Product production line and production method

Abstract

The invention relates to the technical field of metal pipe machining, in particular to a product production line and a production method.The automatic product production line comprises a feeding system, an internal high-pressure forming mold, an automatic sawing mechanism and a robot carrying mechanism; a water injection rod of the internal high-pressure forming mold is provided with a limiting structure for limiting excessive deformation of the sealing element; the automatic sawing mechanism comprises a lifting unit, a size detection unit and a control unit electrically connected with the size detection unit. The size detection unit is used for detecting the size of the saw blade in real time and feeding back the size to the control unit, the control unit adjusts the saw cutting speed in a segmented mode according to the size of the saw blade and the preset cutting position, and the automatic production line of the product can improve the production efficiency and reduce the production cost.

Description

Technical Field

[0001] This invention relates to the field of metal pipe processing technology, and in particular to a product production line and production method. Background Technology

[0002] Internal high pressure forming products are complex hollow components manufactured using internal high pressure forming technology. This technology uses tubes as blanks and uses the combined action of internal ultra-high pressure liquid (100MPa-1000MPa) and axial feeding to make the tube blank fit into the mold cavity, forming an integrated part with variable cross-section, curved axis or multi-pass structure.

[0003] When mass-producing internal high-pressure products (such as 5 million pieces per year), traditional internal high-pressure forming production generally involves a high degree of manual intervention, such as manual loading and unloading and product transfer, and a low degree of automation. Therefore, it is urgent to improve the degree of automation and reduce the dependence on manual labor in order to improve efficiency and reduce costs. Summary of the Invention

[0004] This invention provides a product production line and production method that can improve production efficiency and reduce production costs.

[0005] This invention provides an automated production line for products, comprising:

[0006] The feeding system is used for placing and positioning the pipe blanks for the product.

[0007] Internal high-pressure forming mold, used for internal pressure forming of pipe blanks;

[0008] An automatic sawing mechanism is used to automatically saw the ends of pipes after internal pressure forming.

[0009] The robot handling mechanism is used to transfer the pipe blanks in the feeding system to the inner high-pressure forming mold, and then transfer the formed pipes in the inner high-pressure forming mold to the automatic sawing mechanism for sawing.

[0010] The water injection rod of the internal high-pressure forming mold is provided with a limiting structure to restrict excessive deformation of the sealing element;

[0011] The automatic sawing mechanism includes a lifting unit, a size detection unit, and a control unit electrically connected to the size detection unit; the size detection unit is used to detect the saw blade size in real time and feed it back to the control unit, and the control unit adjusts the sawing speed in segments according to the saw blade size and the preset cutting position.

[0012] In one embodiment of the present invention, the feeding system includes at least two sets of feeding stations, and each set of feeding stations includes multiple stations for product positioning and placement.

[0013] In one embodiment of the present invention, the robot handling mechanism includes:

[0014] robotic arm;

[0015] An end effector is used to pick up products; the end effector is positioned with the robotic arm by a positioning pin and a positioning hole, and is locked in place by a movable plate and a positioning plate.

[0016] In one embodiment of the present invention, the end effector of the robot handling mechanism includes:

[0017] slide rail;

[0018] The clamping assembly is provided in at least two sets, each set of the clamping assembly includes two clamping units, the position of each clamping unit on the slide rail is adjustable, and the two clamping units in each set are used to clamp the two ends of the product.

[0019] In one embodiment of the present invention, the end effector of the robot handling mechanism is further provided with a clamping detection unit for detecting whether the product clamping is in place and / or a fault-proofing detection unit for detecting whether the product clamping position is correct.

[0020] In one embodiment of the present invention, the end effector of the robot handling mechanism is provided with an air gun for cleaning the upper and lower cavities of the inner high-pressure forming mold at an angle.

[0021] This invention provides an automated production method for internal high-voltage products, characterized by comprising the following steps:

[0022] Clamping and picking up materials: The end effector of the robot handling mechanism clamps the product from the feeding system, and the clamping status is confirmed by the clamping detection unit;

[0023] Cavity cleaning: The robot handling mechanism uses an air gun to traverse the upper and lower cavity surfaces of the high-pressure forming mold along a predetermined spatial trajectory;

[0024] Product positioning detection: After placing the product into the cavity of the inner high-pressure forming mold, move the end effector to a set height above the product, and use a position detection sensor to detect the fit between the product and the cavity of the inner high-pressure forming mold;

[0025] Internal high-pressure molding and transfer: After high-pressure molding is completed, the product is removed and the residual liquid is poured out. The product is then transferred to an automatic sawing mechanism for automatic sawing.

[0026] In one embodiment of the present invention, in the step of the end effector of the robot handling mechanism gripping the product from the feeding system and the gripping status being confirmed by the gripping detection unit, the end effector of the robot handling mechanism can grip the product in batches.

[0027] In one embodiment of the present invention, the step of removing the product and pouring out the residual liquid after high-pressure molding, and transferring the product to an automatic sawing mechanism for sawing, includes the following sawing process:

[0028] The cutting stages are divided based on the real-time dimensional changes of the saw blade.

[0029] Different feed rates are applied to the idle section, product contact section, and thick-wall cutting section, with the feed rates decreasing sequentially from the idle section to the product contact section and the thick-wall cutting section.

[0030] In one embodiment of the present invention, in the step of dividing the cutting stage based on the real-time size change of the saw blade, the real-time size change of the saw blade is obtained by monitoring the displacement of the lifting unit and combining it with the initial calibration displacement value of the saw blade.

[0031] The beneficial effects of this invention are as follows: Traditional production of internal high-pressure products relies on manual loading and unloading, resulting in frequent replacement of seals and high downtime rates. Furthermore, manual sawing is prone to quality fluctuations due to operational variations. This invention eliminates or reduces manual handling by coordinating a feeding system with a robotic handling mechanism, significantly improving production line cycle consistency. The limiting structure of the water injection rod optimizes the stress state of the seals, greatly extending their service life and reducing maintenance frequency. The adaptive control of sawing speed dynamically adjusts the feed parameters based on the saw blade wear state or the size of the replaced saw blade, effectively avoiding the risk of blade breakage during thick-walled cutting, ensuring uniform cross-sectional quality, reducing safety hazards during high-speed sawing, and improving sawing efficiency. Attached Figure Description

[0032] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0033] In the attached diagram:

[0034] Figure 1 This is a schematic diagram of the structure of an automated production line for products provided in an embodiment of the present invention;

[0035] Figure 2 This is a schematic diagram of the main structure of the internal high-pressure forming mold provided in one embodiment of the present invention;

[0036] Figure 3 for Figure 2 Enlarged view of the structure at point A;

[0037] Figure 4 This is a schematic diagram of one side structure of the automatic sawing mechanism provided in one embodiment of the present invention;

[0038] Figure 5 This is a schematic diagram of the other side of the automatic sawing mechanism provided in one embodiment of the present invention;

[0039] Figure 6 This is a schematic diagram of the feeding system structure provided in one embodiment of the present invention;

[0040] Figure 7 This is a schematic diagram of a robot handling mechanism provided in one embodiment of the present invention;

[0041] Figure 8 This is a schematic diagram of one side of the end effector structure provided in one embodiment of the present invention;

[0042] Figure 9 This is a schematic diagram of the other side of the end effector provided in one embodiment of the present invention;

[0043] Figure 10 This is a schematic diagram of the connection structure between the robotic arm and the end effector provided in one embodiment of the present invention;

[0044] Figure 11 This is a schematic diagram of the connection between the robotic arm and the end effector provided in one embodiment of the present invention;

[0045] Figure 12 This is a schematic diagram of a water injection rod structure provided in one embodiment of the present invention;

[0046] Figure 13 This is a flowchart of a method provided in one embodiment of the present invention; Attached image description:

[0048] Product 100, Feeding System 1, Internal High-Pressure Molding Mold 2, Water Injection Rod 21, Limiting Structure 211, Seal 22, Ejector Mechanism 23, Ejector Block 231, Upper Mold 201, Lower Mold 202, Mold Cavity 203, Automatic Sawing Mechanism 3, Lifting Unit 31, Dimension Detection Unit 32, Saw Blade 33, Electric Saw Drive Assembly 331, Robot Handling Mechanism 4, Mechanical Arm 41, End Capture 42, Positioning Pin 401, Positioning Hole 402, Movable Clamping Plate 403, Positioning Clamping Plate 404, Slide Rail 421, Clamping Assembly 422, Clamping Unit 4221, Lever Cylinder 42211, Contouring Clamping Arm 42212, Contouring Clamping Block 42213, Clamping Detection Unit 423, Error Prevention Detection Unit 424, Air Gun 43. Detailed Implementation

[0049] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0050] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. The drawings only show the components related to the present invention and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0051] In the following description, numerous details are explored to provide a more thorough explanation of embodiments of the invention. However, it will be apparent to those skilled in the art that embodiments of the invention may be practiced without these specific details. In other embodiments, well-known structures and devices are shown in block diagram form rather than in detail to avoid obscuring embodiments of the invention.

[0052] The internal high-pressure molded products in this case include, for example, pipes with varying cross-sectional dimensions along the axis, such as automobile exhaust pipes and mufflers; for example, curved axis pipes; three-dimensional curved components, such as subframe tube beams, automobile side steps, and luggage rack brackets; and for example, complex pipelines with branches, such as radiator brackets and oil distributors.

[0053] Internal high-pressure forming technology: With internal pressure and axial feed as the core, the pipe is plastically deformed through Pascal's principle to achieve net forming of complex shapes. More than 100 of its products are hollow variable cross-section components, which are lightweight, high-strength and high material utilization.

[0054] In the production of products formed by internal high pressure molding, the main processes are internal high pressure molding and multi-pass sawing, both of which are currently done manually. The main production process is manual material loading, including the following steps:

[0055] The first step is to manually clean the iron filings from the surface of product 100. The second step is to open the inner high-pressure forming mold 2, open the upper and lower mold cavities, and manually pry up one end of the previously produced product 100 with a tool to remove product 100. The third step is to use an air gun 43 to blow air into the upper and lower mold cavities of the inner high-pressure forming mold 2 in turn to clean the iron filings and debris inside the mold cavity 203. The fourth step is to place product 100 into the mold cavity 203 of the lower mold 202 of the inner high-pressure forming mold 2, ensuring that product 100 fits the lower mold 202, and press the start button with both hands. The fifth step is to place the inner high-pressure formed product 100 into the sawing mold cavity of the sawing equipment. The upper mold cavity of the sawing equipment presses down to press product 100, and the saw blade 33 presses down slowly and evenly until product 100 is cut off. Then the upper mold cavity of the sawing equipment moves upward, and the sawing speed is relatively slow.

[0056] After internal high-pressure molding, it usually requires two or more sawing processes, which require multiple people to operate and are relatively dangerous processes in the production environment. There is also a pain point in internal high-pressure molding: during internal high-pressure molding, both sides need to be sealed by expanding polyurethane material to achieve the seal. Generally, the service life of polyurethane is only 20-30 pieces.

[0057] Based on the real-time dimensional changes of the saw blade 33, the cutting stages are divided into three phases: the idle stroke phase refers to the stage during which the saw blade 33 moves from its initial position towards the workpiece, before physical contact occurs between the saw blade 33 and the workpiece; the product contact phase refers to the stage after the saw blade 33's tooth tip approaches or first contacts the workpiece surface, for example, from cutting into the workpiece until the cutting depth reaches 10% to 50% of the workpiece's total wall thickness. This stage is characterized by a non-linear increase in the cutting force borne by the saw blade 33 starting from zero; and the thick-wall cutting phase refers to the stage after the saw blade 33's cutting depth exceeds 10% or 50% of the workpiece's total wall thickness. Until the stage of completely cutting off the workpiece, there are no strict restrictions on the critical points of the idle section, the product contact section, and the thick-wall cutting section. For example, the total length of the idle section, the product contact section, and the thick-wall cutting section is fixed. The idle section can be one centimeter away from the workpiece by the saw blade 33. The product contact section starts immediately after the idle section. The initial position of the product contact section can be when the tip of the saw blade 33 first contacts the surface of the workpiece or before the tip of the saw blade 33 first contacts the surface of the workpiece. The thick-wall cutting section starts immediately after the product contact section.

[0058] Therefore, this case provides an automated production line for products to achieve automated production with fewer or no people, thereby improving equipment versatility and production efficiency.

[0059] like Figure 1-5As shown, the present invention provides an automated production line for products, including a feeding system 1, an internal high-pressure forming mold 2, an automatic sawing mechanism 3, and a robot handling mechanism 4; the feeding system 1 is used for placing and positioning the pipe blanks of product 100; the internal high-pressure forming mold 2 is used for internal pressure forming of the pipe blanks; the automatic sawing mechanism 3 is used for automatically sawing the ends of the pipes after internal pressure forming; the robot handling mechanism 4 is used for transferring the pipe blanks in the feeding system 1 to the internal high-pressure forming mold 2, and transferring the formed pipes in the internal high-pressure forming mold 2 to the automatic sawing mechanism 3 for sawing;

[0060] The water injection rod 21 of the inner high-pressure forming mold 2 is provided with a limiting structure 211 to restrict the excessive deformation of the sealing element 22;

[0061] The automatic sawing mechanism 3 includes a lifting unit 31, a size detection unit 32, and a control unit electrically connected to the size detection unit 32; the size detection unit 32 is used to detect the size of the saw blade 33 in real time and feed it back to the control unit, and the control unit adjusts the sawing speed in segments according to the size of the saw blade 33 and the preset cutting position.

[0062] It should be noted that the automated production line uses a feeding system 1 to position the pipe blanks. This feeding system 1 can adopt a dual-station rotary table structure, a multi-station chain conveyor belt, or an integrated solution of a hopper and robotic arm to ensure that the blanks enter the processing flow in an orderly manner. The inner high-pressure forming mold 2 applies an internal ultra-high-pressure liquid to the pipe blank to make it conform to the cavity of the inner high-pressure forming mold 2. The limiting structure 211 on the water injection rod 21 includes an annular boss, a stepped shoulder, or an adjustable stop to constrain the axial and / or radial deformation space of the sealing element 22. The automatic sawing mechanism 3 is driven by a lifting unit 31 to feed the saw blade 33. The saw blade 33 is driven to rotate by an electric saw drive assembly 331. The electric saw drive assembly 331 is, for example, a servo motor and a reducer connected by a transmission. The electric saw drive assembly 331 moves together with the lifting unit 31, and the saw blade 33 is generally mounted on the electric saw drive assembly 331. The dimension detection unit 32 monitors the wear of the saw blade 33 or the replacement of the new saw blade in real time through laser ranging, visual recognition, or contact sensing. The control unit divides the cutting process into idle stroke, product contact, and thick-wall cutting segments based on the detection data, and outputs differentiated sawing speed commands for each segment. The robot handling mechanism 4 connects each process through the end effector 42, and achieves rapid shape change by using the insertion and cooperation of the positioning pin 401 and the positioning hole 402 and the mechanical locking of the movable clamp 403, completing the entire transfer of the pipe from feeding to forming and then to sawing. In addition to the annular boss, the limiting structure 211 can also be designed as a detachable clamp or a multi-level groove on the outer wall of the water injection rod 21; the dimension detection unit 32 can use an infrared thickness gauge to obtain the status of the saw blade 33; in addition to the servo electric cylinder, the lifting unit 31 can also be controlled by a hydraulic synchronous cylinder or a linear motor to achieve precise displacement; the quick change mechanism of the end effector 42 can adopt a mechanical solution of electromagnetic locking, pneumatic gripper, or wedge groove clamping.

[0063] To address the three major technical problems of low efficiency in manual operation, rapid wear of the seal 22, and unstable sawing quality, the solution principle of this case is as follows: The limiting structure 211 of the water injection rod 21 reduces the stress peak under high pressure conditions by physically limiting the compression stroke of the seal 22, thereby delaying material fatigue; the size detection unit 32 converts the real-time wear of the saw blade 33 or the different sizes of the saw blade 33 that have been replaced into displacement signals. Based on this, the control unit uses a higher speed to shorten the auxiliary time when the lifting unit 31 drives the saw blade 33 to move during the idle stroke. The speed is reduced in the product contact section to avoid cutting impact. In the thick-walled cutting section, the speed of the lifting unit 31 driving the saw blade 33 to move is further reduced to ensure the quality of the cut surface; the robot handling mechanism 4 traverses the mold cavity according to a preset serpentine path, and combined with the height sensor to detect the product 100 fitting status, realizes unmanned operation. All subsystems cooperate through the electrical control system to form a continuous and stable production cycle.

[0064] Traditional production of internal high-pressure products relies on manual loading and unloading, leading to frequent replacements of the seal 22 and high downtime rates. Furthermore, manual sawing is prone to quality fluctuations due to operational variations. This design addresses these issues through integrated design: the coordination between the feeding system 1 and the robotic handling mechanism 4 eliminates or reduces manual handling, significantly improving production line cycle consistency; the limiting structure 211 of the water injection rod 21 optimizes the stress state of the seal 22, greatly extending its service life and reducing maintenance frequency; the adaptive control strategy for sawing speed dynamically adjusts the feed parameters based on the wear state of the saw blade 33 or the size of the replaced saw blade 33, effectively avoiding the risk of blade breakage during thick-walled cutting, ensuring uniform cross-sectional quality, and reducing safety hazards during high-speed sawing.

[0065] like Figure 6 As shown, as an optional embodiment of this case, the feeding system 1 includes at least two sets of feeding stations, and each set of feeding stations includes multiple stations for positioning and placing the product 100.

[0066] The feeding system 1 achieves continuous production by setting up at least two sets of feeding stations. Each set of stations includes multiple independent positioning units to simultaneously accommodate multiple pipe blanks. This design allows one set of stations to perform feeding operations while the other set simultaneously performs processing feeding, eliminating process waiting time. In specific implementations, the feeding station can be embodied in equally divided slots on a rotary double-station table, matrix positioning fixtures on a conveyor belt, or a combination structure of a material rack and a liftable pallet. The positioning unit of each set of stations can use V-blocks with pneumatic clamping mechanisms, vacuum adsorption platforms, or contour positioning pins to ensure precise and controllable axial and radial positions of the pipes. This solution addresses the production line cycle time bottleneck caused by single-point feeding through redundant station configuration, maximizing equipment utilization.

[0067] Traditional single-station material feeding requires machine downtime for replenishment, hindering continuous production line operation. This project utilizes alternating dual-station operation, enabling material feeding and processing to be performed in parallel, reducing auxiliary time to near zero. By precisely matching the switching cycle of the material feeding system 1 with the robot's handling rhythm, production line downtime caused by manual intervention is avoided; the multi-positioning unit design adapts to batch material feeding needs, improving the efficiency of single operations, thereby contributing to the overall increase in production capacity.

[0068] like Figure 10-11 As shown, as an optional embodiment of this case, the robot handling mechanism 4 includes a robotic arm 41 and an end effector 42; the end effector 42 is used to pick up the product 100; the end effector 42 and the robotic arm 41 are positioned by a positioning pin 401 and a positioning hole 402, and are locked together by a movable plate 403 and a positioning plate 404.

[0069] It should be noted that the robot handling mechanism 4 includes a robotic arm 41 and an end effector 42, which are rigidly connected through a quick-change interface. Between the end effector 42 and the robotic arm 41, one is provided with a positioning pin 401, and the other with a positioning hole 402; one is provided with a movable locking plate 403, and the other with a positioning locking plate 404. The robotic arm 41 is, for example, the robotic arm 41 of a six-axis robot; the positioning function of the quick-change interface is completed by the cooperation of the positioning pin 401 and the positioning hole 402. The positioning pin 401 can be designed as a conical pin, cylindrical pin, or diamond pin, and the positioning hole 402 is a conical hole, a smooth hole, or an irregularly shaped hole; the locking function is achieved through the mechanical interlocking of the movable locking plate 403 and the positioning locking plate 404. When the end effector 42 is changed with the product type 100, the positioning pin 401 is inserted into the positioning hole 402 to ensure high repeatability positioning accuracy, and the movable clamping plate 403 is then locked to eliminate the degree of freedom, thereby solving the problem of low efficiency of traditional bolt connection and realizing rapid changeover.

[0070] like Figure 7-9 As shown, as an optional embodiment of this case, the end effector 42 of the robot handling mechanism 4 includes a slide rail 421 and a clamping assembly 422. The clamping assembly 422 is provided in at least two sets, and each set of the clamping assembly 422 includes two clamping units 4221. The position of each clamping unit 4221 on the slide rail 421 is adjustable, and each set of two clamping units 4221 is used to cooperate in clamping the two ends of the product 100.

[0071] It should be noted that the clamping assembly 422 of the end effector 42 is position-adjustable via a slide rail 421, which can be a linear guide, ball screw, or T-slot platform. At least two sets of clamping assemblies 422 are distributed along the slide rail 421, each set including two clamping units 4221, such as pneumatic fingers or electric grippers. Each clamping unit 4221 slides independently to a set position and is then fixed by locking bolts, pneumatic locking pins, or an automatic positioner. The two clamping units 4221 in the same set act on both ends of the tube, forming a stable clamping torque. A scale, photoelectric sensor, or encoder on the slide rail 421 provides position feedback to ensure that the clamping spacing matches the tube length, thereby solving the defect that fixed grippers cannot adapt to products 100 of multiple sizes.

[0072] A single clamping solution is insufficient to handle the transport needs of pipes of different sizes. The internally pressurized products in this invention are S-shaped or serpentine products 100, which traditional clamping components cannot hold, nor can they adapt to the size-adjustable internally pressurized products of this invention. In this invention, the clamping unit 4221 of each set of clamping components 422 can adjust its clamping position by displacement via slide rail 421, thereby accommodating products 100 of different sizes and models to be clamped, and has a wide range of applications.

[0073] like Figure 7-9 As shown, as an optional embodiment of this case, the clamping unit 4221 includes a lever cylinder 42211, a contoured clamping arm 42212, and a contoured clamping block 42213. The contoured clamping arm 42212 is fixedly connected to the side wall of the lever cylinder 42211. A rod is provided on the side of the lever cylinder 42211. The middle part of the contoured clamping block 42213 is hinged to the rod. One end of the contoured clamping block 42213 near the lever cylinder 42211 is hinged to the output rod of the lever cylinder 42211 through a connecting rod assembly.

[0074] like Figure 8 As shown, as an optional embodiment of this case, the end effector 42 of the robot handling mechanism 4 is further provided with a clamping detection unit 423 for detecting whether the product 100 is clamped in place and / or a mistake-proofing detection unit 424 for detecting whether the product 100 is clamped in the correct position. Each clamping assembly 422 may be equipped with two clamping detection units 423 and / or mistake-proofing detection units 424.

[0075] It should be noted that the end effector 42 of the robotic handling mechanism 4 integrates a clamping detection unit 423 and a mistake-proofing detection unit 424 for real-time monitoring of the pipe's status. The clamping detection unit 423 determines the completion status of the clamping action through a pressure sensor, photoelectric switch, or displacement transmitter. The mistake-proofing detection unit 424 uses a laser beam sensor, machine vision system, or ultrasonic probe to emit detection signals to verify whether the axial position of the pipe on the end effector 42 meets the preset value. The two units work independently or collaboratively: the clamping detection unit 423 ensures that the gripping force meets the safety threshold, and the mistake-proofing detection unit 424 scans the distance deviation between the pipe end and the reference surface to prevent process interruption due to positioning errors, thereby solving the reliability defects of manual visual inspection.

[0076] Pipe clamping misalignment or failure to reach the correct position can easily lead to malfunctions in subsequent processes. This solution addresses this issue by using a real-time signal feedback principle. The clamping detection unit 423 converts mechanical contact into an electrical signal threshold comparison, while the error-proofing detection unit 424 calculates the spatial position difference through non-contact or contact measurement. This eliminates subjective errors from manual judgment, improving the accuracy of clamping status detection. The error-proofing mechanism intercepts pipes with abnormal positions from entering the high-pressure forming process, preventing mold damage accidents. The dual detection mechanism enables closed-loop control of the 100% product transfer process, reducing production line downtime.

[0077] like Figure 8 As shown, as an optional embodiment of this case, the end effector 42 of the robot handling mechanism 4 is provided with an air gun 43 for cleaning the upper and lower cavities of the inner high-pressure forming mold 2 at an angle.

[0078] It should be noted that the end effector 42 has an air gun 43 assembly fixedly mounted at an inclined angle, with the air gun 43's spray direction forming an acute angle with the normal to the mold cavity surface. The air gun 43 can be a direct-injection, swirling, or fan-shaped nozzle structure, connected to an external air source via a quick-connect connector. The inclined installation ensures that the high-pressure airflow impacts the mold cavity 203 surface tangentially. When the robot moves along a preset trajectory, the inclined airflow effectively removes iron filings and coolant residue adhering to the recessed areas of the curved surface, making it particularly suitable for cleaning deep cavities or negative angle areas. The air gun 43 is triggered in conjunction with the robot's movement, automatically performing cleaning operations during the intervals between pipe handling processes.

[0079] This design generates a shear force field on the surface of the mold cavity 203 by tilting the spray, causing impurities to peel off along the airflow direction; the sharp angle design increases the airflow coverage area and avoids cleaning dead zones, thereby replacing the manual cleaning operation of the air gun 43 and eliminating the operational risks within the internal high-pressure forming mold 2; it has strong surface adaptability and improves cleaning efficiency compared to manual cleaning; in coordination with robot path planning, the single cleaning cycle is reduced, enabling parallel operation of production and maintenance.

[0080] like Figure 2-3 As shown, as an optional embodiment of this case, the lower mold 202 of the inner high-pressure forming mold 2 is provided with an ejector mechanism 23. The ejector mechanism 23 includes an ejector block 231 that matches the product 100 and an ejector drive component that is pulsatorically connected to the ejector block 231.

[0081] The lower mold 202 of the inner high-pressure forming mold 2 is equipped with an ejector mechanism 23. This component consists of an ejector block 231 that matches the contour of the product 100 and an ejector drive component that drives its lifting and lowering. The ejector drive component can be a hydraulic cylinder or a servo electric cylinder. Under the action of the drive component, the ejector block 231 rises to the positioning surface of the mold cavity 203. After forming, the product 100 is ejected for easy robot gripping. The curved surface of the ejector block 231 fits against the outer wall of the product 100, and the ejection force is evenly distributed to avoid deformation. The ejector drive component provides a constant ejection stroke to ensure the repeatability and positioning accuracy of the product 100 after leaving the mold cavity 203, thereby solving the efficiency and safety hazards of manually prying the product 100.

[0082] As an optional embodiment of this case, the robot handling mechanism 4 includes a path planner that generates a serpentine motion trajectory covering the curved surface of the mold cavity 203.

[0083] The robot handling mechanism 4 integrates a path planner. This module generates a serpentine motion trajectory covering the surface of the mold cavity 203 using grid decomposition, parametric surface scanning, or point cloud reconstruction algorithms. The serpentine path consists of parallel zigzag segments, and the spacing between adjacent paths is adaptively adjusted according to the curvature. The path planner outputs a coordinate sequence to the robot controller, driving the air gun 43 to move along a predetermined trajectory.

[0084] As an optional embodiment of this case, the clamping detection unit 423 is a diffuse reflection sensor. The clamping detection unit 423 uses a diffuse reflection sensor, which detects the intensity of the reflected signal of the clamped object through an integrated structure of the transmitting and receiving ends. The diffuse reflection sensor determines the clamping state based on the reflected light intensity threshold.

[0085] This invention provides an automated production method for a product, characterized by comprising the following steps:

[0086] Clamping and picking up materials: The end effector 42 of the robot handling mechanism 4 clamps the product 100 from the feeding system 1, and the clamping status is confirmed by the clamping detection unit 423 and / or the error prevention detection unit 424.

[0087] Cavity 203 Cleaning: The robot handling mechanism 4 traverses the upper and lower cavity surfaces of the inner high-pressure forming mold 2 along a predetermined spatial trajectory using an air gun 43;

[0088] Product 100 positioning detection: After placing product 100 into the cavity 203 of the inner high pressure forming mold 2, move the end effector 42 to a set height above product 100, and use the position detection sensor to detect the fit between product 100 and the cavity 203 of the lower mold 202 of the inner high pressure forming mold 2.

[0089] Internal high-pressure molding and transfer: After high-pressure molding is completed, product 100 is removed and residual liquid is poured out, and product 100 is transferred to automatic sawing mechanism 3 for automatic sawing.

[0090] It should be noted that during the clamping and picking process, the end effector 42 of the robot handling mechanism 4 picks up the pipe from the feeding system 1, and the clamping detection unit 423 confirms that the clamping status meets the standard through pressure feedback, photoelectric sensing or displacement measurement.

[0091] In the cavity 203 cleaning step, the air gun 43 sprays high-pressure airflow along a predetermined spatial trajectory (such as a serpentine path, grid scanning, or curved surface normal tracking) to clean the upper and lower cavities 203 of the inner high-pressure forming mold 2. The installation angle of the air gun 43 can be fixed as an acute angle, adjusted by a universal joint, or a multi-nozzle array can be used.

[0092] In the product 100 positioning detection step, after the end effector 42 puts the tube into the mold cavity 203, it rises to a set height (3-8mm). The position detection sensor judges the fit between the product 100 and the mold cavity 203 by laser ranging, capacitive sensing or visual comparison.

[0093] In the internal high-pressure forming and transfer steps, the formed product 100 is taken out and tilted to pour out the residual liquid, and then transferred to the automatic sawing mechanism 3. The feed speed is dynamically adjusted according to the wear state of the saw blade 33 during the sawing process.

[0094] This method addresses three major issues: low efficiency of manual operation, incomplete cleaning of the mold cavity 203, and inaccurate positioning of the product 100. The underlying principle is as follows: the clamping detection unit 423 converts physical contact into an electrical signal threshold comparison to ensure that the gripping force and position meet processing requirements; the tilting air gun 43 creates a shearing force field on the surface of the mold cavity 203 through tangential airflow, peeling away attached impurities; the position detection sensor calculates the gap between the pipe and the mold cavity 203 based on non-contact measurement, and the feedback control system corrects the placement posture; the sawing speed is controlled in segments based on real-time wear data or the replaced saw blade 33 to optimize the cutting load, avoiding abnormal tool wear during thick-walled cutting; the entire process achieves process coordination and data closure through an electrical control system.

[0095] Traditional production relies on manual judgment of clamping status, manual cleaning of complex mold cavities 203, and visual inspection of positioning accuracy, resulting in low efficiency and quality fluctuations. This method solves the above problems through systematic control: automatic detection of clamping status eliminates manual intervention, improving the reliability of product handling; cleaning of mold cavities 203 along a predetermined trajectory covers all concave areas of the curved surface, significantly improving cleaning effectiveness and efficiency compared to manual methods; millimeter-level precision fit detection avoids molding defects caused by positioning deviations; and the combination of automatic residual liquid dumping and adaptive sawing control shortens the processing cycle of a single product 100 and significantly extends tool life.

[0096] As an optional embodiment of this case, in the step of the end effector 42 of the robot handling mechanism 4 clamping the product 100 from the feeding system 1 and the clamping state being confirmed by the clamping detection unit 423, the end effector 42 of the robot handling mechanism 4 can clamp the product 100 in batches.

[0097] It should be noted that in the clamping and picking step, the end effector 42 achieves batch gripping of products 100 through a multi-station clamping structure. This structure can be manifested as multiple pneumatic fingers arranged in parallel or an expandable gripper mechanism, simultaneously gripping multiple products 100 positioned in parallel on the feeding system 1. During batch gripping, the clamping detection unit 423 independently monitors each clamping point to ensure that all products 100 reach the preset clamping force threshold and positional tolerance range. This invention transfers multiple products 100 in a single handling action, significantly shortening the picking time of products 100. Single-piece gripping mode restricts the improvement of production line cycle time. This invention utilizes the robot's load margin to simultaneously operate multiple products 100, distributing the picking time to each product 100 unit. A single clamping action completes the transfer of 100 multiple products, and the material handling efficiency is directly proportional to the number of clamping stations; the multi-channel monitoring of the clamping detection unit 423 ensures the reliability of batch operations and avoids missed grabs or uneven clamping force; in coordination with the multi-station design of the feeding system 1, a high-density production cycle is achieved.

[0098] As an optional embodiment of this case, in the step of removing the product 100 after high-pressure molding, pouring out the residual liquid, and transferring the product 100 to the automatic sawing mechanism 3 for sawing, the sawing process includes:

[0099] The cutting stages are divided based on the real-time dimensional changes of the saw blade 33.

[0100] Different feed rates are applied to the idle section, product contact section, and thick-wall cutting section, with the feed rates decreasing sequentially from the idle section to the product contact section and the thick-wall cutting section.

[0101] It should be noted that the sawing process is divided into an idle section, a product contact section, and a thick-wall cutting section based on the real-time dimensional changes of the saw blade 33, with differentiated feed speeds applied at each stage. The idle section refers to the stroke of the saw blade 33 before it contacts the product 100, and the highest feed speed is used. The product contact section is the initial stage when the saw blade 33 cuts into the pipe wall, and the speed can be reduced to 60%-80% of the idle section speed. The thick-wall cutting section corresponds to the thickest section of the pipe, and the speed is further reduced to 30%-50% of the product contact section speed. Speed ​​adjustment is achieved by outputting the control unit to the servo driver, ensuring that the cutting load matches the bearing capacity of the saw blade 33.

[0102] Traditional constant-speed sawing is prone to tool breakage in thick-walled areas. This solution, based on the principles of cutting mechanics, utilizes high speed during the idle phase to shorten auxiliary time; reduced speed during the product contact phase to decrease the impact load upon entry; and low speed during the thick-walled cutting phase to reduce cutting temperature and tool wear. This achieves dynamic adaptation between cutting speed and cross-sectional thickness, avoiding abnormal tool wear. Low-speed cutting in thick-walled areas ensures the perpendicularity of the cross-section, resulting in a 100% product qualification rate and a shorter overall processing cycle compared to constant-speed mode.

[0103] As an optional embodiment of this case, in the step of dividing the cutting stage based on the real-time size change of the saw blade 33, the real-time size change of the saw blade 33 is obtained by monitoring the displacement of the lifting unit 31 and combining it with the initial calibration displacement value of the saw blade 33.

[0104] It should be noted that the real-time dimensional change of the saw blade 33 is indirectly obtained by monitoring the displacement of the lifting unit 31. Specifically, the control unit records the reference position of the lifting unit 31 after the initial installation of the saw blade 33 (such as the zero point of the servo cylinder encoder); during the sawing process, the current position of the lifting unit 31 is collected in real time, and the difference between it and the reference position is the feed compensation amount to compensate for wear of the saw blade 33 or the new saw blade 33 size. Displacement monitoring is achieved through a grating ruler, magnetic grating ruler, or rotary encoder built into the lifting unit 31.

[0105] As an optional embodiment of this case, in the step of the robot handling mechanism 4 traversing the upper and lower mold 202 cavity surfaces of the inner high-pressure forming mold 2 by means of the air gun 43 according to a predetermined spatial trajectory, the predetermined spatial trajectory is a serpentine path.

[0106] It should be noted that in the cleaning step of mold cavity 203, the predetermined spatial trajectory uses a serpentine path to cover the curved surface of the mold cavity. This path is generated by the robot path planner, specifically a parallel sweeping trajectory that reciprocates along the length of the mold. The spacing between adjacent serpentine trajectories can be dynamically adjusted to adapt to the cleaning needs of areas with different curvatures. The robot control system drives the air gun 43 to move according to the sequence of coordinate points along this path, ensuring that the high-pressure airflow continuously sweeps over all recessed areas of the cavity, thereby solving the problem of blind spots in random cleaning modes.

[0107] As an optional embodiment of this case, the height of the mobile terminal pickup 42 above the product 100 is set to 3-8mm in the step of detecting the fit between the product 100 and the cavity 203 of the inner high-pressure forming mold 2 by the sensor.

[0108] It should be noted that in the product 100 positioning and detection step, the end effector 42 moves to a height range of 3-8mm above the product 100. This setting value is determined by the effective range of the position detection sensor and the anti-interference requirements. The sensor emits detection signals (such as laser beams, ultrasonic waves or near-field microwaves) within this height range. The receiving end analyzes the signal reflection intensity or phase difference and calculates the gap value between the surface of the product 100 and the reference surface of the mold cavity 203. The height setting must simultaneously meet the requirements of detection accuracy and anti-collision safety.

[0109] As an optional embodiment of this case, in the step of implementing differentiated feed speeds in the idle section, product contact section, and thick-wall cutting section, and satisfying that the feed speeds of the idle section, product contact section, and thick-wall cutting section decrease sequentially, the control unit compares the real-time displacement with the preset initial displacement and automatically adjusts the fast, slow, and stop positions of the sawing equipment.

[0110] It should be noted that in the segmented control of the sawing speed, the control unit compares the displacement of the drive unit with the preset initial displacement in real time. The initial displacement corresponds to the reference zero point after the new saw blade 33 is installed, and the increase in real-time displacement reflects the dimensional compensation requirements caused by the wear of the saw blade 33. The control unit dynamically corrects the position trigger point of each cutting stage based on the displacement difference: the end position of the idle segment is moved forward to compensate for wear, and the starting position of the thick-walled cutting segment is delayed to adapt to the actual wall thickness. The adjustment of the fast, slow, and stop positions is achieved by resetting the position parameters of the servo drive; alternative solutions include neural network predictive compensation or fuzzy control rule base.

[0111] like Figure 13As shown, the automated production method for the product in this case specifically includes the following steps:

[0112] The first step is for workers to clean the iron filings and debris off the surface of product 100, and then place product 100 into the positioning fixture of the feeding system 1 for feeding.

[0113] In the second step, after the robot handling mechanism 4 is connected to the positioning pin 401 of the quick-change interface and the positioning hole 402 of the end effector 42, the positioning blocks on the robot handling mechanism 4 and the end effector 42 are aligned. Then, the movable plate 403 of the quick-change interface of the robot handling mechanism 4 is inserted into the positioning plate 404 to clamp the end effector 42. In the third step, the lever cylinder 42211 of the first set of clamping components 422 of the end effector 42 clamping the product 100 on the robot handling mechanism 4 is initially in the open state. When it moves to the positioning fixture above the product 100 of the feeding system 1, the lever cylinder 42211 clamps, the contour clamping block holds the product 100, and the clamping detection sensor senses the product 100. Upon receiving the 00 arrival signal, the robot handling mechanism 4 lifts the product 100 as a whole. After raising it to the preset height, it checks again whether the clamping detection sensor has detected the product 100 arrival signal. Once the product 100 is still in place, it moves to the outside of the inner high-pressure forming mold 2. In the fourth step, the mold cavity 203 of the inner high-pressure forming mold 2 is opened. The second set of clamping components 422 of the end effector 42 repeats the above clamping steps to remove the formed product 100 from the inner high-pressure forming mold 2. The ejector mechanism 23 in the inner high-pressure forming mold 2 descends. The upper and lower cleaning air guns 43 of the end effector 42 move in a serpentine pattern from left to right and from top to bottom according to the shape of the upper and lower mold cavities to clean the mold cavity 203. Fifth step: After cleaning the mold cavity 203, the ejector mechanism 23 of the inner high-pressure forming mold 2 ejects, the robot handling mechanism 4 places the product 100 in, the ejector mechanism 23 descends, and the position detection sensors on the end effector 42 of the inner high-pressure forming mold 2 move to 5mm above the product 100 to detect whether the product 100 has fallen into the mold cavity 203 and whether the product 100 fits the mold cavity 203. Sixth step: After the product 100 is formed in the inner high-pressure forming mold 2, the end effector 42 removes the product 100 from the inner high-pressure forming mold 2 and tilts to pour out the water from the product 100. Step 7: The end effector 42 places the formed product 100 into the sawing fixture of the automatic sawing mechanism 3. When the automatic sawing mechanism 3 is turned on, the saw blade 33 is lowered first. The saw blade 33 size is detected by the saw blade 33 detection sensor (the value fed back to the lifting position of the electric cylinder). Then, the initial lifting position value of the electric cylinder is compared with the latest lifting position value, and the cutting speed, slow speed, and stop position of the automatic sawing mechanism 3 are automatically adjusted. The cutting speed of the product 100 at different thicknesses is constantly changed to achieve the optimal cutting speed. For example, the fastest speed is used when the product 100 is in the air-walking position, and the slowest speed is used when it just touches the product 100 and when cutting the thickest part of the last section of the product 100. This is achieved by the lifting unit 31 of the servo electric cylinder. Step 8: After sawing, the product 100 is picked up and unloaded onto the unloading conveyor line by the material handling robot of the automatic sawing mechanism 3. Step 9: After the product 100 is manually inspected, it is sawed again and then proceeded to the sawing and grinding processes.

[0114] In this case, costs were further reduced through batch feeding; quick-change of the self-made end effector 42 was achieved to reduce costs by enabling quick replacement of the high-load end effector 42; and the lifespan of the polyurethane was improved by improving the structure of the water injection rod 21 and increasing the limiting of the expanded polyurethane.

[0115] By automatically cleaning the curved mold cavity 203 with a robot, it can adapt to various complex working conditions; by modifying the automatic sawing mechanism 3 into a servo electric cylinder lifting device, the optimal cutting speed can be achieved and the service life of the saw blade 33 can be improved; by modifying the automatic sawing mechanism 3 into a servo electric cylinder lifting device, the size of the saw blade 33 can be automatically identified by sensors, the saw blade 33 can be automatically adapted to be cut, and the sawing speed, slow speed and stop position can be automatically adjusted, thus improving intelligence; by modifying the automatic sawing mechanism 3 into a retractable mounting platform for the lower mold cavity 202, the space for robot picking and placing materials can be met, and it can make manual operation safer.

[0116] This project's automated production line achieves optimized human-machine collaboration, reducing the original three-process, three-person operation to a single-person, single-machine operation. This eliminates repetitive manual operations and the complex polishing processes required for robotic production. Product production efficiency is 100%, requiring only a single person for automated, intelligent production. The elimination of manual loading and unloading processes further improves efficiency by 50%. This project's innovative automated production line and methods, including low-cost batch loading, internal high-pressure automatic forming, and automatic sawing, save on manual labor and enable one person to operate multiple machines.

[0117] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. An automated production line for a product, characterized in that, include: The feeding system is used for placing and positioning the pipe blanks for the product. Internal high-pressure forming mold, used for internal pressure forming of pipe blanks; An automatic sawing mechanism is used to automatically saw the ends of pipes after internal pressure forming. The robot handling mechanism is used to transfer the pipe blanks in the feeding system to the inner high-pressure forming mold, and then transfer the formed pipes in the inner high-pressure forming mold to the automatic sawing mechanism for sawing. The water injection rod of the internal high-pressure forming mold is provided with a limiting structure to restrict excessive deformation of the sealing element; The automatic sawing mechanism includes a lifting unit, a size detection unit, and a control unit electrically connected to the size detection unit; the size detection unit is used to detect the saw blade size in real time and feed it back to the control unit, and the control unit adjusts the sawing speed in segments according to the saw blade size and the preset cutting position.

2. The automated production line for products according to claim 1, characterized in that, The feeding system includes at least two sets of feeding stations, and each set of feeding stations includes multiple stations for product positioning and placement.

3. The automated production line for products according to claim 1, characterized in that, The robotic handling mechanism includes: robotic arm; An end effector is used to pick up products; the end effector is positioned with the robotic arm by a positioning pin and a positioning hole, and is locked in place by a movable plate and a positioning plate.

4. The automated production line for products according to claim 1, characterized in that, The end effector of the robotic handling mechanism includes: Slide rail; The clamping assembly is provided in at least two sets, each set of the clamping assembly includes two clamping units, the position of each clamping unit on the slide rail is adjustable, and the two clamping units in each set are used to clamp the two ends of the product.

5. The automated production line for products according to claim 1, characterized in that, The end effector of the robot handling mechanism is also equipped with a clamping detection unit for detecting whether the product is clamped in place and / or a mistake-proofing detection unit for detecting whether the product is clamped in the correct position.

6. The automated production line for products according to claim 1, characterized in that, The end effector of the robot handling mechanism is equipped with an air gun for cleaning the upper and lower cavities of the inner high-pressure forming mold.

7. An automated production method for internal high-voltage products, characterized in that, Includes the following steps: The product is gripped from the feeding system by the end effector of the robot handling mechanism, and the gripping status is confirmed by the gripping detection unit. The robot handling mechanism uses an air gun to traverse the upper and lower cavity surfaces of the inner high-pressure forming mold along a predetermined spatial trajectory; After the product is placed into the cavity of the inner high-pressure forming mold, the moving end effector is moved to a set height above the product, and the fit between the product and the cavity of the inner high-pressure forming mold is detected by the position detection sensor. After high-pressure molding is completed, the product is removed and the residual liquid is poured out. The product is then transferred to an automatic sawing mechanism for automatic sawing.

8. The automated production method for internal high-voltage products according to claim 7, characterized in that, In the step of the end effector of the robot handling mechanism gripping the product from the feeding system and the gripping status being confirmed by the gripping detection unit, the end effector of the robot handling mechanism can grip products in batches.

9. The automated production method for internal high-voltage products according to claim 7, characterized in that, The step of removing the product after high-pressure molding, emptying the residual liquid, and transferring the product to an automatic sawing mechanism for sawing includes the following sawing process: The cutting stages are divided based on the real-time dimensional changes of the saw blade. Different feed rates are applied to the idle section, product contact section, and thick-wall cutting section, with the feed rates decreasing sequentially from the idle section to the product contact section and the thick-wall cutting section.

10. The automated production method for internal high-voltage products according to claim 9, characterized in that, In the step of dividing the cutting stage based on the real-time size change of the saw blade, the real-time size change of the saw blade is obtained by monitoring the displacement of the lifting unit and combining it with the initial calibration displacement value of the saw blade.

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