Intelligent production and manufacturing method for spiral roller

Abstract

The invention belongs to the technical field of mining machinery, and discloses an intelligent production and manufacturing method for a spiral roller, which comprises the step of realizing accurate processing through a comparison technology of digital modeling and material object scanning. The method comprises the following steps: firstly, constructing a virtual three-dimensional model and presetting a positioning reference, then scanning a real object by using a laser positioner and a 3D camera to generate a corresponding three-dimensional model, and comparing space coordinate deviations of key feature points of the two to generate a cutting path or welding track program. The whole process adopts modularized intelligent equipment for collaborative operation, a transport vehicle transfers workpieces on a track according to a programmed path, a cutting / welding robot performs automatic operation according to space coordinate point data, and meanwhile, an auxiliary manipulator is arranged to complete a manual auxiliary process. Finally, the sealing performance is verified through a water pressure test, and environment-friendly production is achieved by integrating a dust removal system. According to the technical scheme, the problems that the labor amount of manual machining and manufacturing is large, the production speed is low, and the manufacturing precision is difficult to guarantee are solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of mining machinery, and in particular relates to an intelligent production method for a spiral drum. Background Art

[0002] Traditional spiral drum production is done through manual processing, but manual processing is labor-intensive and has low production speeds, and manufacturing accuracy is difficult to guarantee. Therefore, a new, efficient and precise spiral drum production solution is urgently needed. Summary of the Invention

[0003] The purpose of the present invention is to provide an intelligent production method for a spiral drum to solve the problems existing in the above-mentioned prior art.

[0004] To achieve the above objectives, the present invention provides an intelligent manufacturing method for a spiral drum, comprising:

[0005] Step 1: After the semi-finished product of the drum is processed, it is stored in the semi-finished product storage area of ​​the spiral drum;

[0006] Step 2: Transport the semi-finished roller to the loading / inspection area;

[0007] Step 3: Build a physical 3D model of the semi-finished drum and compare it with the preset 3D model in the control platform. The model comparison includes the position comparison of the gear seat, end disc cutting notch, end disc guard plate, and loading blade. Based on the model comparison results, the positions of the cutting and welding points in 3D space are confirmed. After the positions are confirmed, the semi-finished drum is transported to the spiral drum robot cutting area for cutting.

[0008] Step 4: Transport the cut semi-finished drum to the gear seat welding area for gear seat welding;

[0009] Step 6: After the gear seat welding is completed, the semi-finished drum is transported to the loading blade and end disc guard welding area, and the loading blade / end disc guard is welded with the auxiliary robot and auxiliary machine lifting device;

[0010] Step 7: Transport the semi-finished drum after loading the blades / end disc guards to the drum finished product inspection area for water pressure testing. If the test fails, return to step 6 for manual repair welding. If the test passes, transport the qualified drum finished product to the drum finished product stacking area.

[0011] Optionally, the semi-finished roller and the finished roller are both transported by means of a rail transport vehicle.

[0012] Optionally, the process of constructing the physical three-dimensional model of the semi-finished drum specifically includes:

[0013] Punch more than three positioning holes on the end plate assembly of the semi-finished drum, use a laser locator to find the positioning holes, and combine it with a 3D camera to scan and generate a physical three-dimensional model to import into the control platform.

[0014] Optionally, the model comparison process specifically includes:

[0015] Compare the corresponding positional relationships of the tooth seat, end disc cutting notch, end disc guard plate and loading blade between the physical three-dimensional model and the preset three-dimensional model, and convert the corresponding positional relationships into cutting three-dimensional space points / welding three-dimensional space position points. If the offset dimensions of all position points differ within ±5mm, form cutting lines / welding lines by moving between points, and write the corresponding end disc assembly cutting program / roller semi-finished product tooth seat welding program, loading blade welding program and end disc guard plate welding program. If the position point offset dimensions differ by more than ±5mm, manually adjust the spatial position code of the cutting three-dimensional space point / welding three-dimensional space position point according to the actual size. After adjustment, form cutting lines / welding lines and write the corresponding program.

[0016] Optionally, the specific process of cutting includes:

[0017] The control platform is used to control the cutting robot to move the flame cutting gun head position according to the end plate component cutting program, and cut the end plate component cutting gaps in sequence.

[0018] Optionally, the specific process of the gear seat welding includes:

[0019] Confirm the welding three-dimensional spatial position point, combine with the control platform to control the gear seat handling robot to move the center of the gear seat bottom surface to the center of the water hole corresponding to the semi-finished drum, control the welding robot to move the welding gun head position based on the welding program of the semi-finished drum gear seat, and weld the gear seat in sequence.

[0020] Optional, detailed process for welding loading blades / end disc guards, including:

[0021] The auxiliary machine hoist is controlled by the control platform to lift the loaded blade / end disc guard to the specified position, and the auxiliary robot arm is used to fix the loaded blade / end disc guard. After fixation, the loaded blade / end disc guard is welded by a manual welding gun.

[0022] Optionally, the specific process of conducting water pressure testing includes:

[0023] Connect the water hole of the connecting plate of the drum to be tested with the pipe joint of the water conveying system, set the rated water pressure, start the test, and analyze whether the drum is leaking. If it is not leaking, the test is qualified. If it is leaking, return to step 6 and manually repair the leaking part with welding.

[0024] The technical effects of the present invention are:

[0025] The present invention provides a new intelligent production and manufacturing method for rollers, which utilizes robot processing and machine-assisted processing to manufacture rollers, solving the problems of large labor workload, low production speed and difficulty in ensuring manufacturing accuracy in manual processing, and can provide an effective reference for domestic roller processing and manufacturing. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0027] The accompanying drawings, which constitute part of this application, are intended to provide a further understanding of this application. The exemplary embodiments and descriptions of this application are intended to explain this application and do not constitute an improper limitation on this application. In the accompanying drawings:

[0028] Figure 1 Schematic diagram of the transportation route of the semi-finished spiral drum in an embodiment of the present invention;

[0029] Figure 2 The figure is a schematic diagram of the manufacturing process of the semi-finished spiral drum in an embodiment of the present invention. DETAILED DESCRIPTION

[0030] Various exemplary embodiments of the present invention will now be described in detail. This detailed description should not be considered as limiting the present invention, but rather as a more detailed description of certain aspects, features, and embodiments of the present invention.

[0031] It should be understood that the terms described herein are intended only to describe particular embodiments and are not intended to limit the present invention. In addition, for numerical ranges herein, it should be understood that each intermediate value between the upper and lower limits of the range is also specifically disclosed. Each smaller range between any intermediate value within a stated value or stated range and any other stated value or intermediate value within the stated range is also encompassed by the present invention. The upper and lower limits of these smaller ranges may be independently included or excluded within the scope.

[0032] It will be apparent to those skilled in the art that various modifications and variations may be made to the specific embodiments of the present invention without departing from the scope or spirit of the invention. Other embodiments will be apparent to those skilled in the art from the present invention. The present description and examples are intended to be illustrative only.

[0033] The words “include,” “including,” “have,” “contain,” etc. used in this article are open-ended terms, meaning including but not limited to.

[0034] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments in this application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0035] Example 1

[0036] like Figure 1 - Figure 2 As shown, this embodiment provides an intelligent production method for a spiral drum, comprising:

[0037] After the semi-finished products of the drum are processed, they are stored in the semi-finished product storage area of ​​the spiral drum;

[0038] Transport the semi-finished rollers to the loading / inspection area;

[0039] A physical 3D model of the semi-finished drum is constructed and compared with the preset 3D model in the control platform. The model comparison includes the position comparison of the gear seat, end disc cutting notch, end disc guard plate, and loading blade. The positions of the cutting and welding points in 3D space are confirmed based on the model comparison results. After the positions are confirmed, the semi-finished drum is transported to the spiral drum robot cutting area for cutting.

[0040] Transport the cut semi-finished drum to the gear seat welding area for gear seat welding;

[0041] Transport the semi-finished drum after the gear seat welding is completed to the loading blade and end disc guard welding area, and weld the loading blade / end disc guard with the auxiliary robot and auxiliary machine lifting device;

[0042] The semi-finished roller after loading the blades / end disc guard plate is transported to the roller finished product inspection area for water pressure testing. If the test fails, it returns to the welding step for manual repair welding. If the test passes, the qualified roller finished product is transported to the roller finished product stacking area.

[0043] The core principle of the intelligent production and manufacturing method of the spiral drum provided in this embodiment is to achieve precise processing through the comparison technology of digital modeling and physical scanning. The method first constructs a virtual three-dimensional model and presets the positioning reference, and then uses a laser locator and a 3D camera to scan the physical object to generate a corresponding three-dimensional model. By comparing the spatial coordinate deviations of the key feature points of the two (such as the position of the water hole, the layout of the gear seat, etc.) (allowing a tolerance of ±5mm), a cutting path or welding trajectory program is generated. The entire process uses modular intelligent equipment to work together: the transport vehicle transports the workpiece according to the programmed path on the track, and the cutting / welding robot performs automated operations based on the spatial coordinate point data, and is equipped with auxiliary manipulators to complete the manual auxiliary process. Finally, the sealing is verified by a water pressure test, and an integrated dust removal system is used to achieve environmentally friendly production.

[0044] Steps of intelligent production method of spiral drum:

[0045] Step 1: After the semi-finished product of the spiral drum (including blades, cylinder components, and end plate components) is processed, it is placed in the semi-finished product storage area of ​​the spiral drum by a crane;

[0046] Step 2: Use a crane to place the semi-finished spiral drum on a transport vehicle on a fixed track. The transport vehicle is equipped with a wireless signal and is controlled by a control platform to move the vehicle along the fixed track to the loading / inspection area according to the indicated route.

[0047] Step 3: The loading / inspection area is responsible for the size verification of the three-dimensional model of the drum imported into the control platform with the physical model, mainly including the horizontal position, vertical position and vertical position of multiple water holes on the drum blades; the horizontal position, vertical position and vertical position of the water holes on the end plate assembly; the relative position of the water holes on the blades and the water holes on the end plate; the virtual three-dimensional model of the semi-finished drum of the control platform is constructed and imported through three-dimensional software, and three positioning holes are punched in the end plate assembly (it can also be in other positions, but it is necessary to ensure that the positioning hole size error between the virtual three-dimensional model and the physical three-dimensional model is within ±5mm). The physical three-dimensional model is generated by punching more than three positioning holes on the semi-finished drum end plate assembly, using a laser locator to find the positioning holes, and combining 3D camera scanning to generate a physical three-dimensional model for import into the control platform. The virtual 3D model contains the corresponding positional relationships for the tooth adapter, end disc cutting notch, end disc guard plate, and loading blades. These are then compared with the corresponding positional relationships of the physical 3D model and converted into corresponding 3D cutting points / welding positions. If the offset dimensions of all positions are within ±5mm, the cutting / welding requirements can be met, and cutting / welding lines are formed by moving between points. The corresponding end disc assembly cutting program / roller semi-finished product tooth adapter welding program, loading blade welding program, and end disc guard plate welding program are then written. If the actual deviation is significant, the spatial position codes for the 3D cutting points / welding points can be manually adjusted based on the actual dimensions. Once all is completed, the control platform controls the transport vehicle to move the semi-finished roller along the indicated route on a fixed track to the spiral roller robot cutting area.

[0048] Step 4: Generate a physical three-dimensional model through the laser locator and 3D camera, confirm the position of the cutting three-dimensional space point, and use the control platform to control the cutting robot to move the flame cutting gun head position according to the end plate component cutting program, and cut the end plate component cutting notches in sequence. After all the cuts are completed, control the transport vehicle on the fixed track through the control platform to move the semi-finished roller to the spiral roller robot cutting area according to the indicated route.

[0049] Step 5: Generate a physical three-dimensional model through the laser locator and 3D camera, confirm the three-dimensional spatial position of the welding point, and use the control platform to control the gear seat handling robot to move the bottom center of the gear seat to the center of the water hole corresponding to the semi-finished drum. The welding robot then moves the welding gun head position according to the welding procedure of the semi-finished drum gear seat, and welds the gear seats in sequence. After all the gear seats are welded, the control platform controls the transport vehicle to move the semi-finished drum to the loading blade and end plate guard plate welding area along the indicated route on the fixed track.

[0050] Step 6: Using the auxiliary robot and auxiliary machine hoist, the worker controls the auxiliary machine hoist through the control platform to lift the loaded blade / end disc guard to the designated position, and fixes the loaded blade / end disc guard through the auxiliary robot. The worker only needs to weld the loaded blade / end disc guard with a manual welding gun. After all the welding of the loaded blade / end disc guard is completed, the control platform controls the transport vehicle to move the semi-finished drum to the drum finished product inspection area along the indicated route on the fixed track.

[0051] Step 7: The finished drum inspection area uses water pressure testing to analyze whether the welding of the finished drum meets the requirements and whether there is any water leakage. The drum is connected to the pipe joint of the water delivery system through the established water hole of the connecting plate, and the rated water pressure is set (usually 6.3Mpa). It is analyzed whether the drum is leaking. If there is no leakage, the test is passed. If there is leakage, return to step 5 for manual welding of the leaking part.

[0052] Step 8: After passing the inspection, the transport vehicle is controlled by the control platform to move the finished rollers to the finished roller stacking area along the indicated route on the fixed track.

[0053] It is feasible that all the above steps are carried out by transporting semi-finished products on the conveyor rollers on the predetermined track. The intelligent production line is equipped with ventilation and environmental dust removal environment, including: air-conditioning fan ventilation, mobile dust collector to collect dust, automatic sweeping and holding robot to collect wire and waste, and central dust removal system to collect all waste for secondary recycling or sale.

[0054] In summary, this embodiment provides a new intelligent roller production and manufacturing method, which uses robot processing and machine-assisted processing to manufacture rollers, solving the problems of large labor workload, low production speed and difficulty in ensuring manufacturing accuracy in manual processing and manufacturing, and can provide an effective reference for domestic roller processing and manufacturing.

[0055] The above description is merely a preferred embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present application should be included in the scope of protection of the present application. Therefore, the scope of protection of the present application should be based on the scope of protection of the claims.

Claims

1. An intelligent production method for a spiral drum, characterized in that: include: Step 1: After the semi-finished product of the drum is processed, it is stored in the semi-finished product storage area of ​​the spiral drum; Step 2: Transport the semi-finished roller to the loading / inspection area; Step 3: Build a physical 3D model of the semi-finished drum and compare it with the preset 3D model in the control platform. The model comparison includes the position comparison of the gear seat, end disc cutting notch, end disc guard plate, and loading blade. Based on the model comparison results, the positions of the cutting and welding points in 3D space are confirmed. After the positions are confirmed, the semi-finished drum is transported to the spiral drum robot cutting area for cutting. Step 4: Transport the cut semi-finished drum to the gear seat welding area for gear seat welding; Step 6: After the gear seat welding is completed, the semi-finished drum is transported to the loading blade and end disc guard welding area, and the loading blade / end disc guard is welded with the auxiliary robot and auxiliary machine lifting device; Step 7: Transport the semi-finished drum after loading the blades / end disc guards to the drum finished product inspection area for water pressure testing. If the test fails, return to step 6 for manual repair welding. If the test passes, transport the qualified drum finished product to the drum finished product stacking area.

2. The method according to claim 1, characterized in that The semi-finished roller and the finished roller are both transported by means of rail transport vehicles.

3. The method according to claim 1, characterized in that The process of constructing the physical three-dimensional model of the semi-finished drum specifically includes: Punch more than three positioning holes on the end plate assembly of the semi-finished drum, use a laser locator to find the positioning holes, and combine it with a 3D camera to scan and generate a physical three-dimensional model to import into the control platform.

4. The method according to claim 1, wherein The model comparison process specifically includes: Compare the corresponding positional relationships of the tooth seat, end disc cutting notch, end disc guard plate and loading blade between the physical three-dimensional model and the preset three-dimensional model, and convert the corresponding positional relationships into cutting three-dimensional space points / welding three-dimensional space position points. If the offset dimensions of all position points differ within ±5mm, form cutting lines / welding lines by moving between points, and write the corresponding end disc assembly cutting program / roller semi-finished product tooth seat welding program, loading blade welding program and end disc guard plate welding program. If the position point offset dimensions differ by more than ±5mm, manually adjust the spatial position code of the cutting three-dimensional space point / welding three-dimensional space position point according to the actual size. After adjustment, form cutting lines / welding lines and write the corresponding program.

5. The method according to claim 1, wherein The specific process of the cutting includes: The control platform is used to control the cutting robot to move the flame cutting gun head position according to the end plate component cutting program, and cut the end plate component cutting gaps in sequence.

6. The method according to claim 1, characterized in that The specific process of the gear seat welding includes: Confirm the welding three-dimensional spatial position point, combine with the control platform to control the gear seat handling robot to move the center of the gear seat bottom surface to the center of the water hole corresponding to the semi-finished drum, control the welding robot to move the welding gun head position based on the welding program of the semi-finished drum gear seat, and weld the gear seat in sequence.

7. The method according to claim 1, characterized in that The specific process of welding loading blades / end disc guards includes: The auxiliary machine hoist is controlled by the control platform to lift the loaded blade / end disc guard to the specified position, and the auxiliary robot arm is used to fix the loaded blade / end disc guard. After fixation, the loaded blade / end disc guard is welded by a manual welding gun.

8. The method according to claim 1, characterized in that The specific process of water pressure testing includes: Connect the water hole of the connecting plate of the drum to be tested with the pipe joint of the water conveying system, set the rated water pressure, start the test, and analyze whether the drum is leaking. If it is not leaking, the test is qualified. If it is leaking, return to step 6 and manually repair the leaking part with welding.

Images