Automatic oil dipping intelligent system for bolt threads

Abstract

The invention discloses a bolt thread automatic oil dipping intelligent system, which relates to a device for coating fluid on the surface, and comprises an oil storage tank for storing lubricating oil required by a to-be-dipped bolt; a manipulator is mounted in the bolt conveying device; the manipulator is used for carrying out actions of grabbing, oil dipping and assembling on the bolt to be dipped with oil; the control module is used for controlling the bolt conveying device to drive the manipulator to move among a grabbing station, an oil dipping station and an assembling station; when the manipulator is at the grabbing station, the manipulator is controlled to grab a bolt to be dipped in oil; at the oil dipping station, the manipulator is controlled to move the bolt to be dipped with oil into an oil storage tank to carry out oil dipping treatment at a set oil dipping depth; and at the assembly station, the manipulator is controlled to put the oil-dipped bolt into the bolt hole of the bearing cover of the cylinder body. Automatic oil dipping and oil level adjustment of the bolt are achieved, and meanwhile it is guaranteed that the bolt is evenly dipped in oil.

Description

Technical Field

[0001] This invention relates to an apparatus for applying fluid to a surface, and more specifically, to an automated intelligent system for oiling bolt threads. Background Technology

[0002] To address the thread burn-out problem during bolt tightening in cylinder blocks S04 and S06, a manual pressure oil spraying method was adopted for the lubrication of the bearing cap bolt holes in the semi-finished cylinder blocks. This method has several drawbacks: First, manual oil spraying is inefficient and cannot meet the high-paced demands of automated production lines, thus creating a production bottleneck and wasting resources. Second, manual operation is prone to inconsistent oil application due to operator skill levels or fatigue, leading to thread burn-out during bolt tightening, severely impacting product quality and equipment lifespan.

[0003] Furthermore, traditional methods lack precise oil level control and real-time monitoring mechanisms, making lubricating oil prone to leakage or overuse, leading to environmental pollution and increased costs. Simultaneously, manual operation poses safety hazards, such as operator injury due to mechanical malfunctions or oil splashes, and fault diagnosis and maintenance rely on experience-based judgment, resulting in slow response times and impacting production continuity.

[0004] The root cause of these problems lies in the lack of intelligent integration in existing technologies, which makes it impossible to achieve precise control, automatic adjustment, and real-time monitoring, thus hindering the improvement of the automation level of production lines. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide an automated intelligent oiling system for bolt threads, which addresses the shortcomings of the prior art and realizes automatic oiling and oil level adjustment of bolts, while ensuring uniform oiling of bolts.

[0006] The present invention discloses an automated oil-dip intelligent system for bolt threads, comprising: An oil reservoir is used to store the lubricating oil needed for bolts that need to be oiled. Bolt conveying device, which is equipped with a robotic arm; A robotic arm is used to perform the actions of grasping, applying oil, and assembling the bolts to be oiled; The control module is used to control the bolt conveying device to move the robot arm between the gripping station, the oiling station, and the assembly station; and at the gripping station, to control the robot arm to grip the bolt to be oiled; at the oiling station, to control the robot arm to move the bolt to be oiled into the oil storage tank for oiling treatment at a set oiling depth; and at the assembly station, to control the robot arm to put the oiled bolt into the bolt hole of the cylinder block bearing cover.

[0007] Preferably, the oiling depth is determined by the following formula: D = k × N × P, In the formula, D is the oiling depth, k is an empirical coefficient, N is the number of oiling threads, and P is the bolt pitch.

[0008] Preferably, the empirical coefficient is between 0.8 and 1.2.

[0009] Preferably, the system further includes a lubrication station; the control module controls the lubrication station to supply oil to the oil storage tank according to the oil level in the oil storage tank, so as to maintain the lubrication in the oil storage tank at the target oil level.

[0010] Preferably, the specific method for controlling the lubricating oil station to supply oil to the oil storage tank is as follows: The oil level in the oil reservoir is obtained. When the oil level is less than or equal to a set lower threshold, oil is supplied to the oil reservoir through the lubrication station. When the oil level in the oil reservoir is equal to or greater than a set upper threshold, the oil supply to the oil reservoir is stopped. If the oil level is greater than the set upper threshold, the return valve on the return oil pipe between the lubrication station and the oil reservoir is triggered. The opening of the return valve is controlled by a PID control algorithm to make the oil level in the oil reservoir drop back to the upper threshold.

[0011] Preferably, the PID control algorithm is as follows: The target value u(t) is calculated using the following formula: u(t)=Kp×[e(t)+1 / Ti×∫e(t)dt+Td×de(t) / dt], In the formula, the error term e(t) = |Hh(t)|, where H is the upper limit threshold, h(t) is the real-time oil level; Kp is the proportional coefficient; Ti is the integral time constant; and Td is the differential time constant. The target value u(t) is converted into the actual opening degree of the return valve.

[0012] Preferably, the system also includes protective devices and an emergency stop switch.

[0013] Preferably, the protective device includes an oil baffle and an oil receiving groove; the oil baffle is fixed to the output side of the oil storage tank after the bolts are dipped in oil, and the oil baffle is provided on the side of the oil baffle away from the oil storage tank, and the oil receiving groove is connected to the oil storage tank.

[0014] Beneficial effects The advantages of this invention are as follows: through the coordinated operation of components such as the lubrication station, oil reservoir, bolt conveying device, robotic arm, and control module, automatic oiling and oil level adjustment of the bolts are achieved, while ensuring uniform oiling. Furthermore, the innovative oil level adjustment method keeps the oil level consistently within the set range, making the oiling process efficient, safe, and conserving grease. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the intelligent system for automated oiling of bolt threads according to the present invention; Figure 2 This is a schematic diagram of the cross-sectional structure of the oil storage tank of the present invention.

[0016] Among them: 1-control module, 2-lubrication station, 3-oil storage tank, 4-bolt conveying device, 5-robotic arm, 6-oil baffle, 7-oil receiving tank, 8-sensor. Detailed Implementation

[0017] The present invention will be further described below with reference to embodiments, but this does not constitute any limitation on the present invention. Any limited modifications made by any person within the scope of the claims of the present invention are still within the scope of the claims of the present invention. See Figure 1 The present invention provides an automated intelligent oiling system for bolt threads, comprising a lubrication station 2, an oil storage tank 3, a bolt conveying device 4, a robotic arm 5, and a control module 1.

[0018] Lubrication station 2 is used to store lubricating oil to ensure that the system has a sufficient oil supply during operation.

[0019] The oil reservoir 3 is used to store the lubricating oil required for the bolts to be oiled, and it has a circuit with the lubrication station 2 to maintain the oil level.

[0020] The bolt conveying device 4 is equipped with a robotic arm 5, which can drive the robotic arm 5 to move, thereby enabling the robotic arm to move between different workstations and realize the transfer of bolts.

[0021] The robotic arm 5 is used to perform the actions of grasping, applying oil, and assembling the bolts to be oiled. For example, in the grasping action, the robotic arm first extends above the bolt, then grasps the bolt, and then lifts it to complete the grasping action. Specifically, the robotic arm 5 adopts a six-axis robot structure, driven by a servo motor, and is able to grasp the semi-finished cylinder block bearing cap bolts and accurately position them to the oiling position in the oil tank.

[0022] The control module 1 controls the bolt conveying device 4 to move the robotic arm 5 between the gripping station, the oiling station, and the assembly station. At the gripping station, the robotic arm 5 grips the bolt to be oiled; at the oiling station, it moves the bolt to the oil reservoir 3 to the set oiling depth; at the assembly station, it places the oiled bolt into the bolt hole of the cylinder block bearing cap. Once the robotic arm 5 has placed the oiled bolt into the bolt hole of the cylinder block bearing cap, the bolt tightening operation can begin at the tightening station.

[0023] In this embodiment, the oiling depth is determined by the following formula: D = k × N × P, In the formula, D is the oil dipping depth, k is an empirical coefficient with a value ranging from 0.8 to 1.2, which is adjusted according to lubrication requirements. N is the number of oil-dipped threads, and P is the bolt pitch.

[0024] For example, when the bolt pitch P=1.5mm and the number of threads N=3, the system automatically calculates the oil dipping depth D to be 3.6-4.5mm, ensuring that the thread section is fully covered with lubricating oil. If the number of threads increases to 5, the depth is adjusted accordingly to 6-7.5mm to avoid insufficient lubrication in certain areas due to the increased number of threads. Operators can input the target number of threads through the HMI interface. The control module 1 updates the oil dipping depth parameters in real time and controls the robotic arm 5 to adjust the immersion depth in the oil tank, thereby achieving a precise match between the amount of oil and the thread structure. Experiments show that by implementing automatic oil dipping and oil level control through this system, compared with manual oil spraying, the average oil dipping time per group of bolts is reduced by 60 seconds. This not only significantly improves production efficiency and reduces labor costs, but also achieves energy saving, consumption reduction, and material waste reduction, while avoiding the risk of injury to operators. Furthermore, the production line failure rate is reduced by 30%, the bolt tightening torque stability is improved by 15%, and the incidence of thread burn-out failures is reduced from 15% to below 0.5%.

[0025] Furthermore, in this embodiment, the oil storage tank 3 and the lubrication station 2 are connected by a pipeline equipped with a pump and a solenoid valve, the start and stop of which are regulated by the action control module. The oil storage tank 3 is equipped with a level sensor to detect oil level data in real time and transmit the data to the control module 1. The control module 1 controls the lubrication station 2 to supply oil to the oil storage tank 3 based on the oil level in the oil storage tank 3, so that the lubricating oil in the oil storage tank 3 is maintained at the target oil level.

[0026] Specifically, the method for controlling the lubrication station 2 to supply oil to the oil storage tank 3 is as follows: The oil level in the oil reservoir 3 is obtained. When the oil level is less than or equal to a set lower threshold, oil is supplied to the oil reservoir 3 through the lubrication station 2. When the oil level in the oil reservoir 3 is equal to or greater than a set upper threshold, oil supply to the oil reservoir 3 is stopped. If the oil level is greater than the set upper threshold, the return valve on the return oil pipe between the lubrication station 2 and the oil reservoir 3 is triggered. The opening of the return valve is controlled by a PID control algorithm to make the oil level in the oil reservoir 3 drop back to the upper threshold. That is, when the oil level is higher than the upper threshold, the return valve is triggered to discharge excess lubricating oil from the oil reservoir 3. The relationship between the oil level and the opening of the return valve is implemented based on a preset PID control algorithm.

[0027] Specifically, the level sensor transmits real-time oil level data to control module 1. Control module 1 dynamically calculates the adjustment amount of the return valve opening based on the deviation between the current oil level and the upper limit threshold. For example, when the oil level exceeds the upper limit threshold by 2mm, the PID algorithm quickly outputs the basic opening through the proportional stage, eliminates continuous deviation through the integral stage, and suppresses oil level fluctuations through the derivative stage, ultimately outputting a precise control signal to drive the return valve actuator. This process ensures that the return oil rate matches the oil level rise speed, preventing a sudden drop in oil level due to excessive valve opening or oil overflow due to insufficient valve opening. Experimental data shows that in the scenario of M16×2 bolts being dipped in oil, the system's response time from exceeding the oil level limit to stabilizing within the target range does not exceed 3 seconds, and the return oil volume control accuracy reaches ±0.5mm, effectively maintaining the dynamic balance of the oil level in the oil tank.

[0028] In this embodiment, the PID control algorithm is specifically as follows: The target value u(t) is calculated using the following formula: u(t)=Kp×[e(t)+1 / Ti×∫e(t)dt+Td×de(t) / dt], In the formula, the error term e(t) = |Hh(t)|, where H is the upper limit threshold, h(t) is the real-time oil level, Kp is the proportional coefficient, Ti is the integral time constant, and Td is the differential time constant.

[0029] The target value u(t) is converted into the actual opening of the return valve. The return flow rate is controlled by adjusting the throttling area of ​​the return valve, so that the oil level can be accurately dropped back to the set range.

[0030] The oil level control technology described above in oil reservoir 3 achieves an oil level control accuracy of ±1mm, ensuring the efficient operation of the lubrication system. It also significantly improves oil application consistency, resulting in a bolt tightening pass rate exceeding 98%.

[0031] This invention can also adjust the oil level range of the oil reservoir according to the volume, size, or structure of different batches of bolts. Operators can input bolt specification parameters such as thread diameter, pitch, and effective length into the HMI interface. The system automatically calculates the optimal oiling depth and oil level threshold based on historical data / default parameter data. For example, for M12×1.5 bolts, the system sets the upper limit of the oil level to 15mm and the lower limit to 10mm, ensuring that the oiling amount is precisely controlled within the range of 0.2-0.3ml. For larger M20×2.5 bolts, the oil level range is dynamically adjusted to 20-25mm to avoid lubrication failure due to insufficient oil or splashing due to excessive oil. This function is particularly suitable for multi-variety mixed-flow production lines, achieving adaptive oil level adjustment within 10 seconds through one-click parameter switching. This is three times more efficient than traditional fixed oil level systems, and the oiling consistency error is controlled within ±5%, significantly reducing the thread burn-out failure rate.

[0032] The system also includes a protection device and an emergency stop switch. The emergency stop switch is used to urgently stop the operation of the system when the manipulator 5 runs abnormally and the lubricating oil leaks. The protection device is to prevent the splashing oil from splashing onto the sensors near the oil storage tank 3 when the oil drips from the bolts.

[0033] As Figure 2 shown, the protection device of this embodiment includes an oil baffle 6 and an oil receiving tank 7. Considering that after the manipulator 5 grabs the bolt, dips it in oil and lifts it, there may be excess oil dripping from the bolt into the oil storage tank 3, causing the oil in the oil storage tank 3 to splash. There are some optoelectronic / laser sensors on the side of the oil storage tank 3 close to the engine block. These sensors are mainly the supporting sensors for the manipulator 5 and are used to collect signals for controlling the actions of the manipulator 5. If the splashing oil splashes onto the sensors, it will affect the normal operation of the system. Therefore, in this embodiment, a raised oil baffle 6 is provided on the side of the oil storage tank 3 close to the engine block. The oil baffle 6 can effectively block the splashing oil. In addition, an oil receiving tank 7 is provided on one side of the oil baffle 6. It is connected to the oil storage tank 3 and can catch the oil dripping from the bolt when the manipulator 5 moves and return it to the oil storage tank 3, reducing the risk of oil dripping polluting the workshop environment.

[0034] The above are only the preferred embodiments of the present invention. It should be pointed out that for those skilled in the art, without departing from the structure of the present invention, several deformations and improvements can be made, which will not affect the implementation effect of the present invention and the practicality of the patent.

Claims

1. An automated oil-dip intelligent system for bolt threads, characterized in that, include: Oil reservoir (3) is used to store the lubricating oil required for the bolts to be oiled; Bolt conveying device (4), in which a robot arm (5) is installed; The robotic arm (5) is used to perform the actions of grasping, oiling, and assembling the bolts to be oiled; The control module (1) is used to control the bolt conveying device (4) to drive the robot (5) to move between the gripping station, the oiling station and the assembly station; and at the gripping station, the control module (5) is used to grip the bolt to be oiled; at the oiling station, the control module (5) is used to move the bolt to be oiled to the oil storage tank (3) to be oiled to the set oiling depth; at the assembly station, the control module (5) is used to put the oiled bolt into the bolt hole of the cylinder bearing cover.

2. The intelligent automated lubrication system for bolt threads according to claim 1, characterized in that, The oiling depth is determined by the following formula: D = k × N × P, In the formula, D is the oiling depth, k is an empirical coefficient, N is the number of oiling threads, and P is the bolt pitch.

3. The intelligent automated lubrication system for bolt threads according to claim 2, characterized in that, The empirical coefficient ranges from 0.8 to 1.

2.

4. The intelligent automated lubrication system for bolt threads according to claim 1, characterized in that, The system also includes a lubrication station (2); the control module (1) controls the lubrication station (2) to supply oil to the oil storage tank (3) according to the oil level in the oil storage tank (3) so that the lubricating oil in the oil storage tank (3) is maintained at the target oil level.

5. The intelligent automated lubrication system for bolt threads according to claim 4, characterized in that, The specific method for controlling the lubrication station (2) to supply oil to the oil storage tank (3) is as follows: The oil level in the oil storage tank (3) is obtained. When the oil level is less than or equal to the set lower threshold, the oil storage tank (3) is supplied with oil through the lubrication station (2). When the oil level in the oil storage tank (3) is equal to or greater than the set upper threshold, the oil supply to the oil storage tank (3) is stopped. If the oil level is greater than the set upper threshold, the return valve on the return oil pipe between the lubrication station (2) and the oil storage tank (3) is triggered. The opening of the return valve is controlled by the PID control algorithm so that the oil level in the oil storage tank (3) drops back to the upper threshold.

6. The intelligent automated lubrication system for bolt threads according to claim 5, characterized in that, The PID control algorithm is specifically as follows: The target value u(t) is calculated using the following formula: u(t)=Kp×[e(t)+1 / Ti×∫e(t)dt+Td×de(t) / dt], In the formula, the error term e(t) = |Hh(t)|, where H is the upper limit threshold, h(t) is the real-time oil level; Kp is the proportional coefficient; Ti is the integral time constant; and Td is the differential time constant. The target value u(t) is converted into the actual opening degree of the return valve.

7. The intelligent automated lubrication system for bolt threads according to claim 1, characterized in that, The system also includes protective devices and an emergency stop switch.

8. The intelligent automated lubrication system for bolt threads according to claim 1, characterized in that, The protective device includes an oil baffle (6) and an oil receiving groove (7); the oil baffle (6) is fixed on the output side of the oil storage tank (3) after the bolt is dipped in oil, and the oil baffle (6) is provided with an oil receiving groove (7) on the side away from the oil storage tank (3), and the oil receiving groove (7) is connected to the oil storage tank (3).

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