A multi-station large bearing roller cleaning device

Abstract

The application provides a multi-station large bearing roller cleaning equipment, through self-adaptive clamping of a floating V-shaped groove and cooperation positioning of a jacking rod, zero mechanical hard contact in the whole roller transfer process is realized; a dynamic scheduling system based on real-time station state detection controls a double carrying mechanism to execute priority tasks: roller transfer is triggered immediately when a fine cleaning unit is idle, obstacle removal is automatically cooperated when blow-drying is overtime, and parallel acceleration is started when material loading is accumulated. The scheme completely eliminates roller collision damage, and the damage rate is reduced to below 0.3%, and at the same time, the efficiency bottleneck of the traditional linear process is broken, the single machine capacity is increased by 41.7%, and the unit energy consumption is reduced by 29.3%, solving the problems of high damage rate, cleaning blind area and low efficiency in the automatic cleaning of large rollers.

Description

Technical Field

[0001] This invention relates to the field of roller cleaning equipment technology, and in particular to a multi-station large bearing roller cleaning equipment. Background Technology

[0002] As precision transmission components, the surface cleanliness of bearing rollers directly affects their service life. Currently, the industry commonly uses high-pressure washing equipment for roller cleaning. This type of equipment typically uses chains or conveyor belts to continuously transport the rollers, which are then sprayed clean by multiple sets of high-pressure nozzles during movement. However, this technical solution has the following inherent drawbacks: High roller damage rate: During the conveying process, collisions and friction between rollers are inevitable. Especially for large bearing rollers (diameter > 40mm), their weight is large, and the collision energy increases significantly during high-speed conveying, resulting in a surface scratch rate of over 8%, which seriously reduces the product qualification rate.

[0003] There are blind spots in cleaning: the contact area between the conveyor belt and the rollers forms a cleaning blind spot, which accounts for about 25%-30% of the roller surface area. Residual oil stains spread during subsequent assembly, causing abnormal bearing noise and premature failure.

[0004] Low cleaning efficiency: To ensure cleaning effectiveness, the residence time of the rollers in the cleaning area needs to be extended, resulting in a single production line processing less than 80 pieces per hour. For large-scale roller cleaning scenarios, multiple machines need to operate in parallel, significantly increasing energy consumption and site costs.

[0005] Although ultrasonic cleaning technology, which has emerged in recent years, can reduce collision damage, it has a removal rate of less than 70% for stubborn oil stains in deep holes and grooves of rollers, and the equipment maintenance cost is high, making it difficult to meet the cleanliness requirements of heavy-duty bearings.

[0006] Therefore, there is an urgent need to develop a large-scale bearing roller cleaning equipment that takes into account thorough cleaning, zero damage, and high efficiency, so as to fundamentally solve the problems of roller collision damage, cleaning blind spots, and efficiency bottlenecks in traditional technologies. Summary of the Invention

[0007] To overcome the above-mentioned defects of the prior art, embodiments of the present invention provide a multi-station large bearing roller cleaning device.

[0008] To achieve the above objectives, this invention provides a multi-station large bearing roller cleaning device. Its structure includes a frame, and its innovation lies in the following: a cleaning and drying unit, comprising a cleaning tank and three parallel docking stations; the cleaning and drying unit further includes a coarse cleaning unit, a fine cleaning unit, and a drying unit; a loading station on one side of the coarse cleaning unit and a unloading station on one side of the drying unit; a track, sequentially spanning the loading station, the cleaning and drying unit, and the unloading station; two conveying mechanisms, movably mounted on the track; a cleaning fluid circulation system, including a coarse filter and a fine filter connected in series; the cleaning tank having an outlet and an inlet; the outlet connecting to the input end of the coarse filter and the inlet connecting to the output end of the fine filter; and a control system for dynamically scheduling the task allocation of the two conveying mechanisms.

[0009] Furthermore, the aforementioned control system includes position sensors, station status detectors, and a dynamic scheduling module; the dynamic scheduling module executes the following rules: (a) when the fine washing unit is idle and the coarse washing unit has rollers that have been cleaned, the control conveying mechanism moves the rollers from the coarse washing unit to the fine washing unit; (b) when the drying unit's processing time exceeds 100 seconds, the control conveying mechanism interrupts the current task and transfers the drying unit's rollers; (c) when the backlog of rollers at the loading station reaches 3, the control two conveying mechanisms simultaneously load the rollers at a distance of roller diameter plus 20mm.

[0010] Furthermore, both the loading and unloading stations are equipped with: a support rod perpendicular to the horizontal plane; a support platform fixed to the support rod; a hollow groove on the support platform for placing the roller; guide grooves symmetrically arranged on both sides of the hollow groove; and a material sensor at the bottom of the support platform for detecting the status of the roller above the hollow groove.

[0011] Furthermore, the aforementioned conveying mechanism includes: a gripper cylinder; gripper arms disposed at the two output ends of the gripper cylinder; a guide block disposed at the bottom of the gripper arm, which moves in conjunction with a guide groove; and a floating V-groove disposed at the top of the gripper arm, the center line of which is aligned with the guide block.

[0012] Furthermore, the aforementioned docking station is equipped with: a vertically movable push rod; a rotatable turntable whose center position is aligned with the push rod; and a conveying mechanism that works in conjunction with the push rod to complete the transfer of rollers: when placing the rollers, the V-groove first adaptively adjusts and opens, and after the push rod presses down to fix it, the V-groove is fully opened; when clamping the rollers, the V-groove first adaptively clamps, and then the push rod rises to release.

[0013] Furthermore, the aforementioned floating V-groove is connected to the clamping arm via a buffer mechanism, which includes: an upper clamping block and a lower clamping block located on the end face of the clamping arm; an upper clamping groove and a lower clamping groove located on the back side of the V-groove; the lower clamping block and the lower clamping groove are hinged together; the upper clamping block is movably disposed within the upper clamping groove; a connecting screw passes through the connecting hole of the upper clamping block and the upper clamping groove; and a buffer spring sleeved on the connecting screw is located between the back side of the V-groove and the clamping arm.

[0014] Furthermore, the above-mentioned cleaning box is provided with three liquid filling tanks, each liquid filling tank including: a sealing cover that can move up and down; a fixing ring fixed to the center of the liquid filling tank; several fixing rods connecting the fixing ring and the inner wall of the liquid filling tank; a leakage trough formed between adjacent fixing rods; wherein the turntable is rotatably located inside the fixing ring; a transfer box is provided at the bottom of the loading station and the unloading station, and the liquid outlet is connected to the transfer box (65).

[0015] Furthermore, the aforementioned coarse washing unit includes: a coarse washing ring that can move up and down, located above the liquid filling tank; and several coarse washing nozzles located on the coarse washing ring; the fine washing unit includes: a fine washing ring that can move up and down, located above the liquid filling tank; a lower nozzle located at the center of the turntable; an upper nozzle located at the bottom of the push rod; and several fine washing nozzles located on the fine washing ring; the drying unit includes: a drying ring that can move up and down, located above the liquid filling tank; and several air blowing nozzles located on the drying ring.

[0016] Furthermore, the task allocation of the above-mentioned handling mechanisms can adopt any of the following modes and can be dynamically scheduled and covered: the first handling mechanism is responsible for feeding materials to the coarse washing stage, and the second handling mechanism is responsible for subsequent transfer; the first handling mechanism is responsible for feeding materials to the fine washing stage, and the second handling mechanism is responsible for transfer after fine washing; the first handling mechanism is responsible for feeding materials to the drying stage, and the second handling mechanism is responsible for unloading and transfer.

[0017] Furthermore, the aforementioned handling mechanism is equipped with an anti-collision mechanism. When the distance between two handling mechanisms is less than the roller diameter plus 20mm, the deceleration mechanism is automatically triggered.

[0018] The beneficial effects of this invention are: Achieving zero-damage cleaning of large rollers: Through the adaptive clamping of floating V-grooves and the coordinated positioning of push rods, mechanical hard contact is avoided throughout the roller transfer process; combined with the intelligent optimization of the transport path by a dynamic scheduling system, the risk of collision between rollers is completely eliminated. Actual tests show that the surface damage rate of rollers has been reduced from the industry average of over 8% to below 0.3%, solving the persistent problem of scratches in the automated cleaning of large rollers (diameter > 40mm).

[0019] Breaking through the bottleneck of multi-process collaboration efficiency: Based on a dynamic scheduling mechanism that perceives real-time workstation status, the dual handling mechanisms are precisely controlled to prioritize tasks: roller transfer is triggered immediately when the fine washing unit is idle, automatic collaborative obstacle clearing is performed when drying timeout is exceeded, and parallel acceleration is initiated when material backlog is accumulated. This solution transforms the passive waiting of the traditional linear process into proactive response, increasing single-machine hourly capacity by 41.7% and reducing unit energy consumption by 29.3%, significantly reducing the overall cost of batch cleaning of large rollers. Attached Figure Description

[0020] Figure 1 This is a front perspective view of the present invention.

[0021] Figure 2 This is a perspective view of the back of the invention.

[0022] Figure 3 This is an enlarged view of the cleaning and drying unit of the present invention.

[0023] Figure 4 This is an enlarged view of the handling mechanism of the present invention.

[0024] Figure 5 This is an enlarged view of the back of the V-groove of the present invention.

[0025] Figure 6 This is an enlarged view of the support platform for this invention. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] This invention provides a multi-station large bearing roller cleaning device, and the technical solution is described in detail with reference to the accompanying drawings.

[0028] Overall structure: such as Figure 1-2 As shown, a cleaning tank 11 is located at the bottom of the frame 1. Three parallel docking stations 12 are located on the cleaning tank 11, housing a coarse washing unit 13, a fine washing unit 14, and a drying unit 15, respectively. A loading station 16 is located to the left of the coarse washing unit 13, and a unloading station 17 is located to the right of the drying unit 15. A track 18 spanning all stations is located at the top of the frame 1, and two conveying mechanisms 2 are movably mounted on the track 18 via sliding blocks. The outlet 32 ​​of the cleaning tank 11 is connected to the input of a coarse filter 19 via a pipe. The output of the coarse filter 19 is connected to the input of a fine filter 3, and the output of the fine filter 3 is connected to the inlet 31 of the cleaning tank 11, forming a cleaning fluid circulation system. The control system (not shown) is integrated into an electrical control cabinet on the side of the frame 1.

[0029] Material loading and unloading station structure: such as Figure 6 As shown, both the loading station 16 and the unloading station 17 are equipped with: a support rod 33, vertically fixed to the frame 1; a support platform 34, horizontally fixed to the top of the support rod 33; a perforated groove 35, located at the center of the support platform 34, for placing the roller; guide grooves 37, symmetrically arranged on both sides of the perforated groove 35, with a groove depth of 10mm; and a material sensor 36, installed at the bottom of the support platform 34, with its infrared emitter aligned with the center of the perforated groove 35. When the roller is placed into the perforated groove 35, the material sensor 36 detects a signal interruption, triggering a handling ready command.

[0030] Handling mechanism and handover coordination: 3.1 Structure of the handling mechanism: such as Figure 4 As shown, the conveying mechanism 2 includes: a gripper cylinder 21; two gripper arms 22 fixed to the output end of the gripper cylinder 21; a guide block 4 located at the bottom of the gripper arm 22 and in clearance fit with the guide groove 37 (fitting tolerance ±0.1mm); and a floating V-groove 41 connected to the top of the gripper arm 22 through a buffer mechanism.

[0031] 3.2 V-groove buffer mechanism: such as Figure 5 As shown: The end face of the clamping arm 22 is provided with an upper clamping block 5 and a lower clamping block 51; the back of the V-groove 41 is provided with an upper clamping groove 52 and a lower clamping groove 56; the lower clamping block 51 and the lower clamping groove 56 are hinged by a pin; the upper clamping block 5 is inserted into the upper clamping groove 52, and the connecting screw 54 passes through the connecting hole 53 of the upper clamping block 5 and the upper clamping groove 52; the buffer spring 55 is sleeved on the connecting screw 54, and its two ends are respectively pressed against the back of the V-groove 41 and the end face of the clamping arm 22.

[0032] 3.3 Roller Handover Process: (e.g.) Figure 3-4 As shown, the roller transfer process is as follows: Roller placement: The clamping arm 22 drives the V-groove 41 to move the roller above the turntable 43; the V-groove 41 adaptively adjusts its opening posture (the buffer spring 55 is compressed, and the V-groove slightly swings), so that the roller is initially positioned; the push rod 42 presses down to press the roller tightly in the center of the turntable 43; the V-groove 41 is fully opened. Roller clamping: The V-groove 41 adaptively clamps the roller (the buffer spring 55 adjusts the clamping force); the push rod 42 rises to release the roller; the clamping arm 22 lifts the roller for transfer.

[0033] 4. Cleaning unit structure: 4.1 Liquid filling tank and sealing structure: such as Figure 3 As shown: Liquid filling tank 6: Located on the cleaning tank 11, one for each docking station 12; Sealing cover 61: Lifted and lowered above the liquid filling tank 6 by a cylinder; Fixing ring 62: Welded to the center of the liquid filling tank 6; Fixing rod 63: Radially connects the fixing ring 62 to the inner wall of the liquid filling tank 6, and the spacing between adjacent fixing rods 63 forms a leakage groove 64; Turntable 43: Installed in the fixing ring 62 by a bearing.

[0034] 4.2 Cleaning Execution Units: Coarse Washing Unit 13: The coarse washing ring 131 is suspended above the liquid filling tank 6 by a cylinder, and its inner ring is equipped with 12 coarse washing nozzles 132 (spray pressure 5MPa). Fine Washing Unit 14: The fine washing ring 141 is located above the liquid filling tank 6, and its inner ring is equipped with 8 fine washing nozzles 144 (pressure 8MPa); the lower nozzle 142 is embedded in the center of the turntable 43, and the upper nozzle 143 is located at the bottom of the push rod 42 (aligned with the center hole of the roller). Drying Unit 15: The drying ring 151 is located above the liquid filling tank 6, and its inner ring is equipped with 10 air nozzles 152 (hot air temperature 80℃).

[0035] 5. Dynamic scheduling system: 5.1 Hardware configuration: Position sensor: laser rangefinder, embedded in the inner side of guide block 4 of clamp arm 22; Station status detector: pressure sensor, attached to the bottom of turntable 43; Anti-collision mechanism: infrared ranging module is set on the base of conveying mechanism 2, trigger threshold = roller diameter + 20mm.

[0036] 5.2 Scheduling Rule Execution: The control system dynamically overrides the preset division of labor mode according to the following logic: Fine washing unit priority response: When the pressure signal of fine washing unit 14 disappears (roller moves out) and the idle time is ≥5s, and the pressure of turntable 43 of coarse washing unit 13 lasts for 120s (coarse washing complete), the transport mechanism is immediately controlled to move the coarse washing roller to the fine washing unit. Drying unit timeout coordination: If the processing time of drying unit 15 is >100s (normally 90s), the other transport mechanism is controlled to interrupt the current task and move the drying roller out. Parallel loading acceleration: When there are 3 rollers at the loading station 16 simultaneously, the two transport mechanisms move synchronously with a safe distance (roller diameter + 20mm); the anti-collision mechanism monitors the distance in real time, and if it is less than the safe value, it automatically reduces the speed to 10% of the rated speed.

[0037] 6. Complete workflow: Material Ready: The rollers to be cleaned are placed in the hollow slot 35 of the loading station 16. The material sensor 36 detects the presence of the rollers and sends a ready signal to the control system. Dynamic Scheduling Start: When the fine washing unit 14 is idle: the control system instructs the first transport mechanism to move the rollers to the rough washing unit 13; when the fine washing unit is busy: according to the preset division of labor mode, the designated transport mechanism performs the material loading and transfer. Rough Washing Process: After the rollers are fixed in the rough washing unit 13: the sealing cover 61 moves down to close the liquid addition tank 6; the rough washing ring 131 descends, and the rough washing nozzle 132 sprays cleaning fluid for 120 seconds; after cleaning is completed, the station status detector sends a completion signal. Fine Washing Trigger and Execution: The control system monitors the status of the fine washing unit 14 in real time; if the fine washing unit is idle: immediately dispatch any available transport mechanism to move the rough-washed rollers to the fine washing unit 14; the fine washing ring 141 descends to spray high-pressure cleaning fluid, while the turntable 43 drives the rollers to rotate, and the lower nozzle 142 and upper nozzle 143 rinse the center hole (180 seconds). Drying and Abnormal Response: Normal Process: The second conveying mechanism transfers the finely washed rollers to the drying unit 15, where the drying ring 151 blows hot air (90s). Drying Timeout Response: If the processing time > 100s, the control system dispatches another conveying mechanism to assist in transferring the rollers to the unloading station 17. Parallel Loading (Special Conditions): When there are ≥ 3 rollers piled up at the loading station 16: The control system synchronously dispatches two conveying mechanisms to move in parallel at a safe distance; both mechanisms simultaneously clamp the rollers and transfer them to the coarse washing unit 13. Unloading Completion: The dried rollers are transferred to the unloading station 17 by the conveying mechanism that performed the transfer task, completing the cleaning cycle.

[0038] Technical effectiveness verification: Testing was conducted on Φ50×80mm tapered rollers (contamination standard: GB / T 7324 ZDDP grease):

[0039] Finally, several points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation," "connection," and "linkage" should be interpreted broadly, and can refer to mechanical or electrical connections, or internal connections between two components, or direct connections. Terms such as "upper," "lower," "left," and "right" are only used to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may change. Second, the accompanying drawings of the embodiments disclosed in this invention only involve structures relevant to the embodiments disclosed in this invention; other structures can refer to common designs. Where there is no conflict, the same embodiment and different embodiments of this invention can be combined with each other. Finally, the above descriptions are merely preferred embodiments of this invention and are not intended to limit this invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A multi-station large bearing roller cleaning device, the structure of which includes a frame (1), characterized in that, The frame (1) is provided with: a cleaning and drying unit, including a cleaning tank (11) and three docking stations (12) arranged side by side. The cleaning and drying unit also includes a coarse cleaning unit (13), a fine cleaning unit (14) and a drying unit (15). The coarse cleaning unit (13) has a loading station (16) on one side and the drying unit (15) has a unloading station (17) on one side; a track (18) that spans the loading station (16), the cleaning and drying unit and the unloading station (17) in sequence; two conveying mechanisms (2) that are movably arranged on the track (18); a cleaning fluid circulation system, including a coarse filter (19) and a fine filter (3) connected in series. The cleaning tank (11) is provided with an outlet (32) and an inlet (31). The outlet (32) is connected to the input end of the coarse filter (19) and the inlet (31) is connected to the output end of the fine filter (3); and a control system for dynamically scheduling the task allocation of the two conveying mechanisms (2). Both the loading station (16) and the unloading station (17) are equipped with: a support rod (33) perpendicular to the horizontal plane; a support platform (34) fixed to the support rod (33); a hollow groove (35) on the support platform (34) for placing rollers; guide grooves (37) symmetrically arranged on both sides of the hollow groove (35); and a material sensor (36) at the bottom of the support platform (34) for detecting the status of the rollers above the hollow groove (35). The conveying mechanism (2) includes: a gripper cylinder (21); gripper arms (22) disposed at the two output ends of the gripper cylinder (21); a guide block (4) disposed at the bottom of the gripper arm (22), which moves in conjunction with the guide groove (37); and a floating V-groove (41) disposed at the top of the gripper arm (22), the center line of which is aligned with the guide block (4). The docking station (12) is equipped with: a top rod (42) that can move up and down; a rotatable turntable (43) whose center position is aligned with the top rod (42); the conveying mechanism (2) and the top rod (42) work together to complete the transfer of rollers: when placing the roller, the V-groove (41) first adaptively adjusts to open its posture, and after the top rod (42) presses down to fix it, the V-groove is fully opened; when clamping the roller, the V-groove (41) first adaptively clamps, and then the top rod (42) rises to release; The floating V-groove (41) is connected to the clamping arm (22) through a buffer mechanism, which includes: an upper clamping block (5) and a lower clamping block (51) on the end face of the clamping arm (22); an upper clamping groove (52) and a lower clamping groove (56) on the back of the V-groove (41); the lower clamping block (51) is hinged to the lower clamping groove (56); the upper clamping block (5) is movably disposed in the upper clamping groove (52); the connecting screw (54) passes through the connecting hole (53) of the upper clamping block (5) and the upper clamping groove (52); and the buffer spring (55) sleeved on the connecting screw (54) is located between the back of the V-groove (41) and the clamping arm (22).

2. The multi-station large bearing roller cleaning equipment according to claim 1, characterized in that, The control system includes a position sensor, a station status detector, and a dynamic scheduling module. The dynamic scheduling module executes the following rules: (a) When the fine washing unit (14) is idle and the coarse washing unit (13) has rollers that have been cleaned, the control conveying mechanism moves the rollers from the coarse washing unit to the fine washing unit; (b) When the drying unit (15) takes more than 100 seconds to process, the control conveying mechanism interrupts the current task and transfers the rollers from the drying unit; (c) When the rollers at the loading station (16) accumulate to 3, the control two conveying mechanisms load the rollers synchronously with a spacing of roller diameter plus 20 mm.

3. The multi-station large bearing roller cleaning equipment according to claim 1, characterized in that, The cleaning tank (11) is provided with three liquid filling tanks (6), each liquid filling tank including: a sealing cover (61) that can move up and down; a fixing ring (62) fixed to the center of the liquid filling tank (6); a number of fixing rods (63) connecting the fixing ring (62) and the inner wall of the liquid filling tank (6); a leakage groove (64) formed between adjacent fixing rods (63); wherein the turntable (43) is rotatably disposed inside the fixing ring (62); the bottom of the loading station (16) and the unloading station (17) is provided with a transfer box (65), and the liquid outlet (32) is connected to the transfer box (65).

4. A multi-station large bearing roller cleaning equipment according to claim 3, characterized in that, The coarse washing unit (13) includes: a coarse washing ring (131) that can move up and down, located above the liquid filling tank (6); and a plurality of coarse washing nozzles (132) located on the coarse washing ring (131); the fine washing unit (14) includes: a fine washing ring (141) that can move up and down, located above the liquid filling tank (6); a lower nozzle (142) located at the center of the turntable (43); an upper nozzle (143) located at the bottom of the top rod (42); and a plurality of fine washing nozzles (144) located on the fine washing ring (141); the drying unit (15) includes: a drying ring (151) that can move up and down, located above the liquid filling tank (6); and a plurality of air blowing nozzles (152) located on the drying ring (151).

5. A multi-station large bearing roller cleaning device according to claim 1, characterized in that, The task allocation of the handling mechanism (2) adopts any of the following modes and can be dynamically scheduled and covered: the first handling mechanism is responsible for feeding materials to the coarse washing, and the second handling mechanism is responsible for subsequent transfer; the first handling mechanism is responsible for feeding materials to the fine washing, and the second handling mechanism is responsible for transfer after fine washing; the first handling mechanism is responsible for feeding materials to the drying, and the second handling mechanism is responsible for unloading and transfer.

6. A multi-station large bearing roller cleaning equipment according to claim 2, characterized in that, The transport mechanism (2) is equipped with an anti-collision mechanism. When the distance between the two transport mechanisms is less than the roller diameter plus 20mm, the deceleration mechanism is automatically triggered.

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