Roadheader main bearing gear ring tooth chamfer machining equipment and method

Abstract

The invention relates to the technical field of heading machine main bearing machining, in particular to heading machine main bearing gear ring tooth chamfering machining equipment and method. Comprising an automatic clamping system, a gear ring driving system, a robot system, a visual scanning camera, an upper computer software system and a PLC control system, the automatic clamping system and the gear ring driving system are introduced, and a large main bearing gear ring can be automatically centered, clamped and rotated by a fixed angle in real time; a visual scanning camera is introduced, the main function of accurately scanning the tooth profile of a main bearing gear ring is achieved, tooth profile data are transmitted to an upper computer software system for data processing, and the data are converted into robot languages to control a robot system to conduct tooth chamfering machining; the robot system is introduced, automatic chamfering machining of the main bearing gear ring can be achieved through control of the PLC control system and linkage of the gear ring driving system, the operation intensity is reduced, the machining efficiency is improved, and the chamfering machining precision of the main bearing gear ring is effectively improved.

Description

Technical Field

[0001] This invention relates to the field of tunneling machine main bearing processing technology, and in particular to a machine and method for chamfering the gear ring teeth of a tunneling machine main bearing. Background Technology

[0002] The gear ring of a tunneling machine's main bearing is a component of the main bearing ring. It is generally called the inner ring or outer ring because teeth are machined on both the inner and outer rings (some tunneling machine main bearings have a separate gear ring). The gear ring connects to the cutterhead and meshes with planetary gears. The motor drives the planetary gears to rotate the gear ring, which in turn drives the cutterhead. Since the gear ring bears the main torsional load, its meshing surfaces require heat treatment, specifically quenching to increase surface hardness. After the milling cutterhead machines the gear ring, the upper and lower surfaces of the teeth are sharp angles, and the exit surface has burrs. To ensure that heat treatment does not produce defects, the upper and lower surfaces of the teeth need to be chamfered (while simultaneously removing burrs).

[0003] Currently, the main method for chamfering large gear rings is still handheld angle grinders. This means that the operator holds the angle grinder and manually grinds along the tooth contour. The processing quality is generally poor, the chamfers at both ends of a single tooth are uneven, the labor intensity for the operator is extremely high, the dust generated during chamfering has an impact on the human body, the work efficiency is low, the processing time is long, and it seriously restricts the production capacity of gear rings.

[0004] Therefore, it is necessary to provide a new equipment and method for chamfering the gear ring of the main bearing of a tunneling machine to solve the above-mentioned technical problems. Summary of the Invention

[0005] The main objective of this invention is to provide a chamfering machine for the gear ring of a tunneling machine main bearing, which aims to solve the problem of low processing efficiency of existing equipment.

[0006] To achieve the above objectives, the present invention proposes a machine for chamfering the gear ring of a tunneling machine main bearing, comprising an automatic clamping system, a gear ring drive system, a robot system, a vision scanning camera, a host computer software system, and a PLC control system. The automatic clamping system has a workpiece mounting area at its center for clamping the main bearing gear ring. The gear ring drive system is arranged adjacent to the workpiece mounting area, and the gear ring drive system can drive the main bearing gear ring to rotate. The robotic system is positioned adjacent to the workpiece mounting area; The visual scanning camera can scan and acquire the tooth profile data of the main bearing gear ring, and transmit the tooth profile data to the host computer software system. The host computer software system can generate upper surface machining templates and lower surface machining templates based on tooth profile data and transmit them to the PLC control system. The PLC control system is electrically connected to the automatic clamping system, the gear ring drive system, the robot system, and the host computer software system. The PLC control system can control the automatic clamping system to adjust the position of the main bearing gear ring for alignment, and can also control the gear ring drive system and the robot system to cooperate to perform chamfering machining on the main bearing gear ring based on the upper surface machining templates and lower surface machining templates.

[0007] Optionally, the automatic clamping system includes at least three clamping mechanisms, which are radially and uniformly arranged along the same center, and the workpiece mounting area is formed at the center where the clamping mechanisms meet.

[0008] Optionally, the clamping mechanism includes a first support trolley, a slide block, clamping jaws, and a sliding drive component. The first support trolley is radially arranged along the center of the workpiece mounting area. The slide block is slidably mounted on the first support trolley along its length. The slide block has two sets of clamping jaws spaced apart along the radial direction of the workpiece mounting area, forming a clamping space between the two sets of clamping jaws for mounting the main bearing gear ring. The sliding drive component is mounted on the slide block and can drive the slide block to move along the length direction of the first support trolley. Each clamping mechanism can cooperate to drive the main bearing gear ring to move so as to achieve alignment between the main bearing gear ring and the workpiece mounting area.

[0009] Optionally, the gear ring drive system includes a second support trolley, a movable seat, a movable drive component, a gear drive component, and a drive gear. The second support trolley is radially arranged along the center of the workpiece mounting area. The movable seat is slidably mounted on the second support trolley along its length. The movable drive component is mounted on the movable seat and can drive the movable seat to move along the length of the second support trolley. The gear drive component is mounted on the movable seat. The drive gear is connected to the output shaft of the gear drive component and can mesh with the main bearing gear ring.

[0010] Optionally, the robot system includes a third support trolley, a robot body, a quick-change disc, and a chamfering tool structure. The third support trolley is radially arranged along the center of the workpiece mounting area. The robot body is slidably mounted on the third support trolley. The quick-change disc is detachably connected to the output shaft of the robot body, and the robot body can grasp the chamfering tool structure, the drive gear, and the vision scanning camera respectively through different quick-change discs.

[0011] Optionally, the chamfering tool structure includes a spindle and a profiled end mill, the profiled end mill being connected to the corresponding quick-change disc via the spindle; the end of the profiled end mill away from the spindle is provided with an inner arc cutting edge (A).

[0012] Optionally, the gear chamfering processing equipment for the main bearing gear ring of the tunneling machine further includes a gear storage warehouse and a tool storage warehouse, which are respectively located on both sides of the third support trolley. The gear storage warehouse is used to store different types of drive gears; the tool storage warehouse is used to store different types of chamfering tool structures.

[0013] Optionally, the host computer software system includes a template generation program for generating upper surface machining templates and lower surface machining templates, and a chamfer trajectory calculation program for calculating the chamfer trajectory of the main bearing gear ring.

[0014] In addition, the present invention also provides a method for chamfering the teeth of the main bearing gear ring of a tunneling machine, which uses the aforementioned equipment for chamfering the teeth of the main bearing gear ring to perform chamfering processing on the main bearing gear ring, including the following steps: S1: Install the main bearing gear ring and drive gear, specifically: The main bearing gear ring is clamped into the workpiece mounting area using an automatic clamping system; Select the corresponding drive gear according to the model of the main bearing gear ring, and use the robot body to grab the drive gear through the corresponding quick-change disk and assemble it onto the output shaft of the gear drive component; S2: The robot body uses the corresponding quick-change disk to grasp the visual scanning camera to scan the main bearing gear ring and obtain the tooth profile data. S3: The host computer software system generates upper surface machining templates and lower surface machining templates based on tooth profile data using a template generation program. S4: The robot body performs chamfering on the upper and lower surfaces of the main bearing gear ring using the upper surface machining template and the lower surface machining template, respectively.

[0015] Optionally, the main bearing gear ring is clamped into the workpiece mounting area using an automatic clamping system, including: S1.1. Hoist the main bearing gear ring to the workpiece installation area and place it between the two clamping jaws of each clamping mechanism; S1.2 The sliding drive unit moves the slide block according to the set chuck load value so that the clamping chuck drives the main bearing gear ring to center.

[0016] Optionally, S2 includes: S2.1 The robot body uses the robot language program template to grab the vision scanning camera using the quick-change disk and moves the vision scanning camera to the corresponding position of the main bearing gear ring; S2.2 Adjust the camera parameters of the visual scanning camera and take the number of teeth of the main bearing gear ring within the scanning range of the visual scanning camera as a unit group; S2.3. Use a visual scanning camera to scan the main bearing gear ring to obtain the tooth profile data corresponding to the unit group.

[0017] Optionally, S3 includes: S3.1 Optimize the coordinates of each data point in the tooth profile data corresponding to the unit group to obtain the optimized tooth profile data. The optimization process specifically includes: The X-axis and Y-axis coordinates of each data point are filtered using a window mean to obtain the optimized tooth profile data. The specific formula is as follows: ; in, n The order of the filter window; I These are the original data points; g To optimize the data points of the tooth profile data; Sxy To revolve around the center point ( x , y ) range; The average Z-axis coordinate values ​​of the data points are used to obtain the Z-axis coordinate values ​​of each data point in the optimized tooth profile data. The specific formula is as follows: ; in, Size of the window data range; For the first Z-axis coordinate values ​​of each data point; S3.2 Connect the data points of the optimized tooth profile data in sequence to obtain the optimized tooth profile. S3.3. Convert the optimized gear contour data points and set tooth chamfer template into robot language input template generation program output to obtain the upper surface machining template; S3.4. Based on the upper surface machining template, the lower surface machining template is obtained by translation of the robot world coordinate system and deflection of the robot tool coordinate system.

[0018] Optionally, S4 includes: S4.1 The host computer software system uses the chamfer trajectory calculation program to calculate the tooth chamfer trajectory of this unit group; S4.2 The PLC control system controls the robot body to chamfer each tooth in the unit group according to the tooth chamfering trajectory through the chamfering tool structure; S4.3 The PLC control system controls the gear drive component to drive the main bearing gear ring to rotate to the next unit group and enter the scanning range of the vision scanning camera. S4.4 Determine whether all teeth of the main bearing gear ring within the current scanning range have completed chamfering. If so, complete the chamfering of the entire main bearing gear ring; otherwise, return to S2.3.

[0019] Optionally, S4.2 includes: S4.2.1. Calibrate the chamfer amounts of the upper and lower surfaces of the main bearing gear ring respectively. The chamfer amount of the upper surface includes the Z-axis descent value, X-axis offset value, and Y-axis offset value; the chamfer amount of the lower surface includes the Z-axis ascent value, X-axis offset value, and Y-axis offset value. Specifically: ① Set the adjustment unit value and the initial value of the chamfer amount according to the target chamfer size; ② The robot body operates the chamfering tool structure to perform chamfering according to the current chamfering amount; ③ Measure the current chamfer dimension of the main bearing gear ring. If the error between the current chamfer dimension and the target chamfer dimension is less than the set error threshold, obtain the calibration value of each chamfer quantity; otherwise, adjust each chamfer quantity according to the target chamfer dimension and the adjustment unit value, and then return to step ② until the calibration of the chamfer quantity is completed. S4.2.2 The PLC control system controls the robot body based on the upper and lower surface machining templates to perform chamfering machining on each tooth in the unit group according to the tooth chamfering trajectory and the chamfering amount of the upper and lower surfaces of the main bearing gear ring calibrated in S4.2.1.

[0020] This invention introduces an automatic clamping system and a gear ring drive system, which can automatically center and clamp large main bearing gear rings and rotate them to a fixed angle in real time. A vision scanning camera is introduced, primarily for accurately scanning the tooth contour of the main bearing gear ring. The tooth contour data is transmitted to a host computer software system for data processing and is converted into robot language to control the robot system for tooth chamfering. The introduction of the robot system not only enables automated chamfering of the main bearing gear ring through linkage with the gear ring drive system under the control of the PLC control system, reducing labor intensity, improving processing efficiency, and minimizing human error, but also effectively improves the chamfering accuracy of the main bearing gear ring, resulting in reliable processing quality, good chamfer consistency, and improved production efficiency. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the structure of the equipment for chamfering the gear ring of the main bearing of a tunneling machine in an embodiment of the present invention; Figure 2 This is a schematic diagram of the clamping mechanism in an embodiment of the present invention; Figure 3 This is a schematic diagram of the gear ring drive system in an embodiment of the present invention; Figure 4 This is a schematic diagram of the robot system in an embodiment of the present invention; Figure 5 This is a schematic diagram of the irregular-shaped milling cutter in an embodiment of the present invention; Figure 6 This is a schematic diagram of the chamfer structure of the main bearing gear ring in an embodiment of the present invention; Figure 7 This is a flowchart illustrating the method for chamfering the gear ring of the main bearing of a tunneling machine in an embodiment of the present invention.

[0023] Explanation of icon numbers: 1. Automatic clamping system; 1.1 Workpiece mounting area; 1.2 Clamping mechanism; 1.2.1 First support trolley; 1.2.2 Slide; 1.2.3 Clamping jaws; 1.2.4 Sliding drive component; 2. Gear ring drive system; 2.1 Second support trolley; 2.2 Moving seat; 2.3 Gear drive component; 2.4 Drive gear; 3. Robot system; 3.1 Third support trolley; 3.2 Robot body; 3.3 Quick change plate; 3.4 Chamfering tool structure; 3.4.1 Spindle; 3.4.2 Irregular milling cutter; A. Inner arc cutting edge; 4. Vision scanning camera; 5. Host computer software system; 6. Main bearing gear ring; 6.1 Chamfering area; 7. Gear storage; 8. Tool storage.

[0024] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0026] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0027] Furthermore, in this invention, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0028] In this invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0029] Furthermore, the technical solutions of the various embodiments of the present invention can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by the present invention.

[0030] This invention proposes a chamfering machine for the gear ring of a tunneling machine main bearing, aiming to solve the problem of low processing efficiency of existing equipment.

[0031] See Figures 1 to 6This embodiment provides a chamfering processing device for the main bearing gear ring of a tunneling machine, including an automatic clamping system 1, a gear ring drive system 2, a robot system 3, a vision scanning camera 4, a host computer software system 5, and a PLC control system. The automatic clamping system 1 has a workpiece mounting area 1.1 at its center for clamping the main bearing gear ring 6. The gear ring drive system 2 is adjacent to the workpiece mounting area 1.1 and can drive the main bearing gear ring 6 to rotate. The robot system is adjacent to the workpiece mounting area 1.1. The vision scanning camera 4 can scan and acquire the tooth profile data of the main bearing gear ring 6 and... The tooth profile data is transmitted to the host computer software system 5. The host computer software system 5 can generate upper surface machining templates and lower surface machining templates based on the tooth profile data and transmit them to the PLC control system. The PLC control system is electrically connected to the automatic clamping system 1, the gear ring drive system 2, the robot system 3, and the host computer software system 5. The PLC control system can control the automatic clamping system 1 to adjust the position of the main bearing gear ring 6 for centering, and can also control the gear ring drive system 2 and the robot system 3 to cooperate in chamfering the main bearing gear ring 6 based on the upper surface machining templates and lower surface machining templates. This embodiment of the tunneling machine main bearing gear ring chamfering processing equipment introduces an automatic clamping system 1 and a gear ring drive system 2, which can automatically center and clamp the large main bearing gear ring 6 and rotate it to a fixed angle in real time. A vision scanning camera 4 is introduced, whose main function is to accurately scan the tooth contour of the main bearing gear ring 6. The tooth contour data is transmitted to the upper computer software system 5 for data processing and converted into robot language to control the robot system 3 to perform tooth chamfering processing. The introduction of robot system 3 can not only realize the automated chamfering processing of main bearing gear ring 6 through the control of PLC control system and linkage with gear ring drive system 2, but also reduce the labor intensity, improve processing efficiency, reduce human operation error, effectively improve the chamfering processing accuracy of main bearing gear ring 6, and ensure reliable processing quality and good chamfer consistency, thereby improving production and processing efficiency.

[0032] The automatic clamping system 1 includes at least three clamping mechanisms 1.2, which are radially and uniformly arranged around the same center, and the center where the clamping mechanisms 1.2 meet forms the workpiece mounting area 1.1. The three clamping mechanisms 1.2 cooperate to clamp the main bearing gear ring 6 and can realize the horizontal movement of the main bearing gear ring 6 in three directions to achieve the centering of the main bearing gear ring 6.

[0033] The clamping mechanism 1.2 includes a first support carriage 1.2.1, a slide block 1.2.2, clamping jaws 1.2.3, and a sliding drive component 1.2.4. The first support carriage 1.2.1 is radially arranged along the center of the workpiece mounting area 1.1. The slide block 1.2.2 is slidably mounted on the first support carriage 1.2.1 along its length. The slide block 1.2.2 is provided with two clamping jaws 1.2.3 spaced apart along the radial direction of the workpiece mounting area 1.1, forming a clamping space between the two clamping jaws 1.2.3 for mounting the main bearing gear ring 6. The sliding drive component 1.2.4 is mounted on the slide block 1.2.2 and can drive the slide block 1.2.2 to move along the length of the first support carriage 1.2.1. Each clamping mechanism 1.2 can cooperate to drive the main bearing gear ring 6 to move so as to achieve the alignment of the main bearing gear ring 6 with the workpiece mounting area 1.1. When the sliding drive component 1.2.4 drives the slide block 1.2.2 to move, the clamping jaws 1.2.3 on the slide block 1.2.2 can drive the main bearing gear ring 6 to move, thereby adjusting the position of the main bearing gear ring 6 on the workpiece mounting area 1.1. The three clamping mechanisms 1.2 work together to adjust the position of the main bearing gear ring 6 in different directions, so as to achieve the alignment of the main bearing gear ring 6 with the workpiece mounting area 1.1, and the clamping space provides adjustment space for the alignment of the main bearing gear ring 6.

[0034] In this embodiment, to ensure that each jaw is subjected to a certain load without causing deformation of the gear ring, the load value is preferably set to about 10%. Each clamping jaw 1.2.3 includes two jaw pieces symmetrically arranged in the radial direction along the workpiece mounting area 1.1, so as to distribute the force applied to the main bearing gear ring 6 by the clamping jaw 1.2.3, and avoid the main bearing gear ring 6 from being deformed due to force concentration.

[0035] The gear ring drive system 2 includes a second support carriage 2.1, a movable seat 2.2, a moving drive component, a gear drive component 2.3, and a drive gear 2.4. The second support carriage 2.1 is radially arranged along the center of the workpiece mounting area 1.1. The movable seat 2.2 is slidably mounted on the second support carriage 2.1 along its length. The moving drive component is mounted on the movable seat 2.2 and can drive the movable seat 2.2 to move along the length of the second support carriage. The gear drive component 2.3 is mounted on the movable seat 2.2. The drive gear 2.4 is connected to the output shaft of the gear drive component 2.3 and can mesh with the main bearing gear ring 6. After the automatic centering and clamping of the main bearing gear ring 6 is completed, the robot system 3 selects the corresponding model of the drive gear 2.4 and installs it on the output shaft of the gear drive component 2.3. The moving drive component then drives the movable seat 2.2 to move in a direction close to the main bearing gear ring 6 so that the drive gear 2.4 meshes with the main bearing gear ring 6. The moving drive component is a translational servo motor. In this embodiment, the meshing of the drive gear 2.4 and the main bearing gear ring 6 may require multiple actions to complete. During the meshing process, the torque of the translational servo motor needs to be monitored in real time. If the drive gear 2.4 is not aligned with the workpiece teeth of the main bearing gear ring 6, the torque is too large, and the drive gear 2.4 needs to be moved back a certain distance. The gear ring drive system 2 drives the main bearing gear ring 6 to rotate a certain angle, and the drive gear 2.4 moves forward again under the drive of the translational servo motor to re-engage until the meshing is completed. The gear drive component 2.3 includes a mounting base and a drive motor disposed in the mounting base. The mounting base is disposed on the moving base 2.2, and the output shaft of the drive motor is connected to the drive gear 2.4.

[0036] The robot system 3 includes a third support carriage 3.1, a robot body 3.2, a quick-change platen 3.3, and a chamfering tool structure 3.4. The third support carriage 3.1 is radially arranged along the center of the workpiece mounting area 1.1; the robot body 3.2 is slidably mounted on the third support carriage 3.1; the quick-change platen 3.3 is detachably connected to the output shaft of the robot body, and the robot body can grasp the chamfering tool structure 3.4, the drive gear 2.4, and the vision scanning camera 4 respectively through different quick-change plates 3.3. In this embodiment, the visual scanning camera 4 is a 3D line scanning visual camera. After the scanning of the visual scanning camera 4 is started, the robot grasps the visual scanning camera 4, scans the upper surface of the main bearing gear ring 6, and transmits the tooth profile data to the host computer software system 5. It waits for the software to calculate the gear chamfering trajectory (the chamfering trajectory calculation includes complex operations such as filtering and correction). After the scanning is complete, the robot grasps the spindle of the chamfering tool structure 3.4 and performs chamfering on the gear ring. After chamfering is completed, the servo motor (gear ring drive system 2) drives the main bearing gear ring 6 to automatically rotate 8 teeth. The above operation is repeated until the chamfering of the entire upper surface of the workpiece is completed. The chamfering process of the lower surface is the same as that of the upper surface. The robot body 3.2 is a product purchased directly from the market.

[0037] The chamfering tool structure 3.4 includes a spindle and a profiled end mill 3.4.2. The profiled end mill 3.4.2 is connected to the corresponding quick-change disc 3.3 via the spindle. The end of the profiled end mill 3.4.2 away from the spindle has an inner arc cutting edge A. To prevent burr formation, the cutting edge of the chamfering tool structure 3.4 is optimized to a profiled end mill 3.4.2 with an inner arc cutting edge A. The distance between the midpoints of the inner arc is approximately 0.4 mm. Using the profiled end mill 3.4.2 in this embodiment can effectively suppress burr formation, resulting in uniform chamfering, good consistency, and reliable quality. This greatly avoids chamfering quality problems, reduces manual labor, and improves production efficiency.

[0038] The equipment for chamfering the gear ring of the tunneling machine main bearing also includes a gear storage library 7 and a tool storage library 8. The gear storage library 7 and the tool storage library 8 are located on both sides of the third support trolley 3.1. The gear storage library 7 is used to store different types of drive gears 2.4; the tool storage library 8 is used to store different types of chamfering tool structures 3.4. Considering that different types of gear rings have different modules, a drive gear 2.4 library is added. M20, M22, M24 and M26 module gears are placed in fixed positions inside. The quick-change disc 3.3 in the robot system 3 grasps the drive gear 2.4 in the drive gear 2.4 library through the grasping spindle, and then grasps the corresponding type of drive gear 2.4 and places it on the output shaft of the gear drive component 2.3.

[0039] The host computer software system 5 is equipped with a template generation program for generating upper surface machining templates and lower surface machining templates, and a chamfer trajectory calculation program for calculating the chamfer trajectory of the main bearing gear ring 6.

[0040] In this embodiment, the equipment for chamfering the gear ring of the tunneling machine's main bearing also includes a touch screen, a hand switch, an operating console, audible and visual alarm lights, and other peripheral devices. Operators can control the equipment for chamfering the gear ring of the tunneling machine's main bearing using these peripheral devices.

[0041] See Figure 7 This embodiment provides a method for chamfering the 6th tooth of a tunneling machine main bearing gear ring. The method uses the aforementioned tunneling machine main bearing gear ring chamfering equipment to chamfer the chamfered area 6.1 on the main bearing gear ring 6, and includes the following steps: S1: Install the main bearing gear ring and drive gear, specifically: The main bearing gear ring 6 is clamped into the workpiece mounting area 1.1 by the automatic clamping system 1, including: S1.1. Hoist the main bearing gear ring 6 onto the workpiece mounting area 1.1 and place it between the two clamping jaws 1.2.3 located in each clamping mechanism 1.2; S1.2, the sliding drive component 1.2.4 drives the slide block 1.2.2 to move according to the set chuck load value, so that the clamping chuck 1.2.3 drives the main bearing gear ring 6 to center; Select the corresponding drive gear 2.4 based on the model of the main bearing gear ring 6, and use the robot body 3.2 to pick up the drive gear 2.4 via the corresponding quick-change disc 3.3 and assemble it onto the output shaft of the gear drive component 2.3.

[0042] S2: The robot body 3.2 uses the corresponding quick-change disk 3.3 to grasp the vision scanning camera 4 to scan the main bearing gear ring 6 and obtain the tooth profile data; S2 includes: S2.1 The robot body uses the quick-change disk 3.3 to grab the visual scanning camera 4 through the robot language program template and moves the visual scanning camera 4 to the corresponding position of the main bearing gear ring 6. S2.2 Adjust the camera parameters of the visual scanning camera 4, and take the number of teeth of the main bearing gear ring 6 within the scanning range of the visual scanning camera 4 as a unit group; S2.3. Use the visual scanning camera 4 to scan the main bearing gear ring 6 to obtain the tooth profile data corresponding to the unit group.

[0043] S3: The host computer software system 5 generates upper and lower surface machining templates based on the tooth profile data using a template generation program. This involves sending the data points to the robot language program, where the corresponding tooth chamfer template is used to embed the data points, thus forming the upper surface machining template. (Due to the large number of tooth profile data points, it has been verified that interpolation is unnecessary to achieve a good chamfering effect).

[0044] S3 includes: S3.1 Optimize the coordinates of each data point in the tooth profile data corresponding to the unit group to obtain the optimized tooth profile data. The optimization process specifically includes: The X-axis and Y-axis coordinates of each data point are filtered using a window mean to obtain the optimized tooth profile data. The specific formula is as follows: ; in, n The order of the filter window; I These are the original data points; g To optimize the data points of the tooth profile data; Sxy To revolve around the center point ( x , y ) range; The average Z-axis coordinate values ​​of the data points are used to obtain the Z-axis coordinate values ​​of each data point in the optimized tooth profile data. The specific formula is as follows: ; in, Size of the window data range; For the first Z-axis coordinate values ​​of each data point; S3.2 Connect the data points of the optimized tooth profile data in sequence to obtain the optimized tooth profile. S3.3. Convert the optimized gear contour data points and set tooth chamfer template into robot language input template generation program output to obtain the upper surface machining template; S3.4. Based on the upper surface machining template, the lower surface machining template is obtained by translation of the robot world coordinate system and deflection of the robot tool coordinate system.

[0045] In this embodiment, the upper surface machining template and the lower surface machining template are actually code templates in the robot language. The purpose is to embed the optimized tooth profile data points into the template so that the robot can perform corresponding machining according to the template.

[0046] S4: Robot body 3.2 performs chamfering on the upper and lower surfaces of the main bearing gear ring 6 using the upper surface machining template and the lower surface machining template, respectively.

[0047] S4 includes: S4.1 The host computer software system 5 uses the chamfer trajectory calculation program to calculate the tooth chamfer trajectory of this unit group; S4.2, The PLC control system controls the robot body 3.2 and uses the chamfering tool structure 3.4 to chamfer each tooth in the unit group according to the tooth chamfering trajectory; S4.2 includes: S4.2.1. Calibrate the chamfer amounts of the upper and lower surfaces of the main bearing gear ring 6 respectively. The chamfer amount of the upper surface includes the Z-axis descent value, X-axis offset value, and Y-axis offset value. The chamfer amount of the lower surface includes the Z-axis ascent value, X-axis offset value, and Y-axis offset value. Specifically: ① Set the adjustment unit value and the initial value of the chamfer amount according to the target chamfer size; ② The robot body operates the chamfering tool structure 3.4 to perform chamfering according to the current chamfering amount; ③ Measure the current chamfer dimension of the main bearing gear ring 6. If the error between the current chamfer dimension and the target chamfer dimension is less than the set error threshold, obtain the calibration value of each chamfer quantity; otherwise, adjust each chamfer quantity according to the target chamfer dimension and the adjustment unit value, and then return to step ② until the calibration of the chamfer quantity is completed. S4.2.2 The PLC control system controls the robot body based on the upper surface machining template and the lower surface machining template. 3.2 According to the tooth chamfering trajectory and the chamfering amount of the upper and lower surfaces of the main bearing gear ring 6 calibrated in S4.2.1, the robot body performs chamfering machining on each tooth in the unit group.

[0048] S4.3, the PLC control system controls the gear drive component 2.3 to drive the main bearing gear ring 6 to rotate through the drive gear 2.4 to enter the scanning range of the vision scanning camera 4 in the next unit group; S4.4 Determine whether all teeth of the main bearing gear ring 6 within the current scanning range have completed chamfering. If so, complete the chamfering of the teeth of the entire main bearing gear ring 6; otherwise, return to S2.3.

[0049] S4.4 and beyond also includes checking the chamfer dimensions of the main bearing gear ring 6. If the check is qualified, the clamping jaws 1, 2, and 3 are automatically released, and the next main bearing gear ring 6 to be processed is replaced; otherwise, rework is performed.

[0050] Since the method for chamfering the 6th tooth of the main bearing gear ring of the tunneling machine includes the aforementioned equipment for chamfering the main bearing gear ring of the tunneling machine, the method for chamfering the 6th tooth of the main bearing gear ring of the tunneling machine possesses all the beneficial effects of the aforementioned equipment, which will not be elaborated here.

[0051] All matters not covered in this embodiment are common knowledge. The above are merely preferred embodiments of the present invention and do not limit the patent scope of the present invention. Any equivalent structural transformations made based on the inventive concept of the present invention and the contents of the specification and drawings of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A chamfering machine for the gear ring of a tunneling machine main bearing, characterized in that, It includes an automatic clamping system (1), a gear ring drive system (2), a robot system (3), a vision scanning camera (4), a host computer software system (5), and a PLC control system. The automatic clamping system (1) has a workpiece mounting area (1.1) at its center for clamping the main bearing gear ring (6); The gear ring drive system (2) is arranged adjacent to the workpiece mounting area (1.1), and the gear ring drive system (2) can drive the main bearing gear ring (6) to rotate; The robotic system is arranged adjacent to the workpiece mounting area (1.1); The visual scanning camera (4) can scan and acquire the tooth profile data of the main bearing gear ring (6) and transmit the tooth profile data to the host computer software system (5); The host computer software system (5) can generate upper surface machining template and lower surface machining template according to tooth profile data and transmit them to the PLC control system. The PLC control system is electrically connected to the automatic clamping system (1), the gear ring drive system (2), the robot system (3) and the host computer software system (5). The PLC control system can control the automatic clamping system (1) to adjust the position of the main bearing gear ring (6) for centering, and can also control the gear ring drive system (2) and the robot system (3) to cooperate to perform chamfering on the main bearing gear ring (6) according to the upper surface machining template and lower surface machining template.

2. The equipment for chamfering the gear ring of the tunneling machine main bearing according to claim 1, characterized in that, The automatic clamping system (1) includes at least three clamping mechanisms (1.2), which are arranged radially and uniformly along the same center, and the workpiece mounting area (1.1) is formed at the center where the clamping mechanisms (1.2) meet.

3. The equipment for chamfering the gear ring of the tunneling machine main bearing according to claim 2, characterized in that, The clamping mechanism (1.2) includes a first support trolley (1.2.1), a slide (1.2.2), clamping jaws (1.2.3), and a sliding drive component (1.2.4). The first support trolley (1.2.1) is radially arranged along the center of the workpiece mounting area (1.1). The slide (1.2.2) is slidably mounted on the first support trolley (1.2.1) along the length of the first support trolley (1.2.1). The slide (1.2.2) has two clamping jaws spaced apart along the radial direction of the workpiece mounting area (1.1). The clamping jaws (1.2.3) are arranged in two sets, forming a clamping space for the main bearing gear ring (6) to be installed. The sliding drive (1.2.4) is disposed on the slide (1.2.2). The sliding drive (1.2.4) can drive the slide (1.2.2) to move along the length direction of the first support trolley (1.2.1), and each clamping mechanism (1.2) can cooperate to drive the main bearing gear ring (6) to move so as to achieve the alignment of the main bearing gear ring (6) with the workpiece mounting area (1.1).

4. The equipment for chamfering the gear ring of the tunneling machine main bearing according to claim 3, characterized in that, The gear ring drive system (2) includes a second support trolley (2.1), a movable seat (2.2), a movable drive component, a gear drive component (2.3), and a drive gear (2.4). The second support trolley (2.1) is radially arranged along the center of the workpiece mounting area (1.1). The movable seat (2.2) is slidably arranged on the second support trolley (2.1) along the length direction of the second support trolley (2.1). The movable drive component is arranged on the movable seat (2.2) and can drive the movable seat (2.2) to move along the length direction of the second support. The gear drive component (2.3) is arranged on the movable seat (2.2). The drive gear (2.4) is connected to the output shaft of the gear drive component (2.3) and can mesh with the main bearing gear ring (6).

5. The equipment for chamfering the gear ring of the tunneling machine main bearing according to claim 4, characterized in that, The robot system (3) includes a third support trolley (3.1), a robot body (3.2), a quick-change disc (3.3), and a chamfering tool structure (3.4). The third support trolley (3.1) is radially arranged along the center of the workpiece mounting area (1.1). The robot body (3.2) is slidably mounted on the third support trolley (3.1). The quick-change disc (3.3) is detachably connected to the output shaft of the robot body, and the robot body can grasp the chamfering tool structure (3.4), the drive gear (2.4), and the vision scanning camera (4) respectively through different quick-change discs (3.3).

6. The equipment for chamfering the gear ring of the tunneling machine main bearing according to claim 5, characterized in that, The chamfering tool structure (3.4) includes a spindle and a profiled end mill (3.4.2). The profiled end mill (3.4.2) is connected to the corresponding quick-change disc (3.3) via the spindle. The profiled end mill (3.4.2) has an inner arc cutting edge (A) at one end away from the spindle.

7. The equipment for chamfering the gear ring of a tunneling machine main bearing according to claim 6, characterized in that, The gear chamfering processing equipment for the main bearing gear ring of the tunneling machine also includes a gear storage warehouse (7) and a tool storage warehouse (8). The gear storage warehouse (7) and the tool storage warehouse (8) are respectively located on both sides of the third support trolley (3.1). The gear storage warehouse (7) is used to store different types of drive gears (2.4); the tool storage warehouse (8) is used to store different types of chamfering tool structures (3.4).

8. The equipment for chamfering the gear ring of a tunneling machine main bearing according to any one of claims 1 to 7, characterized in that, The host computer software system (5) is equipped with a template generation program for generating upper surface machining templates and lower surface machining templates, and a chamfer trajectory calculation program for calculating the chamfer trajectory of the main bearing gear ring (6).

9. A method for chamfering the teeth of a tunneling machine main bearing gear ring, comprising using the chamfering machining equipment for the main bearing gear ring (6) as described in claim 8, characterized in that, Includes the following steps: S1: Install the main bearing gear ring and drive gear, specifically: The main bearing gear ring (6) is clamped into the workpiece mounting area (1.1) by the automatic clamping system (1); Select the corresponding drive gear (2.4) according to the model of the main bearing gear ring (6), and use the robot body (3.2) to grab the drive gear (2.4) through the corresponding quick change plate (3.3) and assemble it onto the output shaft of the gear drive component (2.3); S2: The robot body (3.2) uses the corresponding quick-change disk (3.3) to grab the vision scanning camera (4) to scan the main bearing gear ring (6) and obtain the tooth profile data; S3: The host computer software system (5) generates upper surface machining template and lower surface machining template based on tooth profile data according to the template generation program; S4: The robot body (3.2) performs chamfering on the upper and lower surfaces of the main bearing gear ring (6) using the upper surface machining template and the lower surface machining template, respectively.

10. The method for chamfering the gear ring of a tunneling machine main bearing according to claim 9, characterized in that, The main bearing gear ring (6) is clamped into the workpiece mounting area (1.1) by the automatic clamping system (1), including: S1.

1. Hoist the main bearing gear ring (6) to the workpiece installation area (1.1) and place it between the two clamping jaws (1.2.3) set in each clamping mechanism (1.2); S1.2, The sliding drive (1.2.4) drives the slide (1.2.2) to move according to the set chuck load value, so that the clamping chuck (1.2.3) drives the main bearing gear ring (6) to be aligned.

11. The method for chamfering the gear ring of a tunneling machine main bearing according to claim 10, characterized in that, S2 includes: S2.1 The robot body uses the quick-change disk (3.3) to grab the visual scanning camera (4) through the robot language program template and moves the visual scanning camera (4) to the corresponding position of the main bearing gear ring (6); S2.2 Adjust the camera parameters of the visual scanning camera (4) and take the number of teeth of the main bearing gear ring (6) within the scanning range of the visual scanning camera (4) as a unit group; S2.

3. Use a visual scanning camera (4) to scan the main bearing gear ring (6) to obtain the tooth profile data corresponding to the unit group.

12. The method for chamfering the gear ring of a tunneling machine main bearing according to claim 11, characterized in that, S3 includes: S3.1 Optimize the coordinates of each data point in the tooth profile data corresponding to the unit group to obtain the optimized tooth profile data. The optimization process specifically includes: The X-axis and Y-axis coordinates of each data point are filtered using a window mean to obtain the optimized tooth profile data. The specific formula is as follows: ； in, n The order of the filter window; I These are the original data points; g To optimize the data points of the tooth profile data; Sxy To revolve around the center point ( x , y ) range; The average Z-axis coordinate values ​​of the data points are used to obtain the Z-axis coordinate values ​​of each data point in the optimized tooth profile data. The specific formula is as follows: ； in, Size of the window data range; For the first Z-axis coordinate values ​​of each data point; S3.2 Connect the data points of the optimized tooth profile data in sequence to obtain the optimized tooth profile. S3.

3. Convert the optimized gear contour data points and set tooth chamfer template into robot language input template generation program output to obtain the upper surface machining template; S3.

4. Based on the upper surface machining template, the lower surface machining template is obtained by translation of the robot world coordinate system and deflection of the robot tool coordinate system.

13. The method for chamfering the gear ring of a tunneling machine main bearing according to claim 12, characterized in that, S4 includes: S4.1, The host computer software system (5) uses the chamfer trajectory calculation program to calculate the tooth chamfer trajectory of the unit group; S4.2 The PLC control system controls the robot body (3.2) to chamfer each tooth in the unit group according to the tooth chamfering trajectory through the chamfering tool structure (3.4); S4.3, The PLC control system controls the gear drive component (2.3) to drive the main bearing gear ring (6) to rotate to the next unit group and enter the scanning range of the vision scanning camera (4) through the drive gear (2.4); S4.4 Determine whether all teeth of the main bearing gear ring (6) within the current scanning range have been chamfered. If so, complete the chamfering of the teeth of the entire main bearing gear ring (6); otherwise, return to S2.

3.

14. The method for chamfering the gear ring of a tunneling machine main bearing according to claim 13, characterized in that, S4.2 includes: S4.2.

1. Calibrate the chamfer amounts of the upper and lower surfaces of the main bearing gear ring (6) respectively. The chamfer amount of the upper surface includes the Z-axis descent value, X-axis offset value, and Y-axis offset value. The chamfer amount of the lower surface includes the Z-axis ascent value, X-axis offset value, and Y-axis offset value. Specifically: ① Set the adjustment unit value and the initial value of the chamfer amount according to the target chamfer size; ② The robot body operates the chamfering tool structure (3.4) to perform chamfering according to the current chamfering amount; ③ Measure the current chamfer size of the main bearing gear ring (6). If the error between the current chamfer size and the target chamfer size is less than the set error threshold, obtain the calibration value of each chamfer amount; otherwise, adjust each chamfer amount according to the target chamfer size and the adjustment unit value, and then return to step ② until the calibration of the chamfer amount is completed. S4.2.2, The PLC control system controls the robot body (3.2) based on the upper surface machining template and the lower surface machining template to perform chamfering on each tooth in the unit group according to the tooth chamfering trajectory and the chamfering amount of the upper and lower surfaces of the main bearing gear ring (6) calibrated in S4.2.1.

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