Intelligent control system of flange go gauge detection equipment

Abstract

The invention belongs to the field of intelligent control, and provides an intelligent control system of flange go gauge detection equipment, which comprises a rack, and a feeding unit, a detection execution unit, a discharging unit and a conveying unit which are sequentially arranged on the rack, and is characterized in that the detection execution unit at least comprises a go gauge detection unit; the go gauge detection unit comprises a base, a plurality of go gauges arranged in a radial sliding mode, driving air cylinders and a control assembly, the control assembly comprises a controller, pressure sensors arranged on air paths of the driving air cylinders and proportional control valves, and the controller is configured to calculate output detection force of the air cylinders based on air path pressure collected by the pressure sensors. The output detection force is compared with the preset workpiece detection force, the deviation value of the output detection force and the preset workpiece detection force is calculated, the control current of the proportional valve is calculated according to the deviation value, the controller controls the proportional valve to adjust the output air pressure according to the control current, and the defects of go gauge abrasion acceleration, displacement sensor sampling precision reduction and the like caused by detection force fluctuation are effectively overcome.

Description

Technical Field

[0001] This invention relates to the field of gauge testing equipment, and more specifically, to an intelligent control system for a flange gauge testing equipment. Background Technology

[0002] In the automated production process of precision components such as flanges and bearings, go gauge inspection is a core process to ensure product dimensional accuracy and assembly compatibility. This process involves inserting a go gauge (plug gauge / ring gauge) into the mating hole or contact surface of the workpiece, and judging whether the workpiece meets the tolerance requirements based on parameters such as insertion depth and resistance.

[0003] Traditional gob gauge inspection equipment typically uses ordinary solenoid valves to control pneumatic cylinders to drive the gob gauge, or uses open-loop controlled servo motors as the power source. However, these types of equipment have revealed a series of technical defects during long-term operation, which seriously restrict the inspection accuracy and equipment lifespan.

[0004] First, unstable air pressure in the pneumatic cylinder leads to drastic fluctuations in the detection force. The air pressure in the factory's air supply is affected by factors such as the start and stop of the air compressor and the parallel use of air by multiple devices, resulting in fluctuations exceeding ±0.1 MPa. Ordinary solenoid valves can only achieve "on / off" air path switching and cannot continuously regulate air pressure.

[0005] According to the cylinder thrust formula F=P·A-Ff, fluctuations in air pressure P will directly cause a deviation of ±10% or more in the detection force F. For soft flange workpieces such as aluminum alloys, excessive detection force will cause the gauge to damage the workpiece mating surface, or even cause plastic deformation of the workpiece; insufficient detection force will prevent the gauge from being fully in place, causing qualified parts to be mistakenly judged as unqualified.

[0006] Secondly, open-loop control of servo motors suffers from speed fluctuations and response lag. Some devices use servo motors to drive gauges, but their control logic is mostly open-loop speed control, without incorporating feedback adjustment of the detection force. When the gauge contacts the workpiece, the motor speed will fluctuate instantaneously due to sudden load changes, leading to impact-like changes in the detection force. This impact not only accelerates the wear of the gauge, shortening its effective lifespan by more than 30%, but also causes the displacement sensor's sampling data to contain high-frequency noise, reducing detection accuracy.

[0007] Furthermore, the cumulative effect of go gauge wear lacks a compensation mechanism. Traditional equipment relies on manual periodic calibration and replacement of the go gauge, but go gauge wear is a gradual process, and the manual calibration cycle is usually 1-2 weeks, which cannot compensate for the shift in the detection reference caused by wear in real time. When the wear of the go gauge exceeds 0.02mm, its insertion depth detection threshold will show a systematic deviation, leading to misjudgment of batch workpieces and posing a serious quality risk to production.

[0008] The aforementioned defects not only lead to a false judgment rate of 5%-8% for testing equipment, increasing the cost of subsequent manual re-inspection, but also reduce production efficiency by more than 20% due to frequent changes in gauges and equipment downtime for maintenance. With the increasing demands for precision in high-end equipment manufacturing, traditional gauge testing equipment can no longer meet the needs of high-precision and high-efficiency production, necessitating a technical solution that can achieve stable control of the testing force. Summary of the Invention

[0009] The main purpose of this application is to provide an intelligent control system for flange gauge inspection equipment, which effectively solves the defects such as accelerated wear of the gauge caused by fluctuations in the inspection force and decreased sampling accuracy of the displacement sensor.

[0010] To achieve the above objectives, in a first aspect, this application provides an intelligent control system for a flange gauge inspection device, comprising a frame, a loading unit, an inspection execution unit, an unloading unit, and a conveying unit for conveying workpieces between the units sequentially arranged on the frame. The inspection execution unit includes at least a gauge inspection unit, which includes a base fixedly mounted on the frame, a plurality of gauges radially slidably mounted on the outer periphery of the base, and a drive cylinder for driving the gauges to slide. The system also includes a control component, which includes a controller, a pressure sensor mounted on the air path of each drive cylinder, and a proportional control valve. The controller is configured to calculate the output detection force of the cylinder based on the air path pressure collected by the pressure sensor, compare the output detection force with a preset workpiece detection force and calculate the deviation value between the two, calculate the control current of the proportional valve based on the deviation value, and control the proportional valve to adjust the output air pressure according to the control current.

[0011] Optionally, the control current of the proportional valve can be calculated based on the deviation value using a PID algorithm.

[0012] Optionally, control the current ,in , F represents the preset workpiece detection force, and F represents the real-time output detection force of the cylinder. K is the deviation value. pF K iF K dF These are the PID gain coefficients.

[0013] Optionally, the cylinder output detection force Where P is the air pressure collected by the pressure sensor, and A is the effective working area of ​​the cylinder piston. This refers to the frictional force of the cylinder.

[0014] Optionally, K pF =0.5, K iF =0.1, K dF=0.05.

[0015] Optionally, the conveying unit includes a movable frame that is slidably mounted on the frame in the horizontal direction, a plurality of clamping frames that are vertically fixed on the movable frame, a clamping plate that is slidably mounted on the bottom of the clamping frame, and an electromagnetic drive cylinder that drives the clamping plate to move. The movable frame is driven to slide by the movable cylinder.

[0016] Optionally, the detection unit further includes an appearance detection unit, a size detection unit, an airtightness detection unit, and a plug gauge detection unit.

[0017] Optionally, each of the detection units is further provided with a placement channel on one side, the edge of the placement channel is provided with a frame, and a turntable is rotatably provided at the end of the placement channel, the turntable being driven to rotate by a motor.

[0018] Optionally, the feeding unit is a vibratory feeder.

[0019] Optionally, the unloading unit includes a storage box, a workpiece conveyor connected to the storage box, and an arc-shaped guide plate disposed at the connection between the two.

[0020] The present invention provides an intelligent control system for flange gauge testing equipment. Compared with the prior art, its advantages are as follows: the present invention effectively solves the defect of detection force fluctuation in traditional gauge testing equipment through the combined design of "pneumatic proportional valve + pressure sensor + PID closed-loop control", bringing the following significant benefits.

[0021] 1. Significantly improved detection force stability: Through PID closed-loop control, the fluctuation range of the detection force is controlled within ±3N, which is far superior to the fluctuation level of ±15N of traditional equipment. The stable detection force not only avoids damage to the workpiece surface caused by excessive force, but also ensures the consistency of the gauge insertion depth, reducing the detection error rate to below 0.5% and greatly improving the reliability of the detection results.

[0022] 2. Significantly improved go-go gauge life and equipment uptime: Stable control of the detection force eliminates the wear of the go-go gauge by the impact load, extending the effective service life of the go-go gauge by more than 40%, reducing the frequency and cost of go-go gauge replacement, while reducing equipment downtime for maintenance by 60% and increasing the uptime to more than 95%, significantly improving production efficiency.

[0023] 3. Significantly reduced maintenance costs and manual intervention: The automatic adjustment and real-time compensation mechanism for detection force eliminates the need for frequent manual calibration of gauges and adjustment of equipment parameters, reducing equipment maintenance costs by more than 30%. Simultaneously, the significantly increased automation level reduces reliance on operator skills, further minimizing human error in the production process. Attached Figure Description

[0024] The accompanying drawings, which form part of this application, are used to provide a further understanding of the application and to make other features, objects, and advantages of the application more apparent. The illustrative embodiments and descriptions of this application are used to explain the application and do not constitute an undue limitation of the application. In the drawings: Figure 1 This is a schematic diagram of the present invention. Figure 1 ; Figure 2 This is a schematic diagram of the present invention. Figure 2 .

[0025] The components include: 1. Frame; 2. Loading unit; 3. Unloading unit; 4. Workpiece conveyor; 5. Storage box; 6. Arc-shaped baffle; 7. Detection unit; 8. Base; 9. Detection gauge; 10. Drive cylinder; 11. Moving frame; 12. Clamping frame; 13. Moving cylinder; 14. Placement channel; 15. Motor. Detailed Implementation

[0026] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0027] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this application described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0028] In this application, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this application and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0029] Furthermore, in addition to indicating location or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0030] In addition, the term "multiple" should mean two or more.

[0031] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0032] like Figures 1-2 As shown, an intelligent control system for a flange gauge 9 inspection device includes a frame 1, a loading unit 2, an inspection execution unit, an unloading unit 3, and a conveying unit for transporting workpieces between the units, all sequentially arranged on the frame 1. The inspection execution unit includes at least an appearance inspection unit, a dimension inspection unit, an airtightness inspection unit, a gauge inspection unit 7, and a plug gauge inspection unit. The gauge inspection unit 7 includes a base 8 fixedly mounted on the frame 1, a plurality of gauges 9 radially slidably disposed on the outer periphery of the base 8, and a drive cylinder for driving the gauges 9 to slide. 10, wherein the conveying unit includes a movable frame 11 slidably disposed on the frame 1 along the horizontal direction, a plurality of clamping frames 12 vertically fixedly disposed on the movable frame 11, a clamping plate slidably disposed at the bottom of the clamping frame 12, and an electromagnetic drive cylinder for driving the clamping plate to move, and the movable frame 11 is driven to slide by a movable cylinder 13; the loading unit 2 is a vibratory feeder, and the unloading unit 3 includes a storage box 5, a workpiece conveying frame 4 connected to the storage box 5, and an arc-shaped guide plate disposed at the connection between the two, and the workpiece conveying frame 4 adopts belt conveying.

[0033] The specific working principle is as follows: First, the vibrating hopper of the feeding unit 2 automatically sorts the stacked flange workpieces through the spiral track of the vibrating plate, keeping the workpieces in a uniform posture. Then, the conveying unit transports the workpieces one by one to the workstations of each inspection unit for inspection. Products that pass inspection are conveyed to the next inspection station for further inspection. For products that fail inspection, a placement channel 14 is provided on one side of each inspection unit. The edge of the placement channel 14 is provided with a frame, and a turntable is rotatably installed at the end of the placement channel 14. The turntable is driven to rotate by a motor 15, and the workpieces are transported by the conveying unit. Qualified workpieces are clamped into the placement channel 14. A workpiece conveyor belt is installed at the bottom of the placement channel 14. When the workpiece is conveyed to the end of the placement channel 14, the motor 15 drives the turntable to rotate to realize the automatic sorting of workpieces, ensuring that the placement channel 14 can accommodate enough unqualified products before the operator operates, thereby reducing the frequency of operation by the operator. When the workpiece passes the final inspection station, it is conveyed by the conveying unit to the workpiece conveyor frame 4 of the unloading unit 3. The workpiece is then conveyed to the storage box 5 by the workpiece conveyor frame 4. In order to reduce the impact of the workpiece, an arc-shaped baffle 6 is also installed at the connection between the two.

[0034] Regarding the control system, it also includes a control component, which includes a controller, a pressure sensor disposed on the air path of each of the drive cylinders 10, and a proportional control valve. The controller is configured to calculate the output detection force of the cylinder based on the air path pressure collected by the pressure sensor, compare the output detection force with a preset workpiece detection force and calculate the deviation value between the two, calculate the control current of the proportional valve based on the deviation value, and control the proportional valve to adjust the output air pressure according to the control current.

[0035] Preferably, the control current of the proportional valve is calculated based on the deviation value using a PID algorithm. Specifically, the control current... ,in , F represents the preset workpiece detection force, and F represents the real-time output detection force of the cylinder. K is the deviation value. pF K iF K dF These are the PID gain coefficients, and regarding the calculation of the detection force, specifically, the output detection force of the cylinder. Where P is the air pressure collected by the pressure sensor, and A is the effective working area of ​​the cylinder piston. The frictional force of the cylinder is P, which is detected by a pressure sensor, while A is set according to the specifications of the cylinder used. This is related to the cylinder model; typically, small cylinders are used, meaning the cylinder diameter is between φ16 and φ32 mm. The value is typically between 1 and 5N, with 3N being the preferred value. Regarding the PID gain coefficient, K is usually chosen. pF =0.5, K iF =0.1, K dF =0.05, and also regarding The value depends on the material of the workpiece; typically, aluminum alloy flanges are 50N and steel flanges are 80N.

[0036] By controlling the air pressure P through the proportional valve using the above algorithm, the detection force F can be linearly adjusted, thereby achieving closed-loop stable control of the detection force. This avoids defects such as accelerated wear of the gauge and decreased sampling accuracy of the displacement sensor caused by fluctuations in the detection force.

[0037] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An intelligent control system for a flange gauge inspection device, characterized in that, The system includes a frame, a loading unit, a detection execution unit, a unloading unit, and a conveying unit for transporting workpieces between the units, all sequentially arranged on the frame. The detection execution unit includes at least a go gauge detection unit, which includes a base fixedly mounted on the frame, several go gauges radially slidably mounted on the outer periphery of the base, and a drive cylinder for driving the go gauges to slide. The system also includes a control component, which includes a controller, a pressure sensor mounted on the air path of each drive cylinder, and a proportional control valve. The controller is configured to calculate the output detection force of the cylinder based on the air path pressure collected by the pressure sensor, compare the output detection force with a preset workpiece detection force and calculate the deviation value between the two, calculate the control current of the proportional valve based on the deviation value, and control the proportional valve to adjust the output air pressure according to the control current.

2. The intelligent control system for a flange gauge inspection device as described in claim 1, characterized in that: The control current of the proportional valve is calculated based on the deviation value using a PID algorithm.

3. The intelligent control system for a flange gauge inspection device as described in claim 2, characterized in that: Control current ,in , F represents the preset workpiece detection force, and F represents the real-time output detection force of the cylinder. K is the deviation value. pF K iF K dF These are the PID gain coefficients.

4. The intelligent control system for a flange gauge inspection device as described in claim 3, characterized in that, The cylinder output detection force Where P is the air pressure collected by the pressure sensor, and A is the effective working area of ​​the cylinder piston. This refers to the frictional force of the cylinder.

5. The intelligent control system for a flange gauge inspection device as described in claim 3, characterized in that: K pF =0.5,K iF =0.1,K dF =0.05。 6. The intelligent control system for a flange gauge inspection device as described in claim 5, characterized in that: The conveying unit includes a movable frame that is slidably mounted on the frame in the horizontal direction, several clamping frames that are vertically fixed on the movable frame, a clamping plate that is slidably mounted on the bottom of the clamping frame, and an electromagnetic drive cylinder that drives the clamping plate to move. The movable frame is driven to slide by the movable cylinder.

7. The intelligent control system for a flange gauge inspection device as described in claim 6, characterized in that: The detection unit also includes an appearance detection unit, a size detection unit, an airtightness detection unit, and a plug gauge detection unit.

8. The intelligent control system for a flange gauge inspection device as described in claim 7, characterized in that: Each of the detection units is also provided with a placement channel on one side, the edge of the placement channel is provided with a frame, and a turntable is rotatably provided at the end of the placement channel, the turntable being driven to rotate by a motor.

9. The intelligent control system for a flange gauge inspection device as described in claim 1, characterized in that: The feeding unit is a vibratory feeder.

10. The intelligent control system for a flange gauge inspection device as described in claim 1, characterized in that: The unloading unit includes a storage box, a workpiece conveying frame connected to the storage box, and an arc-shaped guide plate disposed at the connection between the two.

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