Flexible automatic carbon fiber embedded block processing unit and processing method

Abstract

The invention relates to a flexible automatic carbon fiber embedded block machining unit and method, and belongs to the field of machining automation and the field of intelligent manufacturing. The six-axis joint robot is located in the middle; the first numerical control milling machine and the second numerical control milling machine are horizontally and symmetrically arranged on the left and right sides of the six-axis joint robot; the loading station is arranged on the front side of the six-axis joint robot; the cutter temporary storage frame is arranged above the loading station; the tray temporary storage frame is arranged on the rear side of the six-axis joint robot. The cutter temporary storage frame and the tray temporary storage frame are oppositely arranged; the first numerical control milling machine, the second numerical control milling machine, the tray temporary storage frame, the cutter temporary storage frame and the loading station are arranged in a square shape; the control system controls the six-axis joint robot to operate the to-be-machined blank for machining. The problems that in an existing production mode, before processing, warehousing and batching are tedious, the labor intensity of workers is high, the quality consistency is poor, the production efficiency is low, and the production balance is insufficient are solved.

Description

Technical Field

[0001] This invention belongs to the fields of mechanical processing automation and intelligent manufacturing, and relates to a flexible automated carbon fiber embedded block processing unit and processing method. Background Technology

[0002] Carbon fiber embedded blocks are widely used in the structural panels of various modules that make up the basic structure of satellites, and are an important component to ensure the strength-to-weight ratio. The difficulties in processing carbon fiber embedded blocks are concentrated in the machining process and the loading and unloading process. There are many machining processes, including manual loading, clamping, alignment, and chip removal, which are labor-intensive and require a large amount of manual work, resulting in a discontinuous production process. The cutting of carbon fiber materials generates a large amount of fine debris and powder. Existing equipment is mostly open-structured, which cannot effectively remove and collect the debris, resulting in poor environmental friendliness and significant impacts on environmental pollution and human health. Due to the limitations of the product material, water-based or oil-based cutting fluids cannot be used for cooling during product cutting; only air cooling can be used, which has low cooling efficiency. Machining carbon fiber materials easily causes tool wear, placing high demands on the cutting tools. Typical carbon fiber embedded parts include two types: threaded embedded parts and clamping embedded parts. Both are made of the same material, formed by molding carbon cloth and epoxy resin into carbon blocks and then machining. They have similar structures, generally cuboid single-hole or double-hole structures, with different structural dimensions and tolerance requirements. They also have similar manufacturing processes, typically requiring rough milling, finish milling, drilling, rough turning, finish turning, threading, and finish grinding. In conventional production, both types of parts are machined one by one using CNC machine tools, with each process heavily reliant on manual operation. Operations such as clamping, alignment, tool setting, and disassembly of individual parts, as well as transfer between processes, all require manual intervention, resulting in low production efficiency and high production costs. When the number of parts reaches a certain level (ranging from tens to hundreds), the consistency of machining quality, production capacity, and delivery cycle become major bottlenecks. Summary of the Invention

[0003] The technical problem solved by this invention is to overcome the shortcomings of the prior art and propose a flexible and automated carbon fiber embedded block processing unit and processing method to overcome the problems of cumbersome pre-processing storage and batching, high labor intensity of personnel, poor quality consistency, low production efficiency and insufficient production balance under the existing production mode.

[0004] The solution of the present invention is:

[0005] A flexible automated carbon fiber embedded block processing unit includes a first CNC milling machine, a second CNC milling machine, a six-axis articulated robot, a pallet buffer rack, a tool buffer rack, a loading station, and a control system;

[0006] The six-axis articulated robot is located in the middle; the first and second CNC milling machines are horizontally and symmetrically arranged on the left and right sides of the six-axis articulated robot; the loading station is located in front of the six-axis articulated robot; the tool buffer is located above the loading station; the pallet buffer is located behind the six-axis articulated robot; the tool buffer and the pallet buffer are placed opposite each other; the first CNC milling machine, the second CNC milling machine, the pallet buffer, the tool buffer, and the loading station form a U-shaped layout; the control system controls the six-axis articulated robot to operate and process the workpiece.

[0007] In the aforementioned flexible automated carbon fiber embedded block processing unit, the pallet buffer rack places the pallet; the blank to be processed is clamped on the pallet; a six-axis articulated robot realizes the movement, loading and unloading of the pallet between the first CNC milling machine, the second CNC milling machine, the pallet buffer rack and the loading station; the first CNC milling machine and the second CNC milling machine realize the processing of the blank to be processed to obtain the product.

[0008] In the aforementioned flexible automated carbon fiber embedded block processing unit, when the blank to be processed is initially clamped on the tray, the front side faces upward; the first CNC milling machine and the second CNC milling machine process the end face, outer contour, and inner hole of the front side of the blank to be processed; after processing, it is flipped to obtain the reverse side of the blank to be processed; the first CNC milling machine and the second CNC milling machine process the end face, outer contour, and inner hole of the reverse side of the blank to be processed to obtain the product.

[0009] In the aforementioned flexible automated carbon fiber embedded block processing unit, the tool buffer rack and loading station located in front of the six-axis articulated robot are equipped with one double-leaf glass door and one single-leaf glass door; the glass door material is explosion-proof glass.

[0010] In the aforementioned flexible automated carbon fiber embedded block processing unit, the loading station is used by the operator to place and retrieve pallets; the pallet buffer rack is used to store and transfer unprocessed pallets and processed pallets; and the tool buffer rack is used to store tools that are to be used and tools that have reached the end of their tool life.

[0011] In the aforementioned flexible automated carbon fiber embedded block processing unit, the first and second CNC milling machines are equipped with automatic opening and closing doors on their sides; and the automatic opening and closing doors are both facing the six-axis articulated robot for transferring and exchanging pallets and tools from the side.

[0012] In the aforementioned flexible automated carbon fiber embedded block processing unit, the front and back outlines of the blank to be processed are both cuboids; the front and back outlines and bottom surface of the blank to be processed are clamped by an OK clamp.

[0013] The processing method of the aforementioned flexible automated carbon fiber embedded block processing unit includes:

[0014] S1. The operator uses OK clips to clamp the blank to be processed on the pallet, with the front side facing up;

[0015] S2. After binding the pallet chip information with the product drawing number and plan number clamped on the pallet in the control system, place the pallet on the loading station and close the double glass door; the six-axis articulated robot identifies the newly bound pallet chip, and after identification, the six-axis articulated robot automatically assembles the pallet gripper and transfers the pallet from the loading station to the pallet buffer rack.

[0016] S3, the pallet buffer rack enables the six-axis articulated robot to transfer and store the pallets on the loading station; after receiving the processing instruction from the central control system, the six-axis articulated robot will transfer the pallet from the pallet buffer rack into the automatic opening and closing door on the side of the machine tool, and transfer it to the machine tool worktable;

[0017] S4. After the front of the blank to be processed is machined on the first or second CNC milling machine, the overall control system issues a pallet removal command, and the six-axis articulated robot removes the pallet from the machine tool worktable and places it on the corresponding pallet buffer rack.

[0018] S5. The control system issues a line exit command, and the six-axis articulated robot transfers the pallet from the pallet buffer rack to the loading station;

[0019] S6. The operator removes the pallet from the loading station, unloads the blank to be processed, flips it over, clamps the blank to be processed onto the pallet with the reverse side facing up, and then places it back onto the loading station.

[0020] S7. Repeat steps S2-S5 to complete the reverse side processing. The operator removes the pallet from the loading station, unloads the reverse side processed parts, and obtains the product after cleaning and self-inspection.

[0021] In the above processing method,

[0022] The tool buffer rack allows the operator to place spare tools. When the control system issues a command, the six-axis articulated robot changes the tool holder, transferring the selected tool from the tool buffer rack to the corresponding machine tool, and then removes the tool to be replaced from the machine tool. The six-axis articulated robot's tool holder adjusts its angle to install the tool taken from the tool buffer rack onto the spindle. After installation, the six-axis articulated robot transfers the replaced tool to the corresponding position in the tool buffer rack.

[0023] In the above processing method, in S1, the OK clip and the tray supporting it are of a universal design; each tray can hold up to 16 blanks to be processed; different specifications of OK clips and their corresponding trays are selected according to different sizes.

[0024] The advantages of this invention compared to the prior art are:

[0025] (1) This invention can realize automated and efficient processing of threaded embedded blocks and clamping embedded parts. By analyzing production data, the flexible automated carbon fiber embedded block processing unit improves the processing efficiency of threaded embedded blocks and clamping embedded parts by 1 time; the product qualification rate increases from 70% to 98%, and the production cost is reduced by 67.7%. In addition, the number of operators is reduced from 2 in conventional processing to 1, which frees up human resources and greatly reduces labor costs.

[0026] (2) This invention achieves fully automated processing of threaded embedded blocks and clamping embedded parts. Within the automated unit, all machining processes, from rough milling, finish milling, drilling, threading, filleting, and hole chamfering, are completed from the blank to the finished product. This breaks the traditional one-to-one strong matching relationship between humans and equipment in production, allowing one person to operate an entire automated processing unit, thus improving processing efficiency and quality stability. Based on this, rapid changeover of composite parts with similar specifications can be achieved.

[0027] (3) The present invention provides a flexible and automated carbon fiber embedded block processing unit and method, which overcomes the problems of poor quality consistency, low production efficiency and insufficient production balance in the existing production mode. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the flexible automated carbon fiber embedded block processing unit of the present invention;

[0029] Figure 2 This is a schematic diagram of the end effector gripper of the robot of the present invention;

[0030] Figure 3 This is a schematic diagram of the end effector tray changing bracket of the robot of the present invention. Detailed Implementation

[0031] The present invention will be further described below with reference to the embodiments.

[0032] This invention provides a flexible and automated carbon fiber embedded block processing unit that uses automated milling to simultaneously produce various carbon fiber embedded block parts. While ensuring product quality consistency, it achieves high-quality, high-efficiency, and balanced production of various carbon fiber embedded block parts and enables rapid changeover of parts with similar specifications.

[0033] Flexible automated carbon fiber embedded block processing units, such as Figure 1As shown, the system specifically includes a first CNC milling machine 1, a second CNC milling machine 3, a six-axis articulated robot 4, a pallet buffer rack 2, a tool buffer rack 5, a loading station 6, and a control system. The six-axis articulated robot 4 is located in the center; the first CNC milling machine 1 and the second CNC milling machine 3 are horizontally symmetrically arranged on the left and right sides of the six-axis articulated robot 4; the loading station 6 is located in front of the six-axis articulated robot 4; the tool buffer rack 5 is located above the loading station 6; the pallet buffer rack 2 is located behind the six-axis articulated robot 4; the tool buffer rack 5 and the pallet buffer rack 2 are placed opposite each other; the first CNC milling machine 1, the second CNC milling machine 3, the pallet buffer rack 2, the tool buffer rack 5, and the loading station 6 form a U-shaped layout, collectively constituting the processing subsystem of a flexible automated carbon fiber embedded block processing unit. Its compact structure facilitates the transfer of blanks and workpieces between processes. The control system controls the six-axis articulated robot 4 to operate and process the blanks to be processed.

[0034] The pallet buffer rack 2 is used to place the pallet; the blank to be processed is clamped on the pallet; the six-axis articulated robot 4 realizes the movement, loading and unloading of the pallet between the first CNC milling machine 1, the second CNC milling machine 3, the pallet buffer rack 2 and the loading station 6; the first CNC milling machine 1 and the second CNC milling machine 3 realize the processing of the blank to be processed to obtain the product.

[0035] When the blank to be processed is initially clamped on the pallet, the front side is facing up; the first CNC milling machine 1 and the second CNC milling machine 3 perform machining on the end face, outer contour and inner hole of the front side of the blank to be processed; after machining, it is flipped to obtain the back side of the blank to be processed; the first CNC milling machine 1 and the second CNC milling machine 3 perform machining on the end face, outer contour and inner hole of the back side of the blank to be processed to obtain the product.

[0036] The tool buffer rack 5 and loading station 6, located in front of the six-axis articulated robot 4, are equipped with one double-leaf glass door and one single-leaf glass door; the glass doors are made of explosion-proof glass. The loading station 6 is used by the operator to place and retrieve pallets; the pallet buffer rack 2 is used to store and transfer unprocessed pallets and processed pallets; the tool buffer rack 5 is used to store tools that are to be used and tools that have reached the end of their tool life.

[0037] The first CNC milling machine 1 and the second CNC milling machine 3 are equipped with automatic opening and closing doors on their sides; and the automatic opening and closing doors are both facing the six-axis articulated robot 4, for transferring and exchanging pallets and tools from the side.

[0038] The front and back outlines of the blank to be processed are both cuboids; the front and back outlines and bottom surface of the blank to be processed are clamped by OK clamps.

[0039] To achieve automated pallet loading and unloading, the machine tools were modified by adding automatic opening and closing doors to the CNC milling machines facing the six-axis articulated robot. The automatic opening and closing doors are driven by cylinders controlled by a PLC. Specifically, the control panel is located on the front of the machine tool, and automatic opening and closing doors are located on the right side of the first CNC milling machine and the left side of the second CNC milling machine for transferring and exchanging workpieces and pallets from the center of the unit to both sides. As needed, both CNC milling machines are equipped with 16-position automatic tool magazines. Based on the product dimensions, both CNC milling machines use 200mm × 200mm four-zero-point positioning for clamping pallets with four-zero-point positioning, and for clamping blanks and products on the pallets.

[0040] The pallet buffer rack adopts a 5-layer × 4-column array design. Each position has 4 zero-point positioning cylindrical structures with a spacing of 200mm × 200mm, which are used to place pallets at fixed points on the storage location. This can effectively avoid positional abnormalities when the six-axis articulated robot grasps the pallet. Each storage location can hold 1 pallet.

[0041] The bottom of the tray is equipped with four positioning and tightening screws spaced 200mm × 200mm. The tray dimensions are 320mm × 320mm. The tray has three long positioning rails, four short positioning rails, and 16 OK clamps. The length, width, and position of the long and short rails are identical across all trays. The height of the threaded block tray rails is 4mm, and the height of the clamping insert tray rails is 11mm. The OK clamp travel is 0–2mm. Therefore, based on the external dimensions of the threaded block and clamping insert, a total of seven tray types are designed, with the long and short rails in the same position across all trays, corresponding to the same product positioning points. The threaded block has four grooves on both sides of the long rails to avoid drilling and threading tools during threaded block machining.

[0042] The unit control system uses a Siemens PLC and is integrated into the control cabinet of the six-axis articulated robot. It is equipped with an HMI touchscreen for viewing the equipment's operating status and enabling human-machine interaction.

[0043] The unit's protective fence is equipped with a safety gate that is linked to an emergency stop signal. When the gate is open, the six-axis articulated robot will not move toward the loading station.

[0044] The processing method of the flexible automated carbon fiber embedded block processing unit specifically includes the following steps:

[0045] S1. The operator uses OK clips to clamp the blanks to be processed onto the pallet, with the front side facing up. The OK clips and the pallets supporting them are of a universal design; each pallet can hold a maximum of 16 blanks to be processed; different sizes of OK clips and their corresponding pallets are selected according to different sizes.

[0046] S2. After binding the pallet chip information with the product drawing number and plan number clamped on the pallet in the control system, place the pallet on the loading station 6 and close the double glass door; the six-axis articulated robot 4 identifies the newly bound pallet chip, and after identification, the six-axis articulated robot 4 automatically assembles the pallet gripper and transfers the pallet from the loading station 6 to the pallet buffer rack 2.

[0047] S3, the pallet buffer rack 2 enables the six-axis articulated robot 4 to transfer and store the pallet on the loading station 6; after receiving the processing instruction from the central control system, the six-axis articulated robot 4 transfers the pallet from the pallet buffer rack 2 into the automatic opening and closing door on the side of the machine tool, and then transfers it to the machine tool worktable, such as... Figure 3 As shown.

[0048] S4. After the front side of the blank to be processed is machined with the outline, end face and hole on the first CNC milling machine 1 or the second CNC milling machine 3, the main control system issues a pallet pick-up command, and the six-axis articulated robot 4 takes the pallet off the machine tool worktable and places it on the corresponding pallet buffer rack 2.

[0049] S5. The control system issues a line-out command, and the six-axis articulated robot 4 transfers the pallet from the pallet buffer rack 2 to the loading station 6.

[0050] S6. The operator removes the pallet from loading station 6, unloads the blank to be processed, flips it over, clamps the blank to be processed onto the pallet with the reverse side facing up, and then places it onto loading station 6.

[0051] S7. Repeat steps S2-S5 to complete the reverse side processing. The operator removes the pallet from loading station 6, unloads the reverse side processed parts, and obtains the product after cleaning and self-inspection.

[0052] The tool buffer rack 5 allows the operator to place spare tools. When the control system issues a command, the six-axis articulated robot 4 changes its tool-loading jaws, transferring the selected tool from the tool buffer rack 5 to the corresponding machine tool, and then removing the tool to be replaced from the machine tool. The tool-loading jaws of the six-axis articulated robot 4 adjust their angle to mount the tool removed from the tool buffer rack 5 onto the spindle. After installation, the six-axis articulated robot 4 transfers the replaced tool to the corresponding position in the tool buffer rack 5, such as... Figure 2 As shown.

[0053] This invention enables automated and efficient processing of threaded inserts and clamping inserts. By analyzing production data, the flexible automated carbon fiber insert processing unit doubles the processing efficiency of threaded inserts and clamping inserts; the product qualification rate increases from 70% to 98%; and production costs are reduced by 67.7%. In addition, the number of operators is reduced from two to one in conventional processing methods, freeing up human resources and significantly reducing labor costs.

[0054] This invention achieves fully automated processing of threaded inserts and clamping inserts. Within an automated unit, all machining processes, from rough milling and finish milling to drilling, threading, filleting, and hole chamfering, are completed from the blank to the finished product. This breaks the traditional one-to-one strong matching relationship between humans and equipment in production, allowing one person to operate an entire automated processing unit, improving processing efficiency and quality stability. Furthermore, it enables rapid changeover of composite parts with similar specifications.

[0055] This invention provides a flexible and automated carbon fiber embedded block processing unit and method, which overcomes the problems of poor quality consistency, low production efficiency and insufficient production balance in the existing production mode.

[0056] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make possible changes and modifications to the technical solutions of the present invention by utilizing the methods and techniques disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solutions of the present invention shall fall within the protection scope of the technical solutions of the present invention.

Claims

1. A flexible, automated carbon fiber embedded block processing unit, characterized in that: It includes a first CNC milling machine (1), a second CNC milling machine (3), a six-axis articulated robot (4), a pallet buffer rack (2), a tool buffer rack (5), a loading station (6), and a control system; Among them, the six-axis articulated robot (4) is located in the middle; the first CNC milling machine (1) and the second CNC milling machine (3) are horizontally symmetrically arranged on the left and right sides of the six-axis articulated robot (4); the loading station (6) is located on the front side of the six-axis articulated robot (4); the tool buffer rack (5) is located above the loading station (6); the pallet buffer rack (2) is located on the rear side of the six-axis articulated robot (4); the tool buffer rack (5) and the pallet buffer rack (2) are placed opposite each other; the first CNC milling machine (1), the second CNC milling machine (3), the pallet buffer rack (2), the tool buffer rack (5) and the loading station (6) form a U-shaped layout; the control system realizes the control of the six-axis articulated robot (4) to operate the blank to be processed for processing.

2. The flexible automated carbon fiber embedded block processing unit according to claim 1, characterized in that: The pallet buffer (2) is used to place the pallet; the blank to be processed is clamped on the pallet; the six-axis articulated robot (4) is used to move, load and unload the pallet between the first CNC milling machine (1), the second CNC milling machine (3), the pallet buffer (2) and the loading station (6); the first CNC milling machine (1) and the second CNC milling machine (3) are used to process the blank to be processed and obtain the product.

3. The flexible automated carbon fiber embedded block processing unit according to claim 2, characterized in that: When the blank to be processed is initially clamped on the pallet, the front side is facing up; the first CNC milling machine (1) and the second CNC milling machine (3) perform machining on the end face, outer contour and inner hole of the front side of the blank to be processed; after machining, it is flipped to obtain the back side of the blank to be processed; the first CNC milling machine (1) and the second CNC milling machine (3) perform machining on the end face, outer contour and inner hole of the back side of the blank to be processed to obtain the product.

4. The flexible automated carbon fiber embedded block processing unit according to claim 1, characterized in that: The tool buffer rack (5) and loading station (6) located in front of the six-axis articulated robot (4) are equipped with a double-leaf glass door and a single-leaf glass door; the glass door is made of explosion-proof glass.

5. The flexible automated carbon fiber embedded block processing unit according to claim 2, characterized in that: The loading station (6) is used by the operator to place and retrieve pallets; the pallet buffer rack (2) is used to store and transfer unprocessed pallets and processed pallets; the tool buffer rack (5) is used to store tools that are to be used and tools that have reached the end of their tool life.

6. The flexible automated carbon fiber embedded block processing unit according to claim 2, characterized in that: The first CNC milling machine (1) and the second CNC milling machine (3) are equipped with automatic opening and closing doors on their sides; and the automatic opening and closing doors are both facing the six-axis articulated robot (4) for transferring and exchanging pallets and tools from the side.

7. The flexible automated carbon fiber embedded block processing unit according to claim 2, characterized in that: The front and back outlines of the blank to be processed are both cuboids; the front and back outlines and bottom surface of the blank to be processed are clamped by an OK clamp.

8. The processing method of the flexible automated carbon fiber embedded block processing unit according to claim 1, characterized in that: include: S1. The operator uses OK clips to clamp the blank to be processed on the pallet, with the front side facing up; S2. After binding the pallet chip information and the product drawing number and plan number clamped on the pallet in the control system, the pallet is placed on the loading station (6) and the double glass door is closed; the six-axis articulated robot (4) identifies the newly bound pallet chip. After identification, the six-axis articulated robot (4) automatically assembles the pallet gripper and transfers the pallet from the loading station (6) to the pallet buffer rack (2). S3, the pallet buffer rack (2) enables the six-axis articulated robot (4) to transfer and store the pallet on the loading station (6); after receiving the processing instruction from the central control system, the six-axis articulated robot (4) transfers the pallet from the pallet buffer rack (2) into the automatic opening and closing door on the side of the machine tool and transfers it to the machine tool worktable; S4. After the front of the blank to be processed is machined on the first CNC milling machine (1) or the second CNC milling machine (3), the overall control system issues a pallet pick-up command, and the six-axis articulated robot (4) picks up the pallet from the machine tool worktable and places it on the corresponding pallet buffer rack (2). S5. The control system issues a line exit command, and the six-axis articulated robot (4) transfers the pallet from the pallet buffer rack (2) to the loading station (6); S6. The operator takes the pallet out of the loading station (6), unloads the blank to be processed, flips it over, clamps the blank to be processed on the pallet with the reverse side facing up, and then puts it on the loading station (6). S7. Repeat steps S2-S5 to complete the reverse processing. The operator takes the pallet out of the loading station (6), unloads the reverse-processed parts, and obtains the product after cleaning and self-inspection.

9. The processing method according to claim 8, characterized in that: The tool buffer rack (5) allows the operator to place spare tools. When the control system gives an instruction, the six-axis articulated robot (4) changes the tool chuck and transfers the selected tool from the tool buffer rack (5) to the corresponding machine tool. The tool to be replaced is removed from the machine tool. The tool chuck of the six-axis articulated robot (4) changes its angle and installs the tool taken from the tool buffer rack (5) on the spindle. After installation, the six-axis articulated robot (4) transfers the replaced tool to the corresponding position of the tool buffer rack (5).

10. The processing method according to claim 8, characterized in that: In S1, the OK clip and the tray supporting it are of a universal design; each tray can hold up to 16 blanks to be processed; different specifications of OK clips and their corresponding trays are selected according to different sizes.

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