Full-automatic fastening device for welding three-piece type ball valve

Abstract

The invention provides a full-automatic fastening device for welding a three-piece type ball valve, and belongs to the technical field of valve manufacturing, the full-automatic fastening device comprises a machine table and a valve body, and further comprises an upper positioning assembly, a sensing assembly and an ejection feeding assembly; the second fastening mechanism integrates a plurality of groups of fasteners I on the same adjusting plate, so that multi-shaft synchronous tightening is realized, and the problem of deviation caused by sequential tightening is avoided; the lower barrel body can float in the axial direction of the connecting barrel, allows slight-angle swing and can be adjusted in a self-adaptive mode, it is guaranteed that the nut is smoothly sleeved with the clamping groove, and the alignment success rate is greatly increased; a quality detection function is seamlessly integrated into an assembling and tightening process, so that whether a gasket exists or not can be judged, and the problems of excessive assembly, nut inclination and the like can be effectively identified; full automation of the discharging process after assembly is completed is achieved through the ejection feeding assembly, the lifting motion of the upper positioning assembly serves as a power source for grabbing and releasing the valve, and an extra driving device does not need to be independently arranged for the grabbing motion.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of valve manufacturing, in particular to a full-automatic fastening device for a welded three-piece ball valve. BACKGROUND

[0002] As a key fluid control component, the manufacturing quality of the three-piece ball valve is directly related to the sealing reliability of the industrial pipeline system. The valve is usually assembled by a left valve body, a right valve body and a middle valve cover through a plurality of circumferentially distributed connecting bolt pairs, and the butt welds of the valve bodies are welded after assembly to form the final pressure boundary.

[0003] In the prior art, the nut fastening process of the three-piece ball valve mainly adopts manual tightening or single-axis semi-automatic tightening, which cannot solve the problems of synchronization and positioning accuracy. Whether manual tightening or semi-automatic tightening, the positioning of the nut and the bolt depends on manual visual calibration. Due to the subjectivity and fatigue of manual operation, the positioning deviation rate is high, which not only leads to an increase in the scrap rate of the bolt pair, but also requires additional labor hours to disassemble the damaged parts, further slowing down the production rhythm, and cannot guarantee that the tightening sleeve and the nut are directly opposite, which has the risk of jamming. In addition, the assembly of the sealing gasket completely depends on manual placement, and under high-intensity production rhythm, it is easy to have problems such as "missing" and "overloading". In the prior art, the detection of the gasket installation state needs to rely on manual secondary inspection, which not only increases the labor cost, but also cannot completely avoid missed detection, leading to unqualified products flowing into the downstream link.

[0004] How to invent a full-automatic fastening device for a welded three-piece ball valve to solve these problems has become a problem that needs to be solved by those skilled in the art. SUMMARY

[0005] In order to make up for the above shortcomings, the present application provides a full-automatic fastening device for a welded three-piece ball valve, which aims to solve the problems mentioned in the above background.

[0006] The present application is implemented as follows:

[0007] The present application provides a full-automatic fastening device for a welded three-piece ball valve, which comprises a machine table and a valve body, a positioning base for positioning the valve body is fixedly installed on the machine table, a lower positioning cavity matched with the valve body is formed on the positioning base, a first fastening mechanism and a second fastening mechanism for fastening the valve body are provided on the machine table, a plurality of guide rods are fixedly installed on the machine table, and a top plate is installed on the top of the guide rod, further comprising:

[0008] The upper positioning assembly is arranged between the second fastening mechanism and the positioning base, and is used for limiting the top of the valve body;

[0009] The sensing assembly is arranged on the second fastening mechanism to sense whether the sealing gasket and the valve body connecting nut are installed correctly.

[0010] The ejection feeding assembly is arranged on the upper positioning assembly and the positioning base to automatically send the assembled valve body out of the positioning base.

[0011] Preferably, the valve body is in a pre-assembly stage, the valve body connecting bolt pair has been inserted into the flange hole, but all the nuts are in an initial relaxation state without reaching the rated pre-tightening force, which facilitates the subsequent accurate positioning and synchronous tightening operation of the valve body assembly by the first fastening mechanism and the second fastening mechanism, and ensures uniform stress on the flange surface and correct compression of the sealing gasket.

[0012] Preferably, the first fastening mechanism comprises a three-axis driving mechanism arranged on the machine table, a sliding seat is fixedly installed on the output end of the three-axis driving mechanism, and fastening piece two and fastening piece three are respectively installed on the sliding seat, wherein fastening piece two is used for fastening the gland nut, and fastening piece three is used for fastening the locking screw.

[0013] Preferably, the second fastening mechanism comprises a telescopic piece two, a mounting plate, a universal joint one, a universal joint two, an adjusting plate, a limiting piece and a fastening piece one, the telescopic piece two is fixedly installed on the top plate, the mounting plate and the adjusting plate are both in sliding connection with the guide rod, the mounting plate and the adjusting plate are connected into a whole through a connecting rod, the output end of the telescopic piece two is fixedly connected with the top of the connecting rod, the mounting plate is located above the adjusting plate, a plurality of brackets are fixedly installed on the mounting plate, a speed reducer motor one is installed on the bracket, the output end of the speed reducer motor one is fixedly connected with the upper part of the universal joint one, the lower part of the universal joint one is fixedly connected with a spring telescopic rod, the lower end of the spring telescopic rod is fixedly connected with the upper part of the universal joint two, and the lower part of the universal joint two is fixedly connected with the fastening piece one used for fastening the valve body connecting nut.

[0014] Preferably, an adjusting groove is formed in the adjusting plate, a positioning bolt is arranged in the adjusting groove, the limiting piece is installed at the bottom of the adjusting plate through the positioning bolt, and the fastening piece one is rotatably connected between the bearing and the limiting piece, and through the cooperation of the adjusting groove and the limiting piece, the fastening piece one can be adjusted to a position matched with the valve body connecting nut.

[0015] Preferably, the upper positioning assembly comprises an upper positioning piece and a telescopic piece one, the upper positioning piece is composed of a connecting plate and a positioning plate, the connecting plate and the positioning plate are connected through bolts, the telescopic piece one is fixed on the machine table, the output end of the telescopic piece one is fixedly connected with the bottom of the connecting plate, the connecting plate is in sliding connection with the guide rod, and the positioning plate is provided with a guide hole through which the fastening piece one passes and an upper positioning cavity matched with the top of the valve body.

[0016] Preferably, the fastener is composed of an upper cylinder and a lower cylinder, the top of the lower cylinder is fixedly connected with a connecting cylinder, the upper end of the connecting cylinder extends to the inside of the upper cylinder, the outer wall of the connecting cylinder in the inside of the upper cylinder is fixedly connected with a protruding block, the inside of the upper cylinder is fixedly connected with a clamping plate for limiting the protruding block, the connecting cylinder and the upper cylinder are elastically connected through a spring, and the bottom of the lower cylinder is provided with a clamping groove matched with the valve body connecting nut.

[0017] Preferably, the induction assembly comprises an inductor fixedly installed in the inside of the lower cylinder, the bottom of the inductor is fixedly connected with a spring No.2, the spring No.2 is located in the clamping groove at the bottom of the lower cylinder, the lower end of the spring No.2 is fixedly connected with a pressing ring, the pressing ring is coaxially arranged with the corresponding valve body connecting bolt pair, and the inductor is electrically connected with an external control system.

[0018] Preferably, the ejection feeding assembly comprises a driving mechanism, a feeding plate and a plurality of accommodating cavities formed in the positioning plate, the accommodating cavities are communicated with the inner cavities of the guide holes and are equal in number, the inside of the accommodating cavities is rotatably connected with a clamping hook, the clamping hook and the accommodating cavity are elastically connected through a spring No.3, the side of the clamping hook away from the corresponding guide hole is fixedly connected with an elastic rope, the lower end of the elastic rope is fixedly connected with the outer side wall of the positioning base after penetrating through the positioning plate, the driving mechanism comprises a gear rack and a speed reducer No.2, the positioning base is provided with an installation cavity matched with the speed reducer No.2, the output end of the speed reducer No.2 is fixedly connected with a gear, the gear and the gear rack are meshedly connected, the feeding plate is provided with a receiving area and a hollow area, the bottom of the feeding plate is fixedly connected with a limiting strip, the inside of the positioning base is provided with a limiting sliding groove matched with the limiting strip, the feeding plate is limitingly and slidingly connected with the limiting sliding groove through the limiting strip and the limiting sliding groove, and the gear rack is fixed at the bottom of the limiting strip.

[0019] Preferably, the size of the hollow area is larger than that of the valve body, the clamping hook clamps the top cover plate of the valve body when the positioning plate contacts with the top of the valve body, the clamping hook is folded into the accommodating cavity when the positioning plate is reset, the distance between the positioning plate and the positioning base at this time is greater than the height of the valve body, the hollow area is located directly above the lower positioning cavity in the initial state, and the feeding plate can transport the valve body to the outside of the positioning base through the receiving area after the valve body is assembled, and then reset to the initial state.

[0020] The beneficial effects of the present application are as follows:

[0021] 1. The second fastening mechanism integrates multiple sets of fasteners onto the same adjusting plate via an integrated connection of a mounting plate and an adjusting plate. All fasteners are driven by independent geared motors, but the rigid constraint of the adjusting plate enables synchronous tightening of multiple axes, avoiding the problems of sequential tightening leading to the compression of the flange surface by the first tightened nut and torque deviation of the second tightened nut. The first fastening mechanism secures the pressure cap nut and locking screw. The fasteners are elastically connected by an upper cylinder, a lower cylinder, and a spring. The lower cylinder can float along the connecting cylinder axis and allow slight angular oscillation. The lower cylinder can adaptively adjust to address the top height and verticality deviations of manually pre-installed nuts, ensuring that the slot smoothly fits the nut. This avoids the problems of "jamming due to misalignment and damage to the nut edge" caused by traditional rigid sleeves, significantly improving the alignment success rate.

[0022] 2. This application seamlessly integrates quality inspection functions into the assembly and tightening process, making judgments immediately upon completion of tightening. This eliminates the need for additional inspection stations or post-production airtightness tests to detect problems, significantly improving inspection efficiency and production line cycle time. By directly monitoring the spring compression / pressure, a physical quantity directly related to nut displacement, it avoids potential misjudgments that might arise from indirect judgments based solely on torque-angle curves. For example, it prevents misjudging abnormal torque caused by thread impurities as a gasket problem, making the inspection results more direct and reliable. This sensing mechanism not only determines the presence or absence of gaskets but also effectively identifies over-installation and installation problems caused by nut tilting, gasket damage, or displacement. It provides a more comprehensive quality control dimension, accurately identifying and removing defective assembly parts before welding. This avoids the enormous waste caused by welding and subsequent processing of unqualified valve assemblies, including welding materials, labor time, energy, and the scrapping of nearly completed valve products, achieving significant cost savings.

[0023] 3. The ejector feeding assembly achieves complete automation of the unloading process after assembly, eliminating the need for manual handling. It utilizes the lifting motion of the upper positioning assembly itself as the power source for gripping and releasing the valves, eliminating the need for additional drive devices (such as cylinders) for gripping actions, simplifying the structure and reducing costs. The feeding plate adopts a hollow area + receiving area design, allowing it to overlap with the main assembly station in space, avoiding each other during operation and connecting during feeding, greatly saving the overall space of the equipment and resulting in a compact layout. Attached Figure Description

[0024] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0025] Figure 1 is the overall structure schematic diagram of the present application;

[0026] Figure 2 is the front view structure schematic diagram of the present application;

[0027] Figure 3 is the structure schematic diagram of the second fastening mechanism when working of the present application;

[0028] Figure 4 is the structure schematic diagram of the second fastening mechanism of the present application;

[0029] Figure 5 is the structure schematic diagram of the first fastening mechanism of the present application;

[0030] Figure 6 is the structure schematic diagram of the first fastening mechanism when working of the present application;

[0031] Figure 7 is the structure schematic diagram of the upper positioning member of the present application;

[0032] Figure 8 is the structure schematic diagram of the positioning base of the present application;

[0033] Figure 9 is the structure schematic diagram of the positioning plate of the present application;

[0034] Figure 10 is the cross-section structure schematic diagram of the positioning plate when descending of the present application;

[0035] Figure 11 is the front view cross-section structure schematic diagram of the positioning plate when descending of the present application;

[0036] Figure 12 is the cross-section structure schematic diagram of the positioning plate when resetting of the present application;

[0037] Figure 13 is the front view cross-section structure schematic diagram of the positioning plate when resetting of the present application;

[0038] Figure 14 is the structure schematic diagram of the feeding plate and driving mechanism of the present application;

[0039] Figure 15 is the structure schematic diagram of the valve body and fastener one of the present application;

[0040] Figure 16 is the cross-section structure schematic diagram of the fastener one of the present application.

[0041] In the figure: 1, machine table; 2, first fastening mechanism; 3, second fastening mechanism; 4, positioning base; 5, upper positioning piece; 6, guide rod; 7, fastener one; 8, driving mechanism; 9, feeding plate; 10, valve body; 21, three-axis driving mechanism; 22, sliding seat; 23, fastener two; 24, fastener three; 31, mounting plate; 32, support; 33, speed reducer motor one; 34, universal joint one; 35, spring telescopic rod; 36, universal joint two; 37, adjusting plate; 38, limiting piece; 41, lower positioning cavity; 42, limiting sliding groove; 51, connecting plate; 52, positioning plate; 53, telescopic piece one; 54, containing cavity; 61, top plate; 62, telescopic piece two; 71, upper cylinder; 72, lower cylinder; 73, connecting cylinder; 74, spring one; 80, mounting cavity; 81, speed reducer motor two; 82, gear; 83, rack; 91, receiving area; 92, hollow area; 93, limiting strip; 371, adjusting groove; 372, positioning bolt; 521, upper positioning cavity; 522, guide hole; 541, clamping hook; 542, spring three; 543, elastic rope; 711, clamping plate; 721, inductor; 722, spring two; 723, pressing ring; 731, protruding block; 911, baffle. DETAILED DESCRIPTION

[0042] To make the objectives, technical solutions, and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some but not all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0043] Embodiment one, refer to Figures 1-16 A full-automatic fastening device for a welded three-piece ball valve includes a machine table 1 and a valve body 10. The machine table 1 is fixedly installed with a positioning base 4 for positioning the valve body 10. The positioning base 4 is formed with a lower positioning cavity 41 matched with the valve body 10, so as to ensure that the valve is placed in a substantially correct position, thereby providing a reference for subsequent accurate positioning and fastening operation. An operator or a feeding manipulator places a preassembled valve body 10 into the lower positioning cavity 41 to complete preliminary radial positioning, thereby simplifying the feeding process and ensuring the initial repeated positioning accuracy of each operation. The machine table 1 is provided with a first fastening mechanism 2 and a second fastening mechanism 3 for fastening the valve body 10. The machine table 1 is fixedly installed with a plurality of guide rods 6, the top of each guide rod 6 is installed with a top plate 61, and the device further includes:

[0044] The upper positioning assembly is arranged between the second fastening mechanism 3 and the positioning base 4, and is used for limiting the top of the valve body 10.

[0045] sensing assembly: the sensing assembly is arranged on the second fastening mechanism 3, used to sense whether the sealing gasket and the valve body connecting nut are installed correctly;

[0046] ejection feeding assembly: the ejection feeding assembly is arranged on the upper positioning assembly and the positioning base 4, used to automatically send out the assembled valve body 10 from the positioning base 4.

[0047] Further, the valve body 10 is in the pre-assembly stage, the valve body connecting bolt pair has been inserted into the flange hole, but all nuts are in the initial relaxation state without reaching the rated pre-tightening force, which facilitates the subsequent precise alignment and synchronous tightening operation of the valve body assembly by the first fastening mechanism 2 and the second fastening mechanism 3, ensures uniform stress on the flange surface and correct compression of the sealing gasket.

[0048] The first fastening mechanism 2 includes a three-axis drive mechanism 21 arranged on the machine table 1, a sliding seat 22 is fixedly installed on the output end of the three-axis drive mechanism 21, a fastener two 23 and a fastener three 24 are respectively installed on the sliding seat 22, wherein the fastener two 23 is used to fasten the gland nut, and the fastener three 24 is used to fasten the locking screw, the three-axis drive mechanism 21 drives the sliding seat 22 to move, so that the fastener two 23 (adapted to the sleeve of the gland nut) is aligned with the valve gland nut, and the fastener three 24 (adapted to the inner hexagonal head of the locking screw) is aligned with the locking screw, then the fastener two 23 and the fastener three 24 are started in turn (external small servo motor), and the fastening is completed according to the preset torque, so as to realize the main fastening and auxiliary fastening of the valve body, and shorten the single workpiece processing cycle.

[0049] The second fastening mechanism 3 comprises a telescopic piece two 62, a mounting plate 31, a universal joint one 34, a universal joint two 36, an adjusting plate 37, a limiting piece 38 and a fastener one 7. The telescopic piece two 62 is fixedly installed on the top plate 61. The mounting plate 31 and the adjusting plate 37 are both in sliding connection with the guide rod 6. The mounting plate 31 and the adjusting plate 37 are connected into an integral whole through a connecting rod. The output end of the telescopic piece two 62 is fixedly connected with the top of the connecting rod. When the telescopic piece two 62 is telescoped, the mounting plate 31 and the adjusting plate 37 can move synchronously. The mounting plate 31 is located above the adjusting plate 37. A plurality of supports 32 are fixedly installed on the mounting plate 31. A speed reducer motor one 33 is installed on the support 32. The output end of the speed reducer motor one 33 is fixedly connected with the upper portion of the universal joint one 34. The lower portion of the universal joint one 34 is fixedly connected with a spring telescopic rod 35. The lower end of the spring telescopic rod 35 is fixedly connected with the upper portion of the universal joint two 36. The lower portion of the universal joint two 36 is fixedly connected with the fastener one 7 for fastening the valve body connecting nut. The second fastening mechanism 3 is responsible for the synchronous tightening of the valve body connecting nut. The telescopic piece two 62 drives the whole mechanism to move downward along the guide rod 6, so that the fastener one 7 is sleeved on the valve body nut. The universal joint one 34, the spring telescopic rod 35 and the universal joint two 36 form a floating head, which can automatically compensate the coaxial error between the fastener and the nut, prevent jamming and provide a rotating torque through the floating head to the fastener one 7, so as to finally tighten the nut to a preset torque, realize multi-axis synchronous tightening, ensure that the valve flange is uniformly stressed, avoid valve body deformation and poor sealing caused by sequential tightening, greatly reduce the requirement for absolute positioning accuracy of the equipment, and improve the reliability and service life.

[0050] An adjusting groove 371 is formed in the adjusting plate 37. A positioning pin 372 is arranged in the adjusting groove 371. The limiting piece 38 is installed at the bottom of the adjusting plate 37 through the positioning pin 372. The fastener one 7 is rotatably connected between the limiting piece 38 and a bearing. Through the cooperation between the adjusting groove 371 and the limiting piece 38, the fastener one 7 can be adjusted to a position matched with the valve body connecting nut. The adjusting groove 371 on the adjusting plate 37 and the limiting piece 38 allow the radial position of each fastener one 7 to be finely adjusted, so as to adapt to the bolt hole distance of valves of different specifications.

[0051] Further, the upper positioning assembly comprises the upper positioning piece 5 and the telescopic piece one 53, the upper positioning piece 5 is composed of the connecting plate 51 and the positioning plate 52, the connecting plate 51 is connected with the positioning plate 52 through bolts, the telescopic piece one 53 is fixed on the machine table 1, the output end of the telescopic piece one 53 is fixedly connected with the bottom of the connecting plate 51, the connecting plate 51 is slidingly connected with the guide rod 6, the positioning plate 52 is provided with the guide hole 522 for the fastener one 7 to pass through and the upper positioning cavity 521 matched with the top of the valve body 10, the upper positioning assembly presses the valve from above in the fastening process to prevent it from being lifted or moved, and forms a complete clamping system together with the positioning base 4, the telescopic piece one 53 drives the connecting plate 51 to move downward along the guide rod 6, and drives the positioning plate 52 to press the top of the valve, the upper positioning cavity 521 on the positioning plate 52 is matched with the top feature of the valve to realize the final accurate positioning, the accurate positioning of the valve in the Z-axis direction is realized, and it is ensured that the valve body assembly will not be separated or misaligned due to stress in the fastening operation, here, the telescopic piece one 53 and the telescopic piece two 62 can be selected as air cylinders or electric cylinders, and the selection is made according to the load and accuracy requirements.

[0052] It should be noted that the fastener one 7 is composed of the upper cylinder body 71 and the lower cylinder body 72, the top of the lower cylinder body 72 is fixedly connected with the connecting cylinder 73, the upper end of the connecting cylinder 73 extends to the inside of the upper cylinder body 71, the outer wall of the connecting cylinder 73 located in the inside of the upper cylinder body 71 is fixedly connected with the protrusion 731 (the protrusion 731 can position the connecting cylinder 73 to avoid separation), the inside of the upper cylinder body 71 is fixedly connected with the clamping plate 711 for limiting the protrusion 731, the connecting cylinder 73 and the upper cylinder body 71 are elastically connected through the spring one 74, the bottom of the lower cylinder body 72 is provided with the clamping groove matched with the valve body connecting nut, after the valve body connecting nut is pre-installed, the tightening degree of each nut may not be consistent due to manual installation, at this time, through the setting of the spring one 74, the lower cylinder body 72 can be adaptively floated to these nuts when the fastener one 7 moves downward as a whole, under the action of the spring one 74, the clamping groove of the lower cylinder body 72 will be automatically sleeved on the outside of the corresponding nut, under the cooperation of the connecting cylinder 73, the protrusion 731 and the clamping plate 711, the upper cylinder body 71 will synchronously rotate with the lower cylinder body 73 to realize the fastening of the valve body connecting nut.

[0053] In this embodiment, the operator or the loading manipulator will put the valve body 10 in the pre-assembled state (the valve body connecting bolt pair has been inserted into the flange hole, and the nut is loose) into the lower positioning cavity 41 of the positioning base 4. The inner wall of the lower positioning cavity 41 is in contact with the outer cylindrical surface of the valve body 10, achieving radial preliminary positioning and avoiding the lateral deviation of the workpiece. Then, the telescopic part one 53 (optional cylinder or electric cylinder, selected according to the load and precision requirements) of the upper positioning assembly is started, and its output end pushes the connecting plate 51 to move vertically downward along the guide rod 6, driving the positioning plate 52 to move synchronously close to the top of the valve body 10. When the upper positioning cavity 521 of the positioning plate 52 completely fits the top cover plate of the valve body 10, the telescopic part one 53 stops moving. At this time, the upper positioning cavity 521 and the lower positioning cavity 41 form an upper and lower wrapping type clamping structure, completely limiting the axial freedom of the valve body 10, preventing the workpiece from being lifted upward or axially moving due to stress during subsequent tightening. At this time, the guide hole 522 on the positioning plate 52 is coaxial with the fastener one 7 of the second fastening mechanism 3, providing a guide channel for the precise alignment of the subsequent fastener one 7 and avoiding interference between the fastener one 7 and the positioning plate 52 when the fastener one 7 is lowered.

[0054] It should be noted that, due to the difference in bolt distribution of different specifications of valve body 10, the positioning bolt 372 is loosened, the limiting part 38 is slid along the adjusting groove 371 of the adjusting plate 37, driving the fastener one 7 to move until the bottom clamping groove of the lower cylinder 72 of the fastener one 7 is aligned with the valve body connecting nut (which can be positioned visually or relying on the scale marks of the adjusting groove 371), and then the positioning bolt 372 is locked to fix the position, and then the different positioning bases 4 and positioning plates 52 are disassembled and replaced to adapt to different specifications of valves.

[0055] Subsequently, the telescopic part two 62 (preferably an electric push rod with controllable thrust) is started to drive the mounting plate 31 and the adjusting plate 37 to move downward along the guide rod 6. The fastener one 7 has a floating self-adaptive structure, which is realized by the upper cylinder 71, the lower cylinder 72, the connecting cylinder 73, the protrusion 731, the clamping plate 711 and the spring one 74. Under the drive of the second fastening mechanism 3, the entire fastener one 7 moves downward. Since the valve body connecting nut is manually preliminarily screwed in the pre-installation stage, there will be a slight deviation in the height of the top end and the perpendicularity relative to the flange plane. At this time, the lower cylinder 72 of the fastener one 7 is not rigidly connected with the upper cylinder 71, but is elastically connected through the connecting cylinder 73 and the spring one 74. When the clamping groove at the bottom of the lower cylinder 72 contacts the top end of the nut, it can independently move axially and slightly swing in angle according to the actual height and inclination of the nut, compressing the spring one 74. This process ensures that the clamping groove can smoothly cover the nut, rather than being stuck or damaged due to impact on the edge of the nut caused by misalignment. It perfectly compensates for the inconsistency caused by manual pre-tightening.

[0056] When the deceleration motor 33 starts, the output torque is transmitted to the fastener 7 through the universal joint 34, the spring telescopic rod 35, and the universal joint 2 36, driving the upper cylinder 71 to rotate. The torque needs to be transmitted to the lower cylinder 72 through elastic connection, which is realized by the cooperation of the protrusion 731 and the clamping plate 711. When the upper cylinder 71 rotates, the clamping plate 711 inside the upper cylinder 71 will push the protrusion 731 on the connecting cylinder 73, thereby driving the entire connecting cylinder 73 and the lower cylinder 72 to rotate together, effectively applying the tightening torque to the nut. This realizes multi-axis synchronous tightening, ensures uniform stress on the valve flange surface, avoids valve body deformation and poor sealing caused by sequential tightening, and greatly reduces the requirement for absolute positioning accuracy of the equipment due to the floating head design, thereby improving reliability and service life.

[0057] The floating design greatly reduces the stringent requirements for nut installation. Even if there is a height difference of a few millimeters or a slight angle difference in the nut position, the fastener 7 can automatically adapt and successfully complete the grabbing and tightening action, avoiding production interruption and equipment failure caused by misalignment, and ensuring smooth operation of the full-automatic production line. The self-adaptive centering function avoids hard collision between the fastener and the nut, prevents the nut corners from being damaged or the threads from being damaged, and improves product quality. This design enables it to better adapt to different types of valves and inevitable manual operation deviations, enhances the versatility and flexibility of the equipment, reduces the tool adjustment time required for product model change, and ensures that each valve body connecting nut can meet the process requirement of pre-tightening force, thereby ensuring the sealing reliability of the valve flange.

[0058] After the second fastening mechanism pre-tightens the valve body connecting nut, the three-axis drive mechanism 21 drives the sliding seat 22 to move, aligning the fastener two 23 (adapted to the sleeve of the gland nut) with the valve gland nut and the fastener three 24 (adapted to the inner hexagonal head of the lock screw) with the lock screw, respectively. After alignment, the corresponding servo motors are started to complete the fastening according to the preset torque, realizing valve body main fastening + auxiliary fastening and shortening the single workpiece processing cycle.

[0059] In the second embodiment, referring to Figures 15-16 , the sensing assembly includes a sensor 721 (which can be a pressure sensor or a displacement sensor) fixedly installed inside the lower cylinder 72. The bottom of the sensor 721 is fixedly connected with a spring two 722, which is located in a clamping groove at the bottom of the lower cylinder 72. The lower end of the spring two 722 is fixedly connected with a compression ring 723, which is coaxially arranged with the corresponding valve body connecting bolt pair. The sensor 721 is electrically connected with the external control system.

[0060] In this embodiment, the sensing assembly is integrated inside the fastener 7, which indirectly judges the installation state of the gasket by monitoring the axial displacement of the compression ring 723. The entire process is divided into three stages: initialization, tightening monitoring, and final determination.

[0061] Initial state: When the second fastening mechanism 3 is not working, the spring 722 is in a natural state of extension, and its elastic force pushes the pressure ring 723 to extend downward out of the clamping groove at the bottom of the lower cylinder 72, and the lower end surface of the pressure ring 723 is about 1-2 mm lower than the end port of the clamping groove. This design ensures that during the downward movement of the fastener 7, the pressure ring 723 will be in contact with the top end of the valve body connecting nut before the clamping groove.

[0062] Tightening process monitoring: When the tightening operation starts, the speed reducer motor 33 drives the fastener 7 to rotate, and the nut starts to move downward along the bolt towards the flange surface under the action of the thread. At this stage, as the nut continues to move downward, the contact pressure between the pressure ring 723 and the top of the nut causes the spring 722 to maintain a substantially stable compression interval. The inductor 721 monitors the compression of the spring 722 or the pressure generated by it in real time and transmits the signal to the external control system. The system identifies that this signal is within the preset tightening in-process threshold interval and judges that the process is normal.

[0063] Tightening completion and final determination: When the nut completely adheres to the flange surface or the intermediate sealing gasket and reaches the preset fastening torque, the nut cannot continue to move downward. At this time, the speed reducer motor 33 stops rotating, the tightening process ends, and the system collects the final signal value of the inductor 721 for determination.

[0064] Normal state gasket correctly installed: The final compression of the spring 722 is within the preset correct threshold range, and the system determines that it is qualified.

[0065] Abnormal state one: missing gasket: If the sealing gasket is missing, the nut needs to move downward by a longer distance to contact the metal flange surface, resulting in a lower final stop position. Therefore, the travel of the pressure ring 723 being lifted is shorter, and the final compression of the spring 722 will be less than the lower limit of the normal range. The inductor 721 signal exceeds the threshold, and the control system determines that it is missing.

[0066] Abnormal state two: multiple gaskets: If multiple gaskets are installed, the contact point between the nut and the flange surface will be higher, and the final stop position will also be higher, resulting in a longer travel of the pressure ring 723 being lifted. The final compression of the spring 722 will be greater than the upper limit of the normal range. The inductor 721 signal exceeds the threshold, and the control system determines that it is abnormal.

[0067] Abnormal state three: nut offset / gasket partial loss: If the nut is tilted or the flange surface has no gasket support, the contact pressure between the pressure ring 723 and the surface of the nut is uneven, and the inductor 721 will detect a dramatic fluctuation in the pressure signal or an abnormal final value. The system also determines that it is abnormal.

[0068] For any abnormal state, the control system will immediately trigger the sound and light alarm device, and suspend the current work flow of the second fastening mechanism 3, waiting for the operator to intervene, so as to prevent the defective parts from flowing into the subsequent welding process.

[0069] The application seamlessly integrates the quality detection function into the assembly tightening process, completes the judgment at the moment when the tightening is completed, and does not need additional detection stations or air tightness tests after the line to find problems, greatly improving the detection efficiency and production line rhythm; By directly monitoring the physical quantity spring compression amount / pressure directly related to the nut displacement amount, the misjudgment caused by simply relying on the torque-angle curve is avoided, for example, the torque abnormality caused by the impurities in the thread is misjudged as a gasket problem, and the detection result is more direct and reliable; The sensing mechanism can not only judge the presence or absence of the gasket, but also effectively identify the installation problems caused by the inclined nut, damaged and displaced gasket, etc., provide a more comprehensive quality control dimension, accurately identify and reject the assembly defective parts before the welding process, avoid the huge waste caused by welding and subsequent processing of unqualified valve assemblies, including welding materials, working hours, energy, and scrapping of almost finished valve products themselves, and achieve significant cost savings.

[0070] Embodiment three, refer to Figures 7-14 The ejection feeding assembly includes a driving mechanism 8, a feeding plate 9, and a plurality of accommodating cavities 54 formed in the positioning plate 52, the accommodating cavities 54 are in communication with the inner cavities of the guide holes 522, and the number of the accommodating cavities 54 is equal to that of the guide holes 522, a clamping hook 541 is rotatably connected to the inside of the accommodating cavity 54, the clamping hook 541 and the accommodating cavity 54 are elastically connected through a spring three 542, a elastic rope 543 is fixedly connected to the side of the clamping hook 541 away from the corresponding guide hole 522, and the lower end of the elastic rope 543 is fixedly connected to the outer side wall of the positioning base 4 after penetrating through the positioning plate 52; when the positioning plate 52 is pressed to tightly press the top of the valve, the clamping hook 541 will contact the flange at the top of the valve, under the action of the spring three 542 and the pressure of the valve, the clamping hook 541 will hook the valve, and in the process of the positioning plate 52 rising and resetting, the assembled valve can be grabbed out of the positioning base 4; when the positioning plate 52 rises to the highest point (reset), the elastic rope 543 starts to play a role at this time, because the lower end of the elastic rope 543 is fixed on the positioning base 4, and the upper end of the elastic rope 543 is connected to the clamping hook 541, the positioning plate 52 rises and tightens the elastic rope 543, thereby generating a rotary torque that forces the clamping hook 541 to release the valve.

[0071] The driving mechanism 8 comprises a reduction motor two 81 and a rack 83, a mounting cavity 80 matched with the reduction motor two 81 is arranged in the positioning base 4, the output end of the reduction motor two 81 is fixedly connected with a gear 82, the gear 82 is in meshing connection with the rack 83, the feeding plate 9 is provided with a receiving area 91 and a hollow area 92, the bottom of the feeding plate 9 is fixedly connected with a limiting strip 93, the inside of the positioning base 4 is provided with a limiting sliding groove 42 matched with the limiting strip 93, the feeding plate 9 is in limiting sliding connection with the limiting sliding groove 42 through the limiting strip 93, the accuracy and stability of the movement track of the feeding plate 9 are ensured, and deviation or jamming of the feeding plate 9 is prevented, the rack 83 is fixed at the bottom of the limiting strip 93, when the reduction motor two 81 rotates, the gear 82 will drive the feeding plate 9 to slide along the limiting sliding groove 42 through the rack 83, the top of the feeding plate 9 corresponding to the receiving area 91 is fixedly connected with a baffle 911, so as to surround the valve on the receiving area 91 and prevent the valve from sliding off the feeding plate 9 in the conveying process.

[0072] It should be noted that the specification of the hollow area 92 is greater than that of the valve body 10, so that the positioning base 4 and the upper positioning assembly can normally perform fastening work when the valve is in this area, and interference with the feeding plate 9 is avoided, the clamping hook 541 of the positioning plate 52 in contact with the top of the valve body 10 clamps the top cover plate of the valve body 10, the clamping hook 541 is folded into the accommodating cavity 54 when the positioning plate 52 is reset, and the distance between the positioning plate 52 and the positioning base 4 is greater than the height of the valve body 10 at this time, so that the valve can be effectively separated from the positioning base 4 at this time, the hollow area 92 in the initial state is located directly above the lower positioning cavity 41, and the positioning and assembly of the valve are not affected, and the feeding plate 9 can transport the valve body 10 to the outside of the positioning base 4 through the receiving area 91 after the valve body 10 is assembled, and then is reset to the initial state, so as to complete the subsequent valve assembly.

[0073] In the embodiment, the hollow area 92 of the feeding plate 9 is located directly above the lower positioning cavity 41 of the positioning base 4 when the device is not working, the specification of the hollow area 92 is greater than that of the valve body 10, so that the valve body 10 can be placed into the lower positioning cavity 41 without affecting, and the positioning plate 52 of the upper positioning assembly is in a descending state, the free end of the clamping hook 541 extends out of the accommodating cavity 54 under the elastic action of the spring three 542, and is clamped on the edge of the top cover plate of the valve body 10.

[0074] When the first fastening mechanism 2 and the second fastening mechanism 3 complete the fastening of all bolts / nuts, the extension piece 53 of the upper positioning assembly is started, driving the positioning plate 52 to vertically rise (reset) along the guide rod 6. In this process, the distance between the positioning plate 52 and the positioning base 4 gradually increases, the elastic rope 543 connecting the clamping hook 541 and the positioning base 4 is gradually tightened, the elastic rope 543 rotates the clamping hook 541 around the rotating shaft of the accommodating cavity 54, and the free end of the clamping hook 541 is gradually folded into the accommodating cavity 54, and the top cover plate of the valve body 10 is no longer clamped (at this time, the distance between the positioning plate 52 and the positioning base 4 is greater than the height of the valve body 10, so that the workpiece is not driven by the positioning plate 52).

[0075] During the folding of the clamping hook 541, the second reduction motor 81 of the driving mechanism 8 is started (it is necessary to point out that when the second reduction motor 81 is started, the valve has been separated from the positioning base 4), the output end of the second reduction motor 81 drives the gear 82 to rotate, the gear 82 is in meshing transmission with the rack 83 (the rack 83 is fixed at the bottom of the limiting strip 93 of the feeding plate 9), and then the feeding plate 9 is pushed to slide horizontally along the limiting slide groove 42 of the positioning base 4 through the limiting strip 93.

[0076] In the initial stage of sliding, the hollow area 92 of the feeding plate 9 moves away from directly above the lower positioning cavity 41, and at the same time, the receiving area 91 gradually moves to below the lower positioning cavity 41, the top of the receiving area 91 is flush with the bottom of the lower positioning cavity 41, and the valve body 10 naturally falls from the lower positioning cavity 41 is just received (the lower positioning cavity 41 has no locking structure, and the workpiece can fall on the receiving area 91 by gravity).

[0077] In the middle stage of sliding, the feeding plate 9 continues to move to the outside of the positioning base 4, and the receiving area 91 drives the valve body 10 to move out of the range of the positioning base 4. Compared with the existing technology of pushing the valve out by the air cylinder and then manually taking it out, the present application is more convenient to take out, and the space between the person and the equipment is isolated, without the risk of collision and injury. At this time, the baffle 911 on the top of the receiving area 91 can prevent the valve body 10 from sliding from the side during translation.

[0078] In the late stage of sliding, when the valve body 10 is transported to the preset unloading station (such as above the conveying belt), the second reduction motor 81 stops rotating, and the operator or subsequent automatic equipment (such as a mechanical arm) takes away the valve body 10.

[0079] After the unloading is completed, the second reduction motor 81 is reversed, the gear 82 and the rack 83 are in meshing transmission, the feeding plate 9 is driven to slide reversely along the limiting slide groove 42, until the hollow area 92 returns to directly above the lower positioning cavity 41 again, and the initial state is restored, waiting for the next valve body 10 to be loaded and assembled.

[0080] The ejection feeding assembly realizes complete automation of the discharging process after assembly, and does not need manual intervention for carrying. The ejection feeding assembly uses the lifting movement of the upper positioning assembly itself as the power source for grabbing and releasing the valve, and does not need to separately set an additional driving device (such as a cylinder) for the grabbing action, thereby simplifying the structure and reducing the cost. The feeding plate 9 adopts the design of a hollow area 92+an accommodating area 91, so that it can overlap with the main assembly station in space, is avoided during work, and is connected during feeding, thereby greatly saving the overall space of the equipment and achieving compact layout.

[0081] The control mode of the present application is automatically controlled by a controller. The control circuit of the controller can be realized by simple programming by those skilled in the art. The power supply is also known in the art. The present application is mainly used for protecting mechanical devices, so the control mode and circuit connection will not be explained in detail.

[0082] It should be noted that the specific type and specifications of the reduction motor and the telescopic member need to be selected and determined according to the actual specifications of the device. The specific selection calculation method uses existing technologies in the art, and therefore will not be described in detail.

[0083] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. For those skilled in the art, the present application can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A fully automatic fastening device for a welded three-piece ball valve, comprising a machine base (1) and a valve body (10), wherein a positioning base (4) for positioning the valve body (10) is fixedly installed on the machine base (1), and a lower positioning cavity (41) matching the valve body (10) is formed on the positioning base (4), characterized in that, The machine base (1) is provided with a first fastening mechanism (2) and a second fastening mechanism (3) for fastening the valve body (10). Several guide rods (6) are fixedly installed on the machine base (1). A top plate (61) is installed on the top of the guide rods (6). The machine base (1) also includes: Upper positioning component: The upper positioning component is disposed between the second fastening mechanism (3) and the positioning base (4) to limit the top of the valve body (10); Sensing component: The sensing component is set on the second fastening mechanism (3) to sense whether the sealing gasket and valve body connecting nut are installed correctly; Ejection feeding assembly: The ejection feeding assembly is set on the upper positioning assembly and the positioning base (4) to automatically feed the assembled valve body (10) out of the positioning base (4).

2. The fully automatic fastening device for a welded three-piece ball valve according to claim 1, characterized in that, The valve body (10) is in the pre-assembly stage. Its valve body connecting bolt pair has been inserted into the flange hole, but all nuts are in the initial relaxed state before reaching the rated pre-tightening force. This state facilitates the subsequent precise alignment and synchronous tightening of the valve body assembly by the first fastening mechanism (2) and the second fastening mechanism (3), ensuring that the flange surface is evenly stressed and the sealing gasket is correctly compressed.

3. The fully automatic fastening device for a welded three-piece ball valve according to claim 1, characterized in that, The first fastening mechanism (2) includes a three-axis drive mechanism (21) set on the machine base (1). A sliding seat (22) is fixedly installed on the output end of the three-axis drive mechanism (21). Fastener two (23) and fastener three (24) are respectively installed on the sliding seat (22). Fastener two (23) is used to fasten the pressure cap nut, and fastener three (24) is used to fasten the locking screw.

4. The fully automatic fastening device for a welded three-piece ball valve according to claim 1, characterized in that, The second fastening mechanism (3) includes a telescopic component two (62), a mounting plate (31), a universal joint one (34), a universal joint two (36), an adjusting plate (37), a limiting component (38), and a fastener one (7). The telescopic component two (62) is fixedly installed on the top plate (61). The mounting plate (31) and the adjusting plate (37) are both slidably connected to the guide rod (6). The mounting plate (31) and the adjusting plate (37) are connected as a whole by a connecting rod, and the output end of the telescopic component two (62) is fixedly connected to the top of the connecting rod. The mounting plate (31) Above the adjusting plate (37), a number of brackets (32) are fixedly installed on the mounting plate (31). A first geared motor (33) is installed on the bracket (32). The output end of the first geared motor (33) is fixedly connected to the upper part of the first universal joint (34). A spring telescopic rod (35) is fixedly connected to the lower part of the first universal joint (34). The lower end of the spring telescopic rod (35) is fixedly connected to the upper part of the second universal joint (36). A fastener (7) for tightening the valve body connecting nut is fixedly connected to the lower part of the second universal joint (36).

5. The fully automatic fastening device for a welded three-piece ball valve according to claim 4, characterized in that, The adjusting plate (37) has an adjusting groove (371), and a positioning bolt (372) is installed in the adjusting groove (371). The limiting member (38) is installed at the bottom of the adjusting plate (37) through the positioning bolt (372). The fastener (7) is rotatably connected to the limiting member (38) through a bearing. Through the cooperation of the adjusting groove (371) and the limiting member (38), the fastener (7) can be adjusted to a position that matches the valve body connecting nut.

6. The fully automatic fastening device for a welded three-piece ball valve according to claim 4, characterized in that, The upper positioning assembly includes an upper positioning component (5) and a telescopic component (53). The upper positioning component (5) is composed of a connecting plate (51) and a positioning plate (52). The connecting plate (51) and the positioning plate (52) are connected by bolts. The telescopic component (53) is fixed on the machine base (1). The output end of the telescopic component (53) is fixedly connected to the bottom of the connecting plate (51). The connecting plate (51) is slidably connected to the guide rod (6). The positioning plate (52) is provided with a guide hole (522) for fastener (7) to pass through and an upper positioning cavity (521) that matches the top of the valve body (10).

7. The fully automatic fastening device for a welded three-piece ball valve according to claim 4, characterized in that, The fastener 7 consists of an upper cylinder (71) and a lower cylinder (72). A connecting cylinder (73) is fixedly connected to the top of the lower cylinder (72). The upper end of the connecting cylinder (73) extends into the interior of the upper cylinder (71). A protrusion (731) is fixedly connected to the outer wall of the connecting cylinder (73) inside the upper cylinder (71). A retaining plate (711) is fixedly connected inside the upper cylinder (71) to limit the protrusion (731). The connecting cylinder (73) and the upper cylinder (71) are elastically connected by a spring (74). The bottom of the lower cylinder (72) is provided with a groove that matches the valve body connecting nut.

8. The fully automatic fastening device for a welded three-piece ball valve according to claim 7, characterized in that, The sensing component includes a sensor (721) fixedly installed inside the lower cylinder (72). A second spring (722) is fixedly connected to the bottom of the sensor (721). The second spring (722) is located in a slot at the bottom of the lower cylinder (72). A pressure ring (723) is fixedly connected to the lower end of the second spring (722). The pressure ring (723) is coaxially arranged with the corresponding valve body connecting bolt pair. The sensor (721) is electrically connected to the external control system.

9. The fully automatic fastening device for a welded three-piece ball valve according to claim 6, characterized in that, The ejector feeding assembly includes a drive mechanism (8), a feeding plate (9), and several receiving cavities (54) opened in the positioning plate (52). The receiving cavities (54) are connected to the inner cavity of the guide hole (522) and are equal in number. A hook (541) is rotatably connected inside the receiving cavity (54). The hook (541) and the receiving cavity (54) are elastically connected by a spring (542). An elastic rope (543) is fixedly connected to the side of the hook (541) away from the corresponding guide hole (522). The lower end of the elastic rope (543) passes through the positioning plate (52) and is fixedly connected to the outer wall of the positioning base (4). The drive mechanism (8) includes a geared motor (81) and a rack (83). The positioning base (4) The feeding plate (9) has an installation cavity (80) that matches the geared motor (81). The output end of the geared motor (81) is fixedly connected to a gear (82). The gear (82) meshes with the rack (83). The feeding plate (9) has a receiving area (91) and a hollow area (92). The bottom of the feeding plate (9) is fixedly connected to a limiting strip (93). The positioning base (4) has a limiting groove (42) that matches the limiting strip (93). The feeding plate (9) is slidably connected to the limiting strip (93) and the limiting groove (42). The rack (83) is fixed to the bottom of the limiting strip (93). A baffle (911) is fixedly connected to the top of the feeding plate (9) corresponding to the receiving area (91).

10. The fully automatic fastening device for a welded three-piece ball valve according to claim 9, characterized in that, The size of the hollow area (92) is larger than that of the valve body (10). When the positioning plate (52) contacts the top of the valve body (10), the hook (541) will hold the top cover of the valve body (10). When the positioning plate (52) is reset, the hook (541) will retract into the receiving cavity (54). At this time, the distance between the positioning plate (52) and the positioning base (4) is greater than the height of the valve body (10). In the initial state, the hollow area (92) is located directly above the lower positioning cavity (41). After the valve body (10) is assembled, the feeding plate (9) can transport the valve body (10) to the outside of the positioning base (4) through the receiving area (91) and then reset to the initial state.

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