Truss automatic production assembly with dynamic pressure adjustment function and using method

Abstract

The invention discloses a dynamic pressure adjusting truss automatic production assembly and a using method, and belongs to the technical field of mechanical automation. Traditional hot-pressing truss production depends on manual feeding and discharging, single machine circulation, one-time pressure fixation and detection and sampling inspection, and is low in efficiency, high in risk, poor in product consistency and high in omission ratio. The truss is used for bearing the four-station hot press, the first measuring scale and the second measuring scale are arranged at the two ends of the truss, the automatic feeding module and the multi-axis mechanical arm are matched, and synchronous pressing of weighing, feeding, partitioned heating and dynamic multi-stage pressure adjustment (based on temperature and deformation sensor feedback) is achieved; the mold cleaning device and the release agent spraying device are used for automatically cleaning and spraying; carrying out online size and defect detection through laser scanning and infrared thermal imaging; and the closed-loop control unit optimizes process parameters in combination with the self-learning model. The whole line and the whole process are automatically operated in parallel, the productivity is improved by 50%, the quality precision reaches + / -0.1 mm, and the safety and the stability are obviously enhanced.

Description

Technical Field

[0001] The present invention belongs to the field of mechanical automation technology, and in particular relates to a dynamic pressure-regulated truss automated production assembly and a method for using the assembly. Background Art

[0002] The traditional production process of hot-pressed truss products relies heavily on manual labor. First, a person manually transports the raw material bins to a weighing station and activates the loading mechanism to release the material. The loose raw material is then manually flattened before being placed into the mold, and the steel backing plate is precisely positioned within the press. After the hot-pressing process is complete, the heavy finished product is manually removed from the press. This entire process is labor-intensive, resulting in low production efficiency and high labor intensity. Furthermore, manual errors can easily lead to structural deviations and inconsistent quality.

[0003] The existing technology still has the following defects when used:

[0004] Traditional hot pressing production relies on manual loading and unloading, feeding, molding, picking up parts, cleaning, spraying, testing and other links. It is labor-intensive and personnel are directly exposed to high temperature and high pressure environment, which poses serious safety hazards.

[0005] Existing processes usually only use single-machine cycle sequential processing, and can only complete one batch of production at a time. The production capacity is limited, the production cycle is long, and it is difficult to meet large-scale demand.

[0006] Traditional hot presses have fixed pressure parameters and one-time pressurization without real-time deformation feedback and adjustment. This can easily cause material rebound, local overpressure or insufficient pressing, resulting in uneven thickness and density distribution of the finished product.

[0007] Existing quality inspections mostly rely on manual sampling or simple caliper measurements. The sampling rate is low and can only detect external dimensions, but cannot detect internal defects. This results in a high missed inspection rate and a large rework rate.

[0008] Traditional process parameters need to be adjusted manually based on experience, and there is no real-time feedback and automatic optimization mechanism. Frequent trial and error and manual debugging are required for different batches of raw materials, which is inefficient and unstable. Summary of the Invention

[0009] A dynamically pressure-regulated truss automated production assembly comprises: a truss, a first measuring scale, a second measuring scale, a first hot press, a second hot press, a third hot press, and a fourth hot press; the first measuring scale is installed at the left lower end of the truss, the second measuring scale is installed at the right lower end of the truss, the first hot press is installed at the right side of the first measuring scale, the second hot press is installed at the right side of the first hot press, the third hot press is installed at the right side of the second hot press, and the fourth hot press is installed at the right side of the third hot press; the first hot press, the second hot press, the third hot press, and the fourth hot press are installed between the first measuring scale and the second measuring scale.

[0010] The method for using the assembly according to claim 1 comprises the following steps:

[0011] Step S1: The raw materials are weighed by the automatic feeding module, and the raw materials and steel backing plate are accurately fed into the hot press mold by the truss robot, and the placement uniformity is corrected by visual positioning;

[0012] Step S2: Start the multi-station hot press, control the temperature of each zone to 200°C ± 1°C, apply pressure according to a multi-stage pressurization strategy, and adjust the pressure in real time based on material deformation;

[0013] Step S3: After the hot pressing is completed, the truss robot takes out the finished product and transfers it to the inspection station;

[0014] Step S4: using a mold cleaning device to remove residues and spraying a release agent;

[0015] Step S5: Use laser scanning and infrared thermal imaging to perform full-size inspection and defect identification on the finished product.

[0016] Step S6: The closed-loop control unit optimizes the hot pressing process parameters for the next cycle through the self-learning model based on the detection results.

[0017] Furthermore, the dynamic pressure distribution algorithm includes multi-stage pressurization control, applying a first pressure in the initial stage, applying a second pressure lower than the first pressure in the pressure holding stage, and adjusting the pressure distribution in real time based on sensor feedback.

[0018] Furthermore, in the visual inspection module, the detection results of the laser scanning device and the infrared thermal imaging device are correlated and analyzed, and a defect is determined when the temperature difference of the temperature field exceeds 15°C.

[0019] Furthermore, the process parameter self-learning model of the closed-loop control unit is trained through a machine learning algorithm to optimize the pressing temperature, pressure curve and holding time.

[0020] Furthermore, the truss manipulator is a multi-axis rectangular coordinate robot, and the end effector is equipped with a visual sensor for real-time correction of the grasping position and posture.

[0021] Furthermore, the feeding mechanism of the automatic feeding module cooperates with the truss manipulator to evenly spread the weighed raw materials on the steel back plate and feed them into the mold cavity.

[0022] Furthermore, the mold cleaning device includes a mechanical brush and a high-pressure airflow nozzle, and the release agent spraying device adopts a spray gun mechanism to form a uniform isolation coating.

[0023] Compared with the prior art, the present invention has the following advantages:

[0024] This invention utilizes a truss to support a multi-station hot press and a double-end measuring scale, coupled with an automatic feeding module and a manipulator, to automate the entire process from raw material weighing, feeding, forming, removing parts, cleaning, spraying, and testing. This significantly reduces operators' direct exposure to high-temperature and high-pressure operations, reducing labor intensity and improving production safety.

[0025] The present invention arranges four hot presses in series between two measuring scales. While one press is loading, the remaining presses are simultaneously pressing or discharging, creating a high-density production flow. Combined with a truss robot for rapid switching between presses, the overall production capacity of the line can be increased by over 50% compared to traditional single-machine cycles.

[0026] Each hot press in this invention utilizes a multi-stage pressurization strategy (initial high pressure → maintaining low pressure) and real-time readings from deformation and temperature sensors. A control unit adaptively adjusts the pressure distribution of each press head according to a dynamic pressure distribution algorithm. This effectively eliminates material springback and uneven regional force distribution, resulting in a more consistent finished product thickness and structural density than traditional fixed processes.

[0027] After the finished product is removed, a laser scanning device generates a millimeter-level (±0.1mm) 3D point cloud, which is compared with the CAD model to measure dimensional deviations. An infrared thermal imaging device captures the temperature field and identifies potential internal defects based on temperature deviations (threshold ≥15°C). This dual inspection method achieves 100% full inspection, significantly reducing missed detection rates and rework rates.

[0028] The test results of the present invention are fed into a process parameter self-learning model via a closed-loop control unit. Using a machine learning algorithm, the system continuously optimizes heating temperature, pressure profile, and dwell time. The system automatically adapts to the changing characteristics of different batches of raw materials, reducing manual trial and error and process debugging time, ultimately optimizing the production curve. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0030] Figure 2 It is a flow chart of the present invention;

[0031] In the figure: 1. Truss; 2. First measuring scale; 3. First hot press; 4. Second hot press; 5. Third hot press; 6. Fourth hot press; 7. Second measuring scale. DETAILED DESCRIPTION

[0032] The subject matter described herein will now be discussed with reference to example embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and are not intended to limit the scope of protection, applicability, or examples set forth in the claims. The functions and arrangements of the elements discussed may be changed without departing from the scope of protection of this specification. Various examples may omit, replace, or add various processes or components as needed. For example, the described method may be performed in an order different from the order described, and various steps may be added, omitted, or combined. In addition, features described relative to some examples may also be combined in other examples.

[0033] As used herein, the term "including" and its variations are open terms meaning "including but not limited to". The term "based on" means "based at least in part on". The terms "one embodiment" and "an embodiment" mean "at least one embodiment". The term "another embodiment" means "at least one other embodiment". The terms "first", "second", etc. may refer to different or the same objects. Other definitions may be included below, whether explicit or implicit. Unless the context clearly indicates otherwise, the definition of a term is consistent throughout the specification.

[0034] Example

[0035] A dynamically pressure-regulated truss automated production assembly comprises: a truss, a first measuring scale, a second measuring scale, a first hot press, a second hot press, a third hot press, and a fourth hot press; the first measuring scale is installed at the left lower end of the truss, the second measuring scale is installed at the right lower end of the truss, the first hot press is installed at the right side of the first measuring scale, the second hot press is installed at the right side of the first hot press, the third hot press is installed at the right side of the second hot press, and the fourth hot press is installed at the right side of the third hot press; the first hot press, the second hot press, the third hot press, and the fourth hot press are installed between the first measuring scale and the second measuring scale.

[0036] The method for using the assembly according to claim 1 comprises the following steps:

[0037] Step S1: The raw materials are weighed by the automatic feeding module, and the raw materials and steel backing plate are accurately fed into the hot press mold by the truss robot, and the placement uniformity is corrected by visual positioning;

[0038] Step S2: Start the multi-station hot press, control the temperature of each zone to 200°C ± 1°C, apply pressure according to a multi-stage pressurization strategy, and adjust the pressure in real time based on material deformation;

[0039] Step S3: After the hot pressing is completed, the truss robot takes out the finished product and transfers it to the inspection station;

[0040] Step S4: using a mold cleaning device to remove residues and spraying a release agent;

[0041] Step S5: Use laser scanning and infrared thermal imaging to perform full-size inspection and defect identification on the finished product.

[0042] Step S6: The closed-loop control unit optimizes the hot pressing process parameters for the next cycle through the self-learning model based on the detection results.

[0043] Raw material weighing and feeding coordination: The first measuring scale is equipped with an electronic weighing sensor and material guide rails. When feeding begins, the raw materials enter the hopper of the first measuring scale through the feeding hopper, and the sensor collects weight data in real time;

[0044] The multi-axis manipulator end effector installed on the truss is equipped with a vacuum suction cup and a cotton picking clamp. After weighing, it can move along the X / Y / Z axes to the first measuring scale position, quickly identify the edge of the material surface through the visual sensor, and accurately grab the friction powder in the hopper;

[0045] The robot then moves to the steel backing plate supply position to grab a piece of steel backing plate, uses the same actuator to evenly spread the powder on the surface of the steel backing plate, and lifts it above the mold cavity of the first hot press;

[0046] Before blanking, the robot cooperates with the positioning pins and visual correction system to align the mold slot and the edge of the steel backing plate to ensure that the raw material and the steel backing plate are placed concentrically and have uniform thickness.

[0047] Multi-station hot pressing collaborative molding: The first to fourth hot presses are installed on the same base, the molds are arranged in a row, and each mold plate is embedded with a zoned heating plate and pressure sensor;

[0048] The robot pushes the tray into the first hot press and sends a "position completed" signal to the closed-loop control unit;

[0049] The control unit starts the heating system and heats the heating plate to ℃±℃ according to the area. At the same time, the hydraulic valves of each hot press are opened in sequence. The initial high pressure is applied to the first hot press, and then switched to the holding pressure after a few seconds.

[0050] During the pressure holding phase, the deformation sensors and temperature sensors at each machine position report data to the control unit in real time. The control unit then fine-tunes the pressure distribution of each hydraulic cylinder through proportional valves based on the material deformation rate and temperature curve to ensure uniform pressure distribution on the four machine positions.

[0051] After completing the pressure holding at the first machine position, the truss robot moves the semi-finished product from the first hot press to the second hot press. At the same time, the first hot press starts the next hot pressing cycle. Therefore, when one machine is feeding, the other machines are performing hot pressing or discharging at the same time, achieving a high-density flow rhythm.

[0052] Mold cleaning and release agent spraying work together: Each hot press is equipped with a mold cleaning device, which includes a retractable mechanical brush arm and a high-pressure airflow nozzle. After the robot arm leaves, the cleaning device automatically extends to the mold cavity, where the mechanical brush rotates to scrape away residual powder, while the nozzle simultaneously blows away small particles.

[0053] After cleaning is completed, the cleaning device is retracted, and the control unit drives the release agent spraying device to move back and forth at a uniform speed along the X direction, spraying a thin and uniform layer of release agent coating to prepare isolation for the next loading.

[0054] Finished product removal and online inspection: After hot pressing is completed and cooled to a safe temperature, the robot reaches into the corresponding machine position, uses a special vacuum flexible gripper to pick up the finished product, and places it on the second measuring scale for weight verification to determine whether there is any leakage or deformation due to over-pressing;

[0055] The robot then carries the finished product to the inspection station, where the laser scanning device moves laterally along the guide rail, collecting a 3D point cloud around the product and comparing it with the pre-stored CAD model in real time to measure the dimensional deviation at the ±.mm level.

[0056] Next, the infrared thermal imaging camera looks down at the surface of the product and captures the temperature field distribution map. The control unit superimposes the hot spots and cold areas on the point cloud model. When the temperature difference in a certain area exceeds ℃, it is judged as a potential internal defect.

[0057] Closed-loop feedback and process optimization: After inspection, the control unit imports data such as dimensional deviation and defect location into a process parameter self-learning model. Based on the parameter-result database of previous batches (temperature, pressure, holding time, and defect rate), the model automatically calculates the optimal heating temperature, pressure values ​​at each stage, and holding time for the next cycle through a machine learning algorithm.

[0058] These optimized parameters are sent by the control unit to each hot press and heating system for use in the next batch of production, thus forming a closed loop of "detection → optimization → feedback → reproduction", greatly reducing manual trial and error and process adjustment time.

[0059] It should be noted that not all steps and units in the above processes and system structure diagrams are required, and some steps or units can be omitted according to actual needs. The execution order of each step is not fixed and can be determined as needed. The device structure described in the above embodiments can be a physical structure or a logical structure, that is, some units may be implemented by the same physical entity, or some units may be implemented by multiple physical entities, or may be implemented by certain components in multiple independent devices.

[0060] The specific embodiments set forth above describe exemplary embodiments, but do not represent all embodiments that can be implemented or fall within the scope of protection of the claims. The term "exemplary" used throughout this specification means "used as an example, instance, or illustration" and does not mean "preferred" or "having advantages" over other embodiments. For the purpose of providing an understanding of the described technology, the specific embodiments include specific details. However, these technologies can be implemented without these specific details. In some instances, in order to avoid obscuring the concepts of the described embodiments, well-known structures and devices are shown in block diagram form.

[0061] The foregoing description of the present disclosure is provided to enable any person skilled in the art to implement or use the present disclosure. Various modifications to the present disclosure will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other variations without departing from the scope of the present disclosure. Therefore, the present disclosure is not limited to the examples and designs described herein, but is intended to be consistent with the widest range of principles and novel features disclosed herein.

Claims

1. A dynamic pressure-regulated truss automated production assembly, comprising: A truss (1), a first measuring scale (2), a second measuring scale (7), a first hot press (3), a second hot press (4), a third hot press (5), and a fourth hot press (6), characterized in that: the first measuring scale (2) is installed at the left end below the truss (1), the second measuring scale (7) is installed at the right end below the truss (1), the first hot press (3) is installed on the right side of the first measuring scale (2), the second hot press (4) is installed on the right side of the first hot press (3), the third hot press (5) is installed on the right side of the second hot press (4), the fourth hot press (6) is installed on the right side of the third hot press (5), and the first hot press (3), the second hot press (4), the third hot press (5), and the fourth hot press (6) are installed between the first measuring scale (2) and the second measuring scale (7).

2. The method for using the assembly according to claim 1, characterized in that: The following steps are involved: Step S1: The raw materials are weighed by the automatic feeding module, and the raw materials and steel backing plate are accurately fed into the hot press mold by the truss robot, and the placement uniformity is corrected by visual positioning; Step S2: Start the multi-station hot press, control the temperature of each zone to 200°C ± 1°C, apply pressure according to a multi-stage pressurization strategy, and adjust the pressure in real time based on material deformation; Step S3: After the hot pressing is completed, the truss robot takes out the finished product and transfers it to the inspection station; Step S4: using a mold cleaning device to remove residues and spraying a release agent; Step S5: Use laser scanning and infrared thermal imaging to perform full-size inspection and defect identification on the finished product. Step S6: The closed-loop control unit optimizes the hot pressing process parameters for the next cycle through a self-learning model based on the detection results.

3. The dynamic pressure-regulated truss automated production assembly and method of use according to claim 2, characterized in that: The dynamic pressure distribution algorithm includes multi-stage pressurization control, applying a first pressure in the initial stage, applying a second pressure lower than the first pressure in the pressure holding stage, and adjusting the pressure distribution in real time based on sensor feedback.

4. The dynamic pressure-regulated truss automated production assembly and method of use according to claim 2, characterized in that: In the visual inspection module, the detection results of the laser scanning device and the infrared thermal imaging device are correlated and analyzed, and a defect is determined when the temperature difference of the temperature field exceeds 15°C.

5. The dynamic pressure-regulated truss automated production assembly and method of use according to claim 2, characterized in that: The process parameter self-learning model of the closed-loop control unit is trained through a machine learning algorithm to optimize the pressing temperature, pressure curve and holding time.

6. The dynamic pressure-regulated truss automated production assembly and method of use according to claim 2, characterized in that: The truss manipulator is a multi-axis rectangular coordinate robot, and the end effector is equipped with a visual sensor for real-time correction of the grasping position and posture.

7. The dynamic pressure-regulated truss automated production assembly and method of use according to claim 2, characterized in that: The feeding mechanism of the automatic feeding module cooperates with the truss manipulator to evenly spread the weighed raw materials on the steel back plate and feed them into the mold cavity.

8. The dynamic pressure-regulated truss automated production assembly and method of use according to claim 2, characterized in that: The mold cleaning device includes a mechanical brush and a high-pressure airflow nozzle, and the release agent spraying device adopts a spray gun mechanism to form a uniform isolation coating.

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