Double-station rotary table automatic overturning type continuous spraying equipment for rubber wheel hubs

Abstract

According to the double-station rotary table automatic overturning type continuous spraying equipment for the rubber wheel hubs, through collaborative innovation of double-station rotary table parallel circulation and servo overturning technologies, the bottleneck of production line interruption is eliminated, a seven-axis precise spraying and quick-change tool system is combined, on the premise that the coating uniformity is guaranteed, the flexible production capacity of the hubs of multiple specifications is remarkably improved, and the production efficiency is improved. The safety accident rate is greatly reduced through the EXde II BT4-level full anti-explosion design, manual configuration is reduced by 60% through a closed-loop continuous operation mode, a high-reliability and low-energy-consumption intelligent spraying solution is provided for rubber wheel manufacturing enterprises, and industrial transformation and upgrading and global competitiveness improvement are effectively supported.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of industrial automatic spraying equipment for agricultural machinery matching hubs, and particularly relates to a double-station rotary table automatic overturning type rubber wheel hub continuous spraying equipment. BACKGROUND

[0002] In the production of hubs matched with agricultural machinery, the rubber wheel hub, as a core component for bearing the weight of the vehicle, the quality of its surface corrosion-resistant coating directly determines the durability and safety of the product. The hub spraying system forms a uniform and dense paint film to isolate moisture and corrosive media, meets the 48-hour neutral salt spray test standard, and becomes a key process link to ensure the service life of rubber wheels in the fields of engineering machinery and agricultural vehicles. With the global transformation of rubber wheel production capacity towards intelligence, continuous spraying systems play an irreplaceable role in improving the protective performance of hubs and achieving mass production rhythm, and are one of the core equipment for technological upgrading in the rubber wheel industry chain.

[0003] Current hub spraying mainly relies on manual operation or primary automation equipment, which has significant technical bottlenecks: manual spraying requires multiple turning operations, the paint film thickness consistency is poor, and long-term exposure of personnel to paint solvents poses health risks. Although existing single-station automation equipment reduces manual intervention, workpiece turning still needs to interrupt the assembly line, making it difficult to break through the efficiency of the rhythm, and lacking an explosion-proof design for paint atomization flammable environments, which can easily cause safety accidents in closed spray rooms. In addition, the lack of adequate tooling adaptability requires replacing the entire set of fixtures when switching between different sizes of hubs, resulting in excessive downtime, which severely restricts flexible production of multiple varieties.

[0004] To improve the above-mentioned defects, the industry has attempted to introduce some technical upgrading solutions, such as:

[0005] Simple rotary tables are used to achieve station switching, but single-station design still cannot parallel feed and spray;

[0006] Basic explosion-proof components are added, but a complete explosion-proof system is not built;

[0007] Modular tooling is used, but fast locking and clamping mechanisms are not integrated, and the replacement process is still cumbersome;

[0008] These improvements have partially improved efficiency or safety, but still cannot systematically solve the three core contradictions of continuous operation interruption, incomplete explosion-proof system, and multi-specification switching delay, which restrict the development process of the rubber wheel manufacturing industry towards high quality, low cost, and less humanization. SUMMARY

[0009] In the field of automatic spraying of rubber wheel hubs, the existing technology faces many challenges. Manual flipping and spraying not only result in poor film uniformity and low work efficiency, but also exposes operators to harmful solvents for a long time, posing a health risk. Even single-station automatic equipment requires interrupting the production line during the flipping process, making it difficult to break through the bottleneck of cycle efficiency. In addition, the lack of adaptability of the tooling causes long switching time for different specifications, and the defects in the explosion-proof design pose a safety hazard. To systematically solve the three core problems of continuous operation interruption, explosion-proof system deficiency, and multi-specification switching delay, this paper proposes an innovative double-station rotary table automatic flipping rubber wheel hub continuous spraying system. This system integrates parallel station switching, servo precise flipping, and modular tooling technology, ultimately achieving unmanned and continuous operation of the entire wheel hub spraying process.

[0010] A double-station rotary table automatic flipping rubber wheel hub continuous spraying equipment, the system is composed of the following core components:

[0011] Double-station rotary table, driven by a heavy-duty divider with a reduction motor, with stiffened ribs added to the square tube welded framework, the wheel hub is rotated between the loading and unloading and spraying stations to realize zero interruption of workpiece flow;

[0012] Flipping mechanism, equipped with explosion-proof servo motors driving the workpiece to flip automatically through a gear set, eliminating manual intervention;

[0013] Seven-axis reciprocating machine, XYZ axis modules are equipped with linear guides and hard limit blocks, combined with a P-axis spray gun with worm and gear reduction, to accurately reproduce the spatial trajectory and ensure film uniformity > 40μm and pass the 48h salt spray test;

[0014] Quick tooling system, different wheel hubs are adapted by the hinged shielding components and quick lock handles buckles on the multi-specification tooling base, significantly improving switching efficiency;

[0015] Paint supply system, 40L stainless steel pressure tank integrates pneumatic stirring and outlet filtration, with low material alarm to ensure uniformity of paint atomization;

[0016] Explosion-proof control cabinet, the explosion-proof cabinet body integrates PLC, touch screen and servo driver to build a complete explosion-proof system;

[0017] System layout, the U / L structure makes the spraying and loading and unloading stations adjacent, and the wheel hub conveying line is directly connected to the loading and unloading end, forming a closed-loop production flow.

[0018] The spraying method of the system realizes single-piece spraying cycle of 60 seconds through double-station parallel operation and automatic flipping spraying, which improves production capacity by 200% compared to traditional manual cycle.

[0019] Advantages:

[0020] The system eliminates the production line interruption bottleneck through the cooperative innovation of double-station rotary table parallel flow and servo turning technology, combines seven-axis precision spraying and quick-changing tooling system, significantly improves the flexible production capacity of multi-specification hubs under the premise of ensuring coating uniformity, EXde II BT4 level full explosion-proof design greatly reduces the safety accident rate, and the closed-loop continuous operation mode reduces the manual configuration by 60%, providing intelligent spraying solutions with high reliability and low energy consumption for rubber wheel manufacturing enterprises, effectively supporting industrial transformation and upgrading and global competitiveness. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 It is a device overall layout diagram of a double-station rotary table automatic turnover type rubber wheel hub continuous spraying equipment.

[0022] In the figure, 1 is a double-station rotary table, 2 is a turnover mechanism, 3 is a seven-axis reciprocating machine, 4 is a quick-changing tooling system, 5 is a paint supply system, and 6 is an explosion-proof control cabinet. DETAILED DESCRIPTION

[0023] In order to deepen the understanding of the present application, the present application will be further described below in combination with examples and drawings, which are only used to explain the present application and do not constitute a limitation on the protection scope of the present application.

[0024] Double-station rotary table, turnover mechanism, seven-axis reciprocating machine, quick-changing tooling system, paint supply system, and explosion-proof control cabinet.

[0025] As shown in Figure 1

[0026] The system adopts U-shaped layout, the spraying station is arranged adjacent to the feeding and discharging station, the hub conveying line is directly connected to the feeding and discharging area, and the manual walkway width is ensured to be greater than or equal to 800mm, and the system core structure includes the following parts:

[0027] Double-station rotary table: the main structure is a 100x100mm square through-welded skeleton, and stiffeners are added to enhance rigidity, the surface is treated by powder spraying, the revolving mechanism is driven by a 1.5kW explosion-proof motor to realize heavy load segmentation, the rotation accuracy is ±0.1°, the rotary table is mainly used to carry a hub with a maximum weight of 25kg, and automatically switches the station between the feeding and discharging station and the spraying station, and the single station switching time is less than or equal to 3 seconds.

[0028] Turnover mechanism: the driving unit adopts a 750W explosion-proof servo motor, the torque is transmitted to the connecting shaft through a gear set with a modulus of 2.5 and a speed ratio of 1:15, the turning speed can be adjusted in the range of 5°-90° / s, in terms of tooling adaptation, the profiled shielding jig is fixed on the rotating shaft through a clamping groove, and can adapt to various hubs with a diameter of less than or equal to 950mm and a height of less than or equal to 270mm.

[0029] ​Seven-axis reciprocating machine: It includes multiple motion modules. The X-axis adopts a closed module with aluminum profile and a stroke of 1500mm, equipped with linear guides and a 1000W explosion-proof servo motor, with a maximum speed of 1.5m / s and a stopping accuracy of ±0.5mm. The Y-axis is driven synchronously by dual modules, with a stroke of 1000mm and a speed of 1.2m / s. The Z-axis is a gear and rack lifting mechanism with a stroke of 400mm, equipped with dual linear guides and a speed of 0.2m / s. The P-axis drives the spray gun to achieve 360° continuous rotation through a worm gear reducer. Its 400W explosion-proof servo motor is placed above the Z-axis to isolate paint contamination. The spray gun is configured with two automatic air spray guns with an atomization pressure adjustment range of 0.3-0.5MPa.

[0030] Quick-change tooling system: Offers tooling bases in two sizes, 950 and 650. The upper and lower shielding parts are made of 3mm stainless steel and connected by hinges. The system adopts a quick-lock handle buckle design, which realizes convenient operation with one press and ensures that the tooling change time is ≤30 seconds.

[0031] Paint supply system: The core is a 40L stainless steel pressure tank, which can withstand a pressure of 0.8MPa. The tank is equipped with an integrated pneumatic stirring motor and an 80-mesh filter screen at the outlet. The system is also equipped with a material shortage alarm sensor. When the paint is insufficient, the alarm is triggered and the control cabinet is linked to issue an audible and visual warning signal.

[0032] Explosion-proof control cabinet: The cabinet adopts an explosion-proof enclosure that conforms to the EXdeIIBT4 standard. The cabinet mainly integrates: PLC controller, touch screen, servo driver matching the power of each axis motor, and explosion-proof three-color alarm light. All connecting cables use tangle-resistant drag chain cables to adapt to the movement requirements of the equipment.

[0033] Implementation Example

[0034] Standard wheel hub, 950mm in diameter, continuous spraying, steps:

[0035] Loading: The operator places the wheel hub on the 950-type tooling base at the loading / unloading station and presses down the quick-lock handle buckle to fix it.

[0036] Workstation switching: Foot pedal start signal → Dual-station turntable rotates 180° → Wheel hub enters the spraying station.

[0037] Front coating: The seven-axis reciprocating machine moves along a preset trajectory and sprays black oil-based paint with air, with the film thickness controlled at 45±5μm.

[0038] Automatic flipping: The flipping mechanism drives the gear set to rotate the workpiece 180° → the reverse side is sprayed.

[0039] Material handling process: The turntable rotates back to its original position → the operator opens the buckle, removes the hub and hangs it on the conveyor line → it enters the drying line.

[0040] Results: Single-piece cycle time 58 seconds, salt spray test up to 52 hours, shift output increased to 480 pieces.

[0041] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A dual-station turntable automatic tilting continuous spraying equipment for rubber wheel hubs, characterized in that, include: Dual-station rotary table, tilting mechanism, seven-axis reciprocating machine, quick-change tooling system, paint supply system and explosion-proof control cabinet; The dual-station turntable includes a revolution mechanism and a reinforced frame. The dual-station turntable carries wheel hub workpieces and rotates and switches between the loading / unloading station and the spraying station. The flipping mechanism is installed on the spraying station side of the dual-station turntable. The flipping mechanism includes a rotary drive unit and a gear transmission assembly. The seven-axis reciprocating machine is set above the spraying station and includes an X-axis left and right movement module, a Y-axis forward and backward movement module, a Z-axis lifting module and a P-axis spray gun rotation mechanism. The quick-change tooling system is located at the loading and unloading station of the dual-station turntable, and includes a detachable hinge-type shielding tooling and a quick-locking buckle mechanism. The paint supply system includes a pressure tank, a low-material alarm device, and a spray gun pipeline connected to the reciprocating machine; The explosion-proof control cabinet integrates a PLC controller, a touch screen, and a servo driver, and is electrically connected to a seven-axis reciprocating machine, a dual-station turntable, and a tilting mechanism via cables.

2. The dual-station turntable automatic tilting type continuous spraying equipment for rubber wheel hubs according to claim 1, characterized in that, The revolution mechanism of the dual-station turntable is composed of a heavy-duty divider driven by a geared motor, and the turntable frame is made of square tubing welded together and equipped with stiffening ribs.

3. The dual-station turntable automatic tilting type continuous spraying equipment for rubber wheel hubs according to claim 1, characterized in that, The rotary drive unit of the flipping mechanism is an explosion-proof servo motor, which drives the gear set through the connecting shaft to rotate the workpiece.

4. The dual-station turntable automatic tilting type continuous spraying equipment for rubber wheel hubs according to claim 1, characterized in that, The X-axis, Y-axis, and Z-axis modules of the seven-axis reciprocating machine are all equipped with linear guides and hard limit blocks, and the P-axis spray gun rotation mechanism achieves 360° continuous rotation through a worm gear reducer.

5. The dual-station turntable automatic tilting type continuous spraying equipment for rubber wheel hubs according to claim 1, characterized in that, The quick-change tooling system includes at least two sizes of detachable tooling bases. The tooling bases are connected to the upper and lower shielding components by hinges and are fixed by quick-lock handle buckles.

6. The dual-station turntable automatic tilting type continuous spraying equipment for rubber wheel hubs according to claim 1, characterized in that, The pressure tank of the paint supply system is equipped with a pneumatic agitator and an outlet filter. It has a capacity of 40L and the tank body has a stainless steel inner liner.

7. The dual-station turntable automatic tilting type continuous spraying equipment for rubber wheel hubs according to claim 1, characterized in that, The explosion-proof control cabinet is an explosion-proof cabinet, and is equipped with a touch screen, PLC controller, servo driver and explosion-proof wiring terminals.

8. The dual-station turntable automatic tilting type continuous spraying equipment for rubber wheel hubs according to claim 1, characterized in that, The overall system layout is U-shaped or L-shaped, with the painting station and loading / unloading station set up adjacent to each other, and the wheel hub conveyor line located on the side of the loading / unloading station.

9. A method for continuous wheel hub spraying based on a dual-station turntable automatic tilting continuous rubber wheel hub spraying equipment according to any one of claims 1-8, characterized in that, Includes the following steps: S1. Place the wheel hub workpiece on the loading and unloading station of the dual-station turntable and fix it with quick-lock buckles; S2. Start the dual-station turntable to rotate, so that the workpiece enters the spraying station; S3, after the seven-axis reciprocating machine sprays the front of the workpiece, the flipping mechanism automatically flips it over to spray the reverse side. S4. The dual-station turntable rotates to send the coated workpiece back to the loading and unloading station, while the uncoated workpiece enters the coating station. The loading and unloading station simultaneously loads new workpieces. S5. Manually remove the coated workpiece and hang it on the conveyor line. Repeat S1-S4 to achieve continuous operation.

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