Closed-loop intelligent servo pressing machine for assembling automobile turbocharging shell

Abstract

The invention discloses a closed-loop intelligent servo press-fitting machine for assembling an automobile turbocharging shell, which comprises a machine base, a clamping and positioning worktable, a servo motor, a servo motor, a servo motor and a servo motor, wherein the upper part of the machine base is provided with the clamping and positioning worktable; the press-fitting mechanism is arranged around the clamping and positioning workbench; the clamping and positioning workbench comprises a mounting base, a coarse positioning assembly, a shell material sensor, an air tap material sensor, a fine positioning assembly and an adjusting assembly, an upper pressing assembly and a code scanning assembly are arranged above the mounting base, and the air tap material sensor is arranged corresponding to the position of the press-fitting mechanism and used for detecting whether an air tap is mounted on the press-fitting mechanism or not. The machine cover is arranged above the machine base, and an operation window and a control panel are arranged on the machine cover. A safety assembly is arranged on the operation window and comprises a double-hand starting switch, an emergency stop switch and a safety optical grating. The machine base is further provided with a recycling bin. A jacking assembly is arranged at the bottom of the mounting base. The problems that in the prior art, multiple air taps cannot be pressed at the same time, the production efficiency is low, and the defective rate is high due to low positioning accuracy are solved.

Description

Technical Field

[0001] This invention relates to the field of assembly equipment technology, and more specifically to a closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings. Background Technology

[0002] Automotive turbocharger housing assembly refers to the process of pressing valves onto a pre-machined turbocharger housing. The turbocharger housing serves as the casing for the turbocharger. A turbocharger is essentially an air compressor that increases the intake air volume by compressing air. It utilizes the inertial force of the exhaust gases from the engine to drive a turbine within the turbine housing. The turbine, in turn, drives a coaxial impeller, which compresses the air supplied through the air filter and forces it into the cylinders. The introduction of this air requires valves, and the turbocharger housing and valves are connected by an interference fit.

[0003] Most turbocharger housing nozzle press-fit devices on the market use hydraulic nozzle press-fitting. However, the stroke of hydraulic press-fitting cannot be precisely controlled, easily leading to overpressure and damage to the nozzle or turbocharger housing. Furthermore, it cannot achieve fully closed-loop control of displacement and pressure. Additionally, it requires hydraulic oil, which can easily cause pipe bursts and contaminate the turbocharger housing during press-fitting. Moreover, most use hard limit positioning, which can easily cause the limit bolts to loosen during prolonged use, leading to machining deviations.

[0004] Based on this, existing technologies employ electric cylinders for press-fitting, such as Chinese patent CN222002492U, which combines vision and electric cylinder drive to complete the press-fitting of air nozzles. However, these all require dedicated machines and cannot simultaneously press-fit multiple types of air nozzles, resulting in low production efficiency and insufficient flexibility. Furthermore, the lack of clamping and precise positioning devices may lead to inaccurate press-fitting of the air nozzles. Summary of the Invention

[0005] The purpose of this invention is to provide a closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings in order to solve the above-mentioned problems, thereby addressing the issues of existing technologies being unable to press-fit multiple air nozzles simultaneously, resulting in low production efficiency and high defect rates due to low positioning accuracy.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings, comprising:

[0007] The machine base has a clamping and positioning worktable on its upper part;

[0008] The pressing mechanism is arranged around the clamping and positioning worktable;

[0009] The clamping and positioning worktable includes a mounting base, a coarse positioning component, a housing material sensor, an air nozzle material sensor, a fine positioning component, and an adjustment component. An upper pressing component and a barcode scanning component are provided above the mounting base. The air nozzle material sensor is located at the position corresponding to the pressing mechanism and is used to detect whether an air nozzle is installed on the pressing mechanism.

[0010] As a further improvement to the above technical solution:

[0011] It also includes a cover, which is located above the base, and has an operation window and control panel.

[0012] The operation window is equipped with safety components, including a two-hand start switch, an emergency stop switch, and a safety light curtain.

[0013] The base is also equipped with a recycling bin.

[0014] The mounting base is equipped with a top material assembly at its bottom.

[0015] The pressing mechanism includes a fixed frame, a sliding frame slidably mounted on the fixed frame, an actuator frame connected to the sliding frame, and an air nozzle mounting frame. One end of the sliding frame is provided with a drive assembly, and the lower part of the sliding frame is slidably mounted on the base.

[0016] The actuator and the sliding frame are slidably engaged, and a pressure sensor is provided between the actuator and the sliding frame.

[0017] The drive assembly includes a drive gearbox mounted on one side of the sliding frame with an axially vertical base and a rack mounted on the base, wherein the rack meshes with the output gear of the drive gearbox.

[0018] Displacement sensors are installed on the fixed platform and the sliding frame.

[0019] This invention also discloses a method for using a closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings, comprising the following steps:

[0020] S1. Place the turbocharger housing on the mounting base and perform coarse positioning using the coarse positioning component. The side of the turbocharger housing should be close to the fine positioning component. At this time, the housing material sensor will give a signal. Press the two-hand start switch to apply a 0.2MPa pressure pre-compression by the upper clamping component. At this time, the turbocharger housing can still rotate.

[0021] S2. By adjusting the component, the workpiece is pressed against the precision positioning component, and then the upper clamping component draws out air pressure through the booster pump and introduces the second stage pressure of 1MPA to completely press the turbocharger housing, so that the turbocharger housing cannot be rotated.

[0022] S3. The barcode scanning component reads the production batch, production tolerance, and required pressing force and pressing distance information on the turbocharger housing, and automatically controls the pressing mechanism to install the air nozzle onto the turbocharger housing.

[0023] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0024] In terms of workpiece positioning, a two-stage pressure clamping method is used: light pre-pressure, fine alignment, and then tightening. This reduces the displacement of the workpiece during clamping, thereby reducing positioning eccentricity, improving positioning accuracy, and preventing damage to the workpiece.

[0025] Regarding the cleanliness of the equipment, the problem of hydraulic oil leakage and contamination of the workpiece caused by the possible pipe bursting during hydraulic pressing has been completely solved by eliminating the hydraulic cylinder. The use of pneumatic cylinders and servo motors directly reduces the possibility of hydraulic contamination of the workpiece.

[0026] In terms of equipment flexibility, the machine can quickly adapt to different air nozzles by changing the nozzle holder, improving equipment compatibility. The pressing device of this closed-loop intelligent servo press-fitting machine is small in size and compact in design. Multiple sets can be installed on the machine base, and the installation position and angle can be adjusted according to the air nozzle position requirements of the turbocharger housing. It can also be extended and retracted by different distances to achieve synchronous pressing of multiple different air nozzles, thereby improving production efficiency.

[0027] Regarding press-fit quality, servo interpolation control enables multiple servo axes to press in synchronously, reaching the final distance simultaneously. This reduces lateral forces on the press shell and avoids uneven force distribution, poor pressing effect, or workpiece damage caused by single-sided pressing. It abandons the hard limit positioning used in hydraulic pressing, offering controllable servo position and equipped with displacement and pressure sensors to more accurately obtain the pressing position and pressure curves, thus improving product quality.

[0028] In terms of safety, it is equipped with a two-hand start button and a safety light curtain. The two-hand start button can effectively prevent accidental operation by personnel. The safety light curtain can quickly stop pressing when personnel accidentally enter the operating area to avoid personal injury. After the pressing device is released, it can continue pressing from the current stop position without damaging the workpiece.

[0029] In terms of intelligence, the equipment is equipped with a barcode scanner that can scan the QR code on the workpiece to trace the manufacturing information of the turbocharger housing (production batch, production tolerance, and the required pressing force and pressing distance for different nozzles); it is also equipped with an intelligent control system that can collect production data and generate curves from the data (nozzle pressing distance and pressure value). The system obtains the qualified curve range through pull-out testing and uploads it to the server via MES. Big data AI is used to determine whether the workpiece is qualified, achieving full closed-loop tracking. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0032] Figure 2 This is a schematic diagram of the structure of the present invention with the cover removed;

[0033] Figure 3 This is one of the schematic diagrams of the clamping and positioning worktable structure of the present invention;

[0034] Figure 4 This is the second schematic diagram of the clamping and positioning worktable structure of the present invention;

[0035] Figure 5 This is the third schematic diagram of the clamping and positioning worktable structure of the present invention;

[0036] Figure 6 This is a schematic diagram of the pressing mechanism of the present invention.

[0037] The reference numerals in the attached drawings are explained as follows: 1. Machine base; 2. Clamping and positioning worktable; 20. Mounting base; 21. Coarse positioning assembly; 22. Housing material sensor; 23. Air nozzle material sensor; 24. Fine positioning assembly; 25. Adjustment assembly; 26. Upper clamping assembly; 27. Barcode scanning assembly; 28. Material ejection assembly; 3. Pressing mechanism; 30. Drive assembly; 31. Fixed frame; 32. Sliding frame; 33. Actuating frame; 34. Air nozzle mounting frame; 35. Pressure sensor; 36. Drive gearbox; 37. Rack; 38. Displacement sensor; 4. Machine cover; 5. Control panel; 61. Two-hand start switch; 62. Emergency stop switch; 63. Safety light curtain; 7. Recovery bin. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0039] like Figure 1 As shown, the closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings in this embodiment includes:

[0040] The base 1 has a clamping and positioning worktable 2 on its upper part; the clamping and positioning worktable 2 is used to place the worm gear booster housing.

[0041] Pressing mechanism 3, multiple pressing mechanisms 3 are arranged around clamping and positioning worktable 2; the specific number is set according to the number of air nozzles, and the installation position is adjusted according to the corresponding position of the air nozzles.

[0042] like Figures 2 to 5 As shown, the clamping and positioning worktable 2 includes a mounting base 20, a coarse positioning component 21, a housing material sensor 22, an air nozzle material sensor 23, a fine positioning component 24, and an adjustment component 25. An upper clamping component 26 and a barcode scanning component 27 are located above the mounting base 20. The air nozzle material sensor 23 is positioned corresponding to the pressing mechanism 3 and is used to detect whether an air nozzle is installed on the pressing mechanism 3. A top-feeding component 28 is located at the bottom of the mounting base 20. The mounting base 20 has a hollow area, allowing the top-feeding component 28 to push the worm gear pressurizing housing upwards. The mounting base 20 has a platform matching the shape of the worm gear pressurizing housing for quick positioning. The coarse positioning component 21 allows the worm gear pressurizing housing to continue moving, so that the adjustment component 25 can drive the worm gear pressurizing housing to rotate. The fine positioning component 24 is a positioning post, and the worm gear pressurizing housing has precise positioning points. When the positioning post and the precise positioning points are aligned, the positioning and installation are completed. The upper clamping component 26 is a cylinder structure. The adjusting component 25 consists of a cylinder and a stop rod. The cylinder extends and retracts, causing the stop rod to move, which in turn causes the worm gear booster housing to rotate, so that the precise positioning point of the worm gear booster housing fits into the precision positioning component 24.

[0043] The machine cover 4 is located above the machine base 1. The machine cover 4 has an operation window and a control panel 5. The operation window includes safety components, including a two-hand start switch 61, an emergency stop switch 62, and a safety light curtain 63. The two-hand start switch 61 requires both hands to press to start, ensuring that both hands are removed from the machine during startup. The emergency stop switch 62 is used in case of emergencies; pressing it will stop the machine immediately. The safety light curtain 63 is used to stop the machine immediately if it is obstructed by the operator during production. The control panel 5 includes a human-machine interface (host computer for collecting sensor parameters and writing control judgment parameters), a PLC, and intelligent control software.

[0044] The base 1 is also equipped with a recycling bin 7.

[0045] like Figure 6 As shown, the pressing mechanism 3 includes a fixed frame 31, a sliding frame 32 slidably mounted on the fixed frame 31, an actuator frame 33 connected to the sliding frame 32, and an air nozzle mounting frame 34. A drive assembly 30 is provided at one end of the sliding frame 32, and the lower part of the sliding frame 32 is slidably mounted on the base 1. The drive assembly 30 is a servo motor.

[0046] The actuator 33 and the sliding frame 32 are slidably engaged, and a pressure sensor 35 is provided between the actuator 33 and the sliding frame 32.

[0047] The drive assembly 30 includes a drive gearbox 36 mounted on an axial vertical base 1 on one side of the sliding frame 32, and a rack 37 mounted on the base 1. The rack 37 meshes with the output gear of the drive gearbox 36. The drive gearbox 36 is a reduction gearbox. Displacement sensors 38 are installed on the fixed frame 31 and the sliding frame 32.

[0048] This embodiment also discloses a method for using a closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings, including the following steps:

[0049] S1. Place the turbocharger housing on the mounting base 20 and perform coarse positioning using the coarse positioning component 21. The side of the turbocharger housing should be close to the fine positioning component 24. At this time, the housing material sensor 22 will receive a signal. When no material is detected, the intelligent control system will prompt that material should be released and will not proceed to the next step. When material is detected, the equipment will start and perform the turbocharger housing positioning action first: press the two-hand start switch 61, and the upper clamping component 26 will apply a 0.2MPa pressure pre-compression. At this time, the turbocharger housing can still rotate.

[0050] S2. By adjusting component 25, the workpiece is pressed against the precision positioning component 24, and then the upper pressing component 26 draws out air pressure through the booster pump and introduces the second stage pressure of 1MPA to completely press the turbocharger housing, so that the turbocharger housing cannot be rotated.

[0051] S3, the barcode scanning component 27 reads the production batch, production tolerance, and required pressing force and pressing distance information on the turbocharger housing, and automatically controls the pressing mechanism 3 to install the air nozzle onto the turbocharger housing.

[0052] In use, the operator removes the nozzle from the hopper and places it on the nozzle mounting bracket 34. Pressing the start button activates the press-fit mechanism 3. The nozzle material sensor 23 detects the nozzle, and the press-fit mechanism 3 begins operation: the servo motor rotates, amplifying the torque through the drive gearbox 36. The front drive gear of the drive gearbox 36 then rotates, converting the rotational motion into linear motion via the fixed rack 37 and three sets of linear bearings and guide rods. This drives the sliding frame 32 to extend forward. Simultaneously, the displacement sensor 38 records the displacement value, working in conjunction with the servo motor for closed-loop control. When the nozzle contacts the turbocharger housing, the linear guide rail below the pressure sensor 35 ensures a fixed and highly accurate nozzle movement direction. Because the nozzle and turbocharger housing are interference-fitted, the pressure is transmitted to the quick-change nozzle mounting bracket when the nozzle contacts the turbocharger housing. The quick-change nozzle mounting bracket then transmits the pressure to the nozzle mounting bracket 34, which accurately collects the data via the pressure sensor 35. This data is then processed in conjunction with the data from the displacement sensor 38.

[0053] The transmission mechanism uses a gear and rack system, which is more efficient than the previous gear transmission followed by ball screw transmission due to its single-stage transmission. It also requires no maintenance or lubrication, making maintenance simpler. At the same time, the structure is more compact, allowing multiple air nozzles to be pressed in simultaneously. The force is more even than that of a single air nozzle, resulting in less damage to the turbocharger housing.

[0054] The nozzle mounting bracket 34 has a keyway for quick adjustment of the height of the quick-change nozzle holder. The quick-change nozzle holder also has a rotating function, allowing for rapid rotation of the nozzle to achieve the desired angle, accommodating different nozzle installation positions and angles. By changing the quick-change nozzle holder, different nozzle models can be adapted.

[0055] When pressing in multiple models simultaneously, multiple pressing mechanisms 3 can be used at the same time. One pressing mechanism 3 is set as the driving shaft, and the other shafts are set as driven shafts. Through servo interpolation control, multiple mechanisms are pressed in synchronously, so that all air nozzles are pressed into the turbocharger housing at the same time, with a consistent pressing distance. This ensures that the turbocharger housing is subjected to force on all four sides, resulting in less displacement of the main body and effectively avoiding damage to the turbocharger housing.

[0056] If anyone obstructs the safety light curtain during equipment operation, the equipment will stop immediately. When pressing is restarted, due to the servo pressing mechanism, pressing mechanism 3 will continue pressing from the current stopped position, preventing the pressing nozzle from failing. After pressing is completed, displacement and pressure sensors provide feedback data to effectively monitor the pressing pressure and position, and upload the data to the server via MES to determine whether the workpiece is qualified, achieving full closed-loop tracking.

[0057] This invention provides a turbocharger housing nozzle closed-loop intelligent servo press-fitting machine that precisely positions the turbocharger housing without damaging it, offers good operational safety and cleanliness, can quickly adapt to different nozzles, and simultaneously assembles multiple nozzles with a high yield rate. Furthermore, it features precise nozzle pressing position, stable pressure, and feedback on pressure and pressing distance to determine whether the nozzle pressing is qualified.

[0058] In terms of workpiece positioning, a two-stage pressure clamping method is used: light pre-pressure, fine alignment, and then tightening. This reduces the displacement of the workpiece during clamping, thereby reducing positioning eccentricity, improving positioning accuracy, and preventing damage to the workpiece.

[0059] Regarding the cleanliness of the equipment, the problem of hydraulic oil leakage and contamination of the workpiece caused by the possible pipe bursting during hydraulic pressing has been completely solved by eliminating the hydraulic cylinder. The use of pneumatic cylinders and servo motors directly reduces the possibility of hydraulic contamination of the workpiece.

[0060] In terms of equipment flexibility, the machine can quickly adapt to different air nozzles by changing the nozzle holder, improving equipment compatibility. The pressing device of this closed-loop intelligent servo press-fitting machine is small in size and compact in design. Multiple sets can be installed on the machine base, and the installation position and angle can be adjusted according to the air nozzle position requirements of the turbocharger housing. It can also be extended and retracted by different distances to achieve synchronous pressing of multiple different air nozzles, thereby improving production efficiency.

[0061] Regarding press-fit quality, servo interpolation control enables multiple servo axes to press in synchronously, reaching the final distance simultaneously. This reduces lateral forces on the press shell and avoids uneven force distribution, poor pressing effect, or workpiece damage caused by single-sided pressing. It abandons the hard limit positioning used in hydraulic pressing, offering controllable servo position and equipped with displacement and pressure sensors to more accurately obtain the pressing position and pressure curves, thus improving product quality.

[0062] In terms of safety, it is equipped with a two-hand start button and a safety light curtain. The two-hand start button can effectively prevent accidental operation by personnel. The safety light curtain can quickly stop pressing when personnel accidentally enter the operating area to avoid personal injury. After the pressing device is released, it can continue pressing from the current stop position without damaging the workpiece.

[0063] In terms of intelligence, the equipment is equipped with a barcode scanner that can scan the QR code on the workpiece to trace the manufacturing information of the turbocharger housing (production batch, production tolerance, and the required pressing force and pressing distance for different nozzles); it is also equipped with an intelligent control system that can collect production data and generate curves from the data (nozzle pressing distance and pressure value). The system obtains the qualified curve range through pull-out testing and uploads it to the server via MES. Big data AI is used to determine whether the workpiece is qualified, achieving full closed-loop tracking.

[0064] Within the technical scope disclosed in this invention, any variations or substitutions that can be easily conceived should be included within the protection scope of this invention. Therefore, the protection scope of this invention should be determined by the scope of the claims.

Claims

1. A closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings, characterized in that, include: The machine base (1) has a clamping and positioning worktable (2) on its upper part; The pressing mechanism (3) is set around the clamping and positioning worktable (2); The clamping and positioning worktable (2) includes a mounting base (20), a coarse positioning component (21), a housing material sensor (22), an air nozzle material sensor (23), a fine positioning component (24), and an adjustment component (25). An upper pressing component (26) and a barcode scanning component (27) are provided above the mounting base (20). The air nozzle material sensor (23) is set at the position corresponding to the pressing mechanism (3) and is used to detect whether an air nozzle is installed on the pressing mechanism (3).

2. The closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings according to claim 1, characterized in that: It also includes a cover (4), which is located above the base (1), and the cover (4) is equipped with an operation window and a control panel (5).

3. The closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings according to claim 1, characterized in that: The operation window is equipped with safety components, including a two-hand start switch (61), an emergency stop switch (62), and a safety light curtain (63).

4. The closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings according to claim 1, characterized in that: The base (1) is also provided with a recovery bin (7).

5. The closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings according to claim 1, characterized in that: The mounting base (20) is provided with a top material assembly (28) at its bottom.

6. The closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings according to any one of claims 1-5, characterized in that: The pressing mechanism (3) includes a fixed frame (31), a sliding frame (32) slidably mounted on the fixed frame (31), an execution frame (33) connected to the sliding frame (32), and an air nozzle mounting frame (34). One end of the sliding frame (32) is provided with a drive assembly (30), and the lower part of the sliding frame (32) is slidably mounted on the base (1).

7. The closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings according to claim 5, characterized in that: The actuator (33) is slidably engaged with the sliding frame (32), and a pressure sensor (35) is provided between the actuator (33) and the sliding frame (32).

8. The closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings according to claim 6, characterized in that: The drive assembly (30) includes a drive gearbox (36) mounted on one side of a sliding frame (32) on an axially vertical base (1) and a rack (37) mounted on the base (1), wherein the rack (37) meshes with the output gear of the drive gearbox (36).

9. The closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings according to claim 7, characterized in that: Displacement sensors (38) are installed on the fixed frame (31) and the sliding frame (32).

10. A method of using the closed-loop intelligent servo press-fitting machine for assembling automotive turbocharger housings as described in claim 8, characterized in that, Includes the following steps: S1. Place the turbocharger housing on the mounting base (20) and perform coarse positioning through the coarse positioning component (21). The side of the turbocharger housing is close to the fine positioning component (24). At this time, the housing material sensor (22) has a signal. Press the two-hand start switch (61) and the upper clamping component (26) will perform 0.2MPa pressure pre-compression. At this time, the turbocharger housing can still rotate. S2. By adjusting the component (25), the workpiece is pressed against the precision positioning component (24), and then the upper pressing component (26) draws out air pressure through the booster pump and introduces the second stage pressure of 1MPA to completely press the turbocharger housing, so that the turbocharger housing cannot be rotated. S3, the barcode scanning component (27) reads the production batch, production tolerance and required pressing force and pressing distance information on the turbocharger housing, and automatically controls the pressing mechanism (3) to install the air nozzle onto the turbocharger housing.

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