of the open car is transferred to the automatic full welding station 4, the door positioning fixture lifts and clamps the lower side door 7 of the open car, and the welding robot 403 performs welding. The two ends of the hinge are welded simultaneously, and the welding distance is controlled within 50mm. The weld seam of the lower side door 7 of the open car is welded by laser weld tracking. After the work is completed, the door positioning fixture falls and the door is transferred to the next station by the double-speed chain 8; when manually spot welding the hanging ring seat, the hanging ring will affect the robot welding, and a cylinder with an electromagnet is installed on the fixture to suck up the hanging ring.

[0030] The welding robot 403 is suspended by two robots with 1400mm arm span, and two robots with 2000mm arm span are sitting on the ground. The suspended robots are arranged symmetrically on the side to avoid interference between the robots during the welding process.

[0031] Among them, welding robot 403 is Qianjiang Robot QJR6-1400H model robot.

[0032] Specific implementation method six: Figure 6 As shown, the manual grinding and pressing station 5 includes a rotary clamping fixture 501 and a grinder; The rotary clamping fixture 501 is provided on one side of the speed chain 8. The rotary clamping fixture 501 is used to lift and clamp the lower side door 7 of the open car on the speed chain 8. After the polishing is completed, the lower side door 7 of the open car is rotated and placed on the speed chain 8. The grinding machine is used to grind the weld seam on the lower side door 7 of the gondola.

[0033] After the lower side door 7 of the open car is transferred to the manual polishing and pressing station 5, the rotary clamping fixture 501 lifts and clamps the door, and manually polishes it. After one side is polished, it is rotated. After the work is completed, the rotary clamping fixture 501 falls, and the speed chain 8 transfers the lower side door 7 of the open car to the next station; the rotary clamping fixture 501 has positioning and rotation functions.

[0034] Specific implementation method seven: Figure 7 As shown, the automatic unloading station 6 includes an unloading robot 601 and a plurality of electromagnets 602; The unloading robot 601 is arranged on one side of the end of the double-speed chain 8 , and a plurality of electromagnets 602 are installed on the end effector of the unloading robot 601 .

[0035] The unloading robot 601 unloads the lower side door 7 of the open car by magnetic attraction. The unloading robot 601 has two axes, a rotary axis and a lifting axis, and unloads by automatic control. The electromagnet 602 is installed on the end effector of the unloading robot 601 through a spring, and the electromagnet 602 absorbs the positions of the four bosses of the lower side door 7 of the open car.

[0036] The above description is merely a preferred embodiment of the present invention and does not constitute any form of limitation to the present invention. Although the present invention has been disclosed as a preferred embodiment as above, it is not intended to limit the present invention. Any technician familiar with the present profession can make some changes or modifications to equivalent embodiments of equivalent changes using the technical content disclosed above without departing from the scope of the technical solution of the present invention. However, any simple modification, equivalent replacement and improvement of the above embodiments made according to the technical essence of the present invention, within the spirit and principles of the present invention, without departing from the content of the technical solution of the present invention, shall still fall within the scope of protection of the technical solution of the present invention.

Claims

1. Intelligent production equipment for lower side doors of railway freight cars, characterized by: It includes a manual loading station (1), an automatic assembly station (2), a manual lettering and spot welding hanging ring seat station (3), an automatic full welding station (4), a manual grinding and pressing station (5), an automatic unloading station (6) and a double-speed chain (8); A manual loading station (1), an automatic assembling station (2), a manual letter pressing and spot welding hanging ring seat station (3), an automatic full welding station (4), a manual grinding and pressing station (5) and an automatic unloading station (6) are sequentially arranged along the double-speed chain (8) from the starting end to the end thereof.

2. The intelligent production equipment for lower side doors of railway freight car gondolas according to claim 1 is characterized in that: The manual loading station (1) includes a power-assisted manipulator (101), a loading workbench (102), and a plurality of electromagnets (103); The power-assisting manipulator (101) is arranged on one side of the loading workbench (102), and a plurality of electromagnets (103) are installed on the end effector of the power-assisting manipulator (101).

3. The intelligent production equipment for lower side doors of railway freight car gondolas according to claim 1 is characterized in that: The automatic assembly station (2) includes a truss manipulator (201), a spot welding robot (202), a door positioning fixture (203), and a folding positioning and pressing fixture (204); The door positioning fixture (203) and the folding positioning and pressing fixture (204) are arranged side by side below the truss manipulator (201), and the spot welding robot (202) is arranged on one side of the folding positioning and pressing fixture (204).

4. The intelligent production equipment for lower side doors of railway freight car gondolas according to claim 1 is characterized in that: The manual lettering and spot welding hanging ring seat station (3) comprises a lettering machine (301) and a door positioning fixture (302); The door positioning fixture (302) is arranged below the embossing machine (301).

5. The intelligent production equipment for lower side doors of railway freight car gondolas according to claim 1 is characterized in that: The automatic full welding station (4) includes a door positioning fixture, a door frame (402), four sets of welding robots (403) and four sets of welding machines (404); The door positioning fixture is arranged below the door frame (402), and the door positioning fixture is installed on the double-speed chain (8). Two sets of welding robots (403) are installed on the door frame (402). The two sets of welding robots (403) are symmetrically arranged on both sides of the door positioning fixture, and a set of welding machines (404) is installed on the execution end of each set of welding robots (403).

6. The intelligent production equipment for lower side doors of railway freight car gondolas according to claim 5 is characterized in that: The automatic full welding station (4) also includes four sets of weld seam trackers; The weld seam tracker is installed at the execution end of the welding robot (403).

7. The intelligent production equipment for lower side doors of railway freight car gondolas according to claim 1 is characterized in that: The manual grinding and pressing station (5) includes a rotary clamping fixture (501) and a grinder; A rotating clamping fixture (501) is provided on one side of the double-speed chain (8). The rotating clamping fixture (501) is used to lift and clamp the lower side door (7) of the open car on the double-speed chain (8). After polishing, the lower side door (7) of the open car is rotated and placed on the double-speed chain (8). The grinding machine is used for grinding the weld seam on the lower side door (7) of an open car.

8. The intelligent production equipment for lower side doors of railway freight car gondolas according to claim 1 is characterized in that: The automatic unloading station (6) includes an unloading robot (601) and a plurality of electromagnets (602); The unloading robot (601) is arranged on one side of the end of the double-speed chain (8), and a plurality of electromagnets (602) are installed on the end effector of the unloading robot (601).

Images