Automatic machining line and method for magnetically soft alloy rotary parts

Abstract

The invention belongs to the technical field of numerical control machining of automatic production lines, and discloses an automatic machining line and method for magnetically soft alloy rotary parts, the automatic machining line comprises a truss manipulator, two precise numerical control lathes, a feeding / discharging bin, a turnover mechanism, a cleaning mechanism and a buffering and sampling inspection mechanism, and all the mechanisms are cooperatively controlled by a numerical control system. The machining method comprises the steps of feeding, machining of the non-clamping end through the first numerical control lathe, overturning, buffering and sampling inspection, cleaning, machining of the remaining part through the second numerical control lathe and discharging. In order to solve the problems that the soft magnetic alloy is poor in machining performance and prone to cracks and slag falling, the machining quality and consistency are remarkably improved through multiple measures such as automatic assembly line solidification clamping, machining and detection processes, copper sheet pasting claw clamping injury prevention, tiny cutting output control, online measurement compensation, error proofing program and thin film chuck precise clamping, and the machining efficiency is improved. According to the method, the part qualification rate is controlled to be 99.8% or above, meanwhile, 24-hour continuous production is achieved, the machining efficiency is improved by two times or above, the problem of dependence on high-tech workers is effectively solved, and the requirement for large-batch and high-quality magnetically soft alloy part delivery in the fields of aerospace and the like is met.

Description

Technical Field

[0001] This invention belongs to the field of CNC machining technology for automated production lines, specifically relating to an automated line and method for machining soft magnetic alloy rotary parts, which is particularly suitable for the mass production and high-quality manufacturing of iron-cobalt-vanadium soft magnetic alloy rotary structural parts widely used in the aerospace field. Background Technology

[0002] In the aerospace field, critical components such as servo actuators and solenoid valves extensively utilize rotating structural parts made of iron-cobalt-vanadium soft magnetic alloys with high saturation magnetic induction, such as end caps and moving iron cores. While these materials possess superior magnetic properties, their coarse grains and poor toughness result in extremely poor machinability. During traditional CNC turning, improper clamping force, unreasonable cutting parameters, or tool wear can easily induce defects such as microcracks, chipping, or slag formation on the part's surface. These micro-defects may expand during subsequent use, seriously threatening the reliability and service life of the components.

[0003] Currently, the machining of such parts heavily relies on experienced senior technicians. Operators need to rely on their personal experience to carefully adjust the clamping method, cutting parameters, and tool condition during the machining process to avoid the risk of material cracking. This traditional manual operation mode has the following prominent drawbacks: 1. Unstable quality: The processing quality is highly dependent on the operator's skill level and condition. Process parameters are difficult to standardize, resulting in poor quality consistency between different batches and even different workpieces.

[0004] 2. Prone to damage: During manual clamping, the chuck or gripper may leave scratches on the surface of the part or cause stress concentration, leading to cracks.

[0005] 3. Low efficiency: Manual loading and unloading, measurement, tool changing and other auxiliary processes take a long time and cannot achieve continuous production, making it difficult to meet the large-volume and fast-paced delivery requirements of modern aerospace equipment.

[0006] 4. High costs: The reliance on highly skilled workers drives up labor costs, and the high scrap rate leads to increased material costs.

[0007] Therefore, how to build an automated solution that can stably, efficiently, and with high quality process soft magnetic alloy rotary parts, and fundamentally overcome the dependence on human experience, has become a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0008] This invention addresses the problems of difficult and inefficient machining of soft magnetic alloy rotating parts by proposing an automated machining line and method for such parts. Through the design of a fully automated production line, the optimal process and flow are solidified, minimizing manual intervention, thereby steadily improving machining quality (especially preventing microcracks) and significantly increasing production efficiency to meet the needs of mass production.

[0009] The technical solution of this invention is implemented as follows: In a first aspect, the present invention provides an automated line for processing soft magnetic alloy rotary parts. This automated line is a highly integrated flexible manufacturing unit (FMC), mainly comprising: Gantry robot: As the core of material handling, it is responsible for automatically grabbing, moving and placing parts between various workstations.

[0010] Two precision CNC lathes (Lathe 1 and Lathe 2) are responsible for roughing and finishing the features at both ends of the part, respectively. The two lathes employ different clamping strategies to adapt to different process requirements.

[0011] Loading and unloading hoppers: enable centralized storage and automatic supply / collection of raw materials and finished products.

[0012] Flipping mechanism: It changes the posture of the part after it has been machined on the first lathe, and provides the correct positioning reference for machining on the second lathe.

[0013] Cleaning mechanism (preferably an ultrasonic cleaner): Removes chips and oil residues remaining on the positioning surface of the part after the initial processing, ensuring the accuracy and reliability of the secondary clamping.

[0014] Buffer and sampling inspection mechanism: Located between or after the flipping and cleaning stations, it is used to balance the possible cycle time differences between the two lathes and provide online manual sampling points to achieve quality monitoring without interrupting the main production line.

[0015] The movement and execution commands of all the above-mentioned mechanisms are coordinated and controlled by the central CNC system or the onboard computers of the two lathes through NC programs, forming a complete closed-loop automated machining system. Its standard machining process is fixed as follows: loading → machining on the first CNC lathe (non-clamping end) → flipping → buffering and sampling inspection → cleaning → machining on the second CNC lathe (remaining part) → unloading.

[0016] As a further technical solution of the present invention: the gantry robot is equipped with a 180-degree swing cylinder and two three-jaw grippers, which are used for loading and unloading respectively; the fingers of the grippers are made of steel, and copper sheets are attached to the outer surface used to contact the parts.

[0017] As a further technical solution of the present invention: the flipping mechanism includes a 90-degree rotating cylinder, a workpiece clamping gripper and a material table; the fingers of the workpiece clamping gripper are made of steel, and copper sheets are attached to the outer surface for contacting the parts.

[0018] As a further technical solution of the present invention: the first precision CNC lathe uses a common chuck to clamp parts, and the aluminum top block installed on the lathe turret pushes the parts into the chuck for positioning and clamping; the second precision CNC lathe uses a thin-film chuck to clamp parts, and the spring device on the robotic gripper gently springs the parts into the chuck for positioning and clamping.

[0019] As a further technical solution of the present invention: the automatic line also includes an error prevention control unit, which is configured to: before grooving, detect the actual width of the grooving tool by an in-machine probe and compare it with the preset width range of the tool in the program; if it is not within the preset range, trigger an alarm and interrupt the processing program.

[0020] As a further technical solution of the present invention: the automatic line is also equipped with a spindle blowing device for cleaning the positioning surface of the part before clamping.

[0021] Secondly, the present invention provides an automatic machining method for soft magnetic alloy rotary parts applied to the above-mentioned automated lines, the method comprising the following steps: S1. Automatic feeding and initial clamping: The gantry robot grabs the blank from the feeding bin and transfers it to the first CNC lathe. Before clamping, the spindle is cleaned with air to clean the positioning surfaces. After the robot moves the part to the position of the ordinary chuck, it releases, and the special aluminum top block on the first lathe turret smoothly pushes the part into the chuck and clamps it.

[0022] S2, First-order automated machining: Automatic tool setting using an in-machine tool setter. Machining is performed according to a preset machining program optimized for soft magnetic alloys, with strict control over roughing cutting parameters (e.g., length ≤ 0.1mm / tool, diameter ≤ 0.2mm / tool). During machining, the in-machine probe measures key dimensions in real time and compares them with theoretical values, automatically compensating for tool wear to ensure machining accuracy.

[0023] S3. Automatic Flipping: The robot arm places the part after the first processing into the flipping mechanism. After clamping the part, the flipping mechanism rotates 90 or 180 degrees to change its posture, and then the robot arm takes it out, so that the processed surface becomes the new clamping or positioning reference.

[0024] S4. Buffer and In-Process Sampling Inspection: The robotic arm places the flipped parts into the buffer tray. This balances the production cycle and allows operators to randomly select parts for rapid inspection, achieving process quality control.

[0025] S5. Automatic Cleaning and Drying: The robotic arm picks up the unprocessed parts and feeds them into an ultrasonic cleaner to thoroughly clean the processed surfaces that will serve as the positioning reference for the next step. Immediately after cleaning, the surfaces are dried with clean compressed air to ensure no water stains or residue remain.

[0026] S6. Second-stage precision clamping and machining: The robotic arm transfers the part to the second CNC lathe. It is cleaned again with air blowing before clamping. The second lathe uses a high-precision thin-film chuck, and the part is gently pushed into position by the built-in spring mechanism of the robotic arm gripper, achieving non-destructive, high coaxiality automatic clamping. An airtightness test may be performed after clamping. Subsequently, all remaining features of the part are machined, also using optimized cutting parameters and online measurement compensation technology.

[0027] S7. Automatic unloading: After processing is completed, the robotic arm takes out the finished parts and places them neatly in the unloading bin, completing the entire processing cycle.

[0028] As a further technical solution of the present invention: in the CNC lathe machining process of step S2 and / or step S6, for soft magnetic alloy materials, the single cutting amount in the roughing stage is controlled to be no more than 0.1 mm in the length direction and no more than 0.2 mm in the diameter direction.

[0029] As a further technical solution of the present invention: during the processing of steps S2 and S6, an in-machine tool setter is used for automatic tool setting, and an in-machine probe is used to measure and compare the dimensions of the parts being processed in real time, and tool compensation is automatically performed based on the comparison results.

[0030] As a further technical solution of the present invention: the cleaning in step S5 is ultrasonic cleaning, which aims to remove excess material from the machined positioning surface of the part, and after cleaning, compressed air is used to dry the surface of the part.

[0031] As a further technical solution of the present invention: the clamping process of the part on the second precision CNC lathe in step S6 includes: cleaning the clamping surface by blowing air through the spindle; gently popping the part into the diaphragm chuck by the spring built into the robotic gripper; and after clamping, performing an airtightness test to ensure the reliability and accuracy of clamping and positioning.

[0032] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. Excellent and stable processing quality: Automated equipment (copper sheet gripper, thin-film chuck) eliminates human-caused clamping damage; solidified and optimized small depth of cut and low feed cutting parameters fundamentally avoid material cracking caused by excessive cutting stress; online measurement and automatic compensation ensure consistent dimensional accuracy. Overall, an ultra-high pass rate of over 99.8% is achieved.

[0033] 2. Significantly improved production efficiency: It enables 24-hour uninterrupted "lights-out production". The automated assembly line operation reduces auxiliary time to almost zero, and the overall processing efficiency is more than twice that of traditional manual operation.

[0034] 3. Reduce reliance on highly skilled workers: By embedding valuable processing experience into equipment, programs, and process parameters, the technical requirements for operators on the production line are significantly reduced, solving the bottleneck problem of a shortage of highly skilled workers.

[0035] 4. Intelligent error prevention capability: By integrating error prevention programs such as tool width detection, it can automatically identify tool installation errors before processing to prevent batch quality accidents.

[0036] 5. Flexibility and monitorability: The buffer mechanism enables the production line to have a certain cycle time buffering capacity; the sampling inspection station facilitates the implementation of process quality control, achieving a balance between high quality and high efficiency.

[0037] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the planar layout of the automated processing line according to an embodiment of the present invention.

[0039] Figure 2 This is a flowchart illustrating the overall process of the automatic processing method of the present invention.

[0040] Figure 3 A schematic diagram of a soft magnetic alloy end cap part for applying the present invention.

[0041] Figure 4 A schematic diagram of a soft magnetic alloy moving iron core part for applying the present invention.

[0042] Explanation of the labels in the diagram: 1-Gantry robot; 2-First precision CNC lathe; 3-Second precision CNC lathe; 4-Loading bin; 5-Unloading bin; 6-Tilting mechanism; 7-Cleaning mechanism; 8-Buffer and sampling inspection mechanism. Detailed Implementation

[0043] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of the embodiments of this invention will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The described embodiments are some embodiments of this invention, but not all embodiments.

[0044] The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the invention, and should not be construed as limiting the invention.

[0045] Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of this invention.

[0046] The following is in conjunction with the appendix Figure 1-4 The embodiments of the present invention will be described in detail below.

[0047] Example 1 This invention discloses the machining of 1J22 soft magnetic alloy end cap parts. Reference Figure 1 The automated line in this embodiment is arranged as follows: one side of the line is the loading bin 4, and the other side is the unloading bin 5. In the middle, a first precision CNC lathe 2, a flipping mechanism 6, a buffer and sampling mechanism 8, a cleaning mechanism 7, and a second precision CNC lathe 3 are arranged sequentially. A gantry robot 1 spans the entire line and is responsible for all transfer operations.

[0048] Machining a typical 1J22 end cap part (e.g.) Figure 3 The detailed process (as shown) is as follows: Loading and First-Stage Machining: The gantry robot 1 picks up the blank from the loading bin 4. Its gripper fingers are made of steel, with 0.5mm thick brass sheets attached to the contact surfaces to ensure sufficient clamping force without damaging the soft magnetic alloy surface. The blank is fed into the first lathe 2. After the spindle is pneumatically purged, the aluminum top block on the turret pushes the part into the three-jaw chuck, clamping the maximum outer diameter. Before machining begins, a fault-prevention procedure is executed: the in-machine probe checks the grooving tool width, confirming it is within the range of 0.99-1.1mm before proceeding. Machining parameters are strictly followed: Rough turning of outer diameter / inner hole: speed n=600r / min, feed f=0.05mm / r, depth of cut (diameter) ≤0.2mm; End face: n=300r / min, f=0.03mm / r. Finishing parameters are similar, but the depth of cut is halved. During machining, the probe automatically checks the inner hole diameter every 10 pieces processed and performs compensation.

[0049] Flipping and Buffering: After the first step is completed, the robot arm places the part into the flipping mechanism 6. The grippers of the flipping mechanism are also fitted with copper sheets. After clamping the part, they rotate 180° so that the machined inner hole and end face face outward. The robot arm removes the part and places it on the tray of the buffering and sampling mechanism 8. At this time, the quality inspector can use go / no-go gauges to sample and check the dimensions of the machined inner hole.

[0050] Cleaning and Second-Stage Machining: The robotic arm grasps the unmachined outer diameter of the part and places it into an ultrasonic cleaner 7. The machined inner hole and end face are cleaned for 2 minutes and then dried. It is then fed into the second lathe 3. Before clamping, the spindle is purged with air. The robotic arm's springs gently spring the part into a pre-opened diaphragm chuck. After the chuck retracts, it precisely clamps the finished outer diameter. An airtightness test is performed to ensure proper clamping. Then, the threads, grooves, and other features on the other end of the part are machined. The roughing parameters are the same as in the first stage, and the finishing process ensures the final dimensions.

[0051] Material unloading: After all processing is completed, the robotic arm puts the finished product into the finished product tray in the unloading bin 5.

[0052] Example 2 This invention discloses the machining of 1J22 soft magnetic alloy moving iron core parts. For example Figure 4 The moving iron core part shown has a similar machining process to the end cover, following the same procedure. Figure 2 The general process is shown. The main difference lies in the specific machining features and dimensions. For example, in the first machining sequence, the first lathe 2 needs to complete all internal and external diameter machining except for a small diameter hole (such as a Φ7 hole). On the second lathe 3, the small diameter hole, end face groove, and final finish turning are mainly completed. All damage prevention measures (copper sheeting, air blowing cleaning, spring-pull clamping, small depth of cut) and quality control measures (online measurement, buffer sampling inspection) are applied in the same way.

[0053] System Control and Variations: In the system of this invention, the onboard computers of two CNC lathes can form a distributed control system. Each computer can control the actions of the robotic arm at its nearest workstation. When commands conflict, the system follows a "first-come, first-served" queue principle. Those skilled in the art can adjust the relative positions of the flipping mechanism 6, the cleaning mechanism 7, and the buffer mechanism 8 according to the actual workshop space and specific product processes, for example, placing the cleaning mechanism before the buffer mechanism. This does not depart from the core idea of ​​this invention to achieve automated high-quality processing through a fixed process.

[0054] In summary, this invention provides a complete, reliable, and efficient automated solution for brittle and difficult-to-machine soft magnetic alloy rotating parts through the deep integration of hardware (automatic line) and software (method, parameters, program), and has extremely high industrial application value.

[0055] Example 3 like Figure 1As shown, the 1J22 soft magnetic alloy rotary parts processing automatic line may include: a gantry robot, two precision CNC lathes, loading / unloading bins, a tilting mechanism, a cleaning mechanism, a buffer and sampling mechanism. The motion execution commands of each mechanism are controlled by the on-board computers of the two precision CNC lathes through NC programs. Each on-board computer can independently issue control commands. When the same mechanism receives multiple operation commands, it completes the actions in the order of receipt.

[0056] In some embodiments, the upper and lower hoppers are separate and located on opposite sides of the automated line.

[0057] This invention proposes an automated line machining method for 1J22 soft magnetic alloy end cap parts, which may include the following steps: S1, the gantry moves to the top of the loading bin, and the robotic arm sequentially grabs the outer diameter of the parts to be processed in the bin. The robotic arm includes a 180-degree swing cylinder and two three-jaw grippers, one for loading and one for unloading. The grippers grab the outer diameter of the parts, and the gripper fingers are made of steel with copper sheets attached to the contact surface with the parts to prevent damage to the surface of the soft magnetic alloy parts. Then it moves to the top of the first precision CNC lathe, the CNC lathe opens the upper protective door, and the robotic arm extends into the CNC lathe 1 to send the parts to the chuck of the CNC lathe.

[0058] S2, the spindle blows air to keep the surface of the clamping and positioning surface clean. The robot releases its gripper and pushes the part into the chuck through the aluminum top block device installed on the turret. Then the chuck clamps the maximum outer diameter of the part.

[0059] Automatic tool setting is performed using an in-machine tool setter. Then, the non-clamping end features of the end cap part are machined. To prevent excessive turning stress on the part surface from causing cracking and slag shedding of the soft magnetic alloy material, the depth of cut and removal amount of each cut must be controlled. At the same time, the tool life must be closely monitored during roughing and finishing.

[0060] S21, rough machining of the outer diameter. To save tooling costs, the cutting inserts used for finishing can be used to remove the machining allowance in the end face and outer diameter direction of the end cap. The depth of cut per cut in the length direction is about 0.1 mm, and the depth of cut per cut in the diameter direction is about 0.2 mm.

[0061] When machining the outer diameter and inner hole, the machine tool speed n=600r / min and the feed rate f=0.05mm / r. When machining the end face, the machine tool speed n=300r / min and the feed rate f=0.03mm / r. Since 1J22 soft magnetic alloy is prone to cracking and slag shedding after heat treatment, the machine tool speed and feed rate for rough machining are selected with reference to the finishing parameters and are the same as the finishing parameters.

[0062] S22, rough machining of the inner hole, removing the excess material from the inner hole of the end cap, with a cutting depth of approximately 0.2mm per cut in the diameter direction.

[0063] S23, rough cut the outer groove, using a 1.5mm wide grooving tool, remove it in two steps along the groove depth direction.

[0064] S24, finish machining of the outer diameter to dimension, with a depth of cut of approximately 0.05 mm per cut in the length direction and approximately 0.1 mm per cut in the diameter direction. When turning the outer diameter, the machine tool speed is n=600 r / min and the feed rate is f=0.05 mm / r. When flattening the end face, the machine tool speed is n=300 r / min and the feed rate is f=0.03 mm / r.

[0065] S25, precision-cut outer groove, precision-machined end faces of the outer groove, groove opening, and groove bottom rounded corners, with a groove bottom removal rate of approximately 0.08mm. The groove end face is about 0.15mm, the rotation speed is selected as n=600r / min, and the feed rate is f=0.05mm / r.

[0066] S26, precision boring, the amount of material removed in the direction of the inner diameter is about 0.05mm.

[0067] S27, clear the roots, ensuring the root radius R0.1max.

[0068] During machining, an in-machine probe is used to measure the dimensions of the parts, enabling real-time automatic tool compensation. Simultaneously, the tool change frequency is fixed based on the part characteristics to prevent machining cracks in soft magnetic alloy parts caused by tool dulling.

[0069] In some embodiments, if the accuracy of the in-machine tool setter is greater than 0.02mm and the tool setting does not meet the requirements for subsequent precision machining, an in-machine probe can be used to compare and measure the machining dimensions of the part during the machining process to achieve automatic tool compensation.

[0070] In some embodiments, different machined parts contain annular groove features of different sizes. To prevent incorrect or confused installation of the grooving tool in the turret, a CNC machining error-proofing program is added before grooving. The positions of the left and right edges of the grooving tool are obtained through an in-machine probe, the tool width is calculated, and the tool width is compared with the preset tool width range of the program. Only if it meets the preset range can the subsequent grooving program be executed; otherwise, an alarm is triggered. The following is an illustrative program compiled according to this process on the SIMENS CNC system: % L920 RENTL="CAO1.0" R11=4 L925 R191=ABS($TC_DP[13,1]) G0 G53 X0 Z0 T="CAO1.0" G507G0X86.Z5. M56 G4F2. STOPRE M57 G54 D1 L920 RENTL="CAO1.0" R11=3 L925 G0 G53 X0 Z0 R192=ABS($TS_DP4[13,1]) R190 = ABS(R191 + R192) IF R190>1.1 MSG(“Incorrect blade width”) STOPRE M0 ENDIF IF R190<0.999 MSG(“Incorrect blade width”) STOPRE M0 ENDIF % After the first precision CNC lathe machining is completed (S3), the robotic arm picks up the part and places it into the flipping mechanism. The flipping mechanism consists of a 90-degree rotating cylinder, a three-finger workpiece clamping gripper, and a worktable. Similar to the robotic arm's gripper, the gripper fingers are made of steel, with copper sheets attached to their contact surfaces with the workpiece. The robotic arm places the workpiece onto the flipping table, the rotating cylinder rotates downwards, and once in position, the workpiece clamping gripper grasps it. The rotating cylinder then rotates upwards, and the robotic arm picks up the part from the workpiece clamping gripper, achieving a change in the workpiece's posture between machining processes. This flipping mechanism transforms the workpiece's posture from the previously machined state to the posture required for the next machining process, effectively flipping the workpiece and acting as an intermediate bridge.

[0071] S4: Pick up parts and place them in the buffer and sampling inspection area. The buffer and sampling inspection mechanism consists of a material tray and an infrared detection device, located next to the cleaning mechanism. The material tray in the buffer area can be used to balance the cycle time of different batches of parts on two precision CNC lathes. The infrared detection device is used to identify the position and number of parts placed in the sampling inspection area. Parts on the buffer material tray can be randomly manually inspected to monitor the processing quality of the parts.

[0072] S5: The unmachined outer surface of the part is picked up and sent to the cleaning mechanism, which is an ultrasonic cleaner. This ultrasonically cleans the part surface, removing excess material from the machined surface that will serve as the positioning surface in subsequent processes. This prevents scratches and misalignment during clamping caused by the presence of excess material. After cleaning, the part is air-dried to ensure no water stains remain on its surface.

[0073] In some embodiments, the order of the flipping mechanism, cleaning mechanism, buffer and sampling area may vary and can be arranged reasonably according to processing requirements and site limitations.

[0074] S6, the robotic arm picks up the part and moves it above the second precision CNC lathe. The CNC lathe opens its upper protective door, and the robotic arm delivers the part to be processed to the machine tool chuck. The second precision CNC lathe uses a diaphragm chuck to meet the coaxiality and perpendicularity requirements of both ends of the part after it is turned around, without damaging the already machined surfaces. Excess material on the clamping surface is cleaned by air blowing from the spindle. Then, a spring built into the robotic gripper springs the part into the diaphragm chuck and clamps its outer diameter. The spindle then continues air blowing while performing an airtightness test to ensure reliable and accurate automatic clamping and positioning. The second precision CNC lathe then processes the remaining dimensions.

[0075] S61, rough machining of the outer diameter, using the cutting tool used for finishing to remove the machining allowance in the end face and outer diameter direction of the end cap, wherein the depth of cut per cut in the length direction is about 0.1mm and the depth of cut per cut in the diameter direction is about 0.2mm.

[0076] When roughing the outer diameter and inner hole, the machine tool speed is n=600r / min and the feed rate is f=0.05mm / r. When flattening the end face, the machine tool speed is n=300r / min and the feed rate is f=0.03mm / r.

[0077] S62, rough machining of the inner hole, removing the excess material from the inner hole of the end cap, with a cutting depth of approximately 0.2mm per cut in the diameter direction.

[0078] S63, semi-finished internal hole, with a cutting depth of approximately 0.05 mm per cut in the length direction and approximately 0.1 mm per cut in the diameter direction. It is the same tool used for the subsequent finishing of the internal hole.

[0079] S64, cut the inner groove, use a comma-shaped cutter to machine the inner groove to the required dimensions.

[0080] S65, finishing the outer diameter to dimension, with a depth of cut of approximately 0.05 mm per cut in the length direction and approximately 0.1 mm per cut in the diameter direction. When turning the outer diameter, the machine tool speed n = 600 r / min and the feed rate f = 0.05 mm / r. When flattening the end face, the machine tool speed n = 300 r / min and the feed rate f = 0.03 mm / r.

[0081] S65, finish machining of the inner hole to size, with a depth of cut of approximately 0.03 mm per cut in the length direction and approximately 0.1 mm per cut in the diameter direction. The rotation speed is selected as n=600 r / min, and the feed rate is f=0.05 mm / r.

[0082] S66, clear the roots, ensuring the root radius R0.1max.

[0083] S7. After processing is completed, the robotic arm picks up the parts and places them on the unloading tray.

[0084] In another embodiment, an automated line machining method for 1J22 soft magnetic alloy moving iron core parts is proposed. The machining process is similar to that for end cap parts, and the machining method may include the following steps: S1, the gantry moves to the top of the loading bin, the robot grabs the outer diameter of the parts to be processed in the bin in sequence, and then moves to the first precision CNC lathe to send the parts to the CNC lathe chuck.

[0085] S2: Spindle air blowing keeps the surface of the clamping and positioning surface clean. The robot releases its gripper, and the part is pushed into the chuck by the aluminum top block device mounted on the turret. The chuck then clamps the outer diameter of the part. Automatic tool setting is performed using an in-machine tool setter. S21, rough machining of the outer diameter, using the cutting tool used for finishing to remove the machining allowance in the direction of the moving iron core end face and the outer diameter, where the depth of cut per cut in the length direction is approximately 0.1 mm and the depth of cut per cut in the diameter direction is approximately 0.2 mm. When rough machining the outer diameter and inner hole, the machine tool speed is n=600 r / min and the feed rate is f=0.05 mm / r.

[0086] S22, rough machining of the inner hole, removing the excess material in the inner hole, with a cutting depth of approximately 0.2mm per cut in the diameter direction.

[0087] S23, finish machining of internal holes, except for Φ7 hole, all other internal holes and tapers to size, with a cutting depth of about 0.05mm per cut in the length direction and about 0.1mm per cut in the diameter direction. When turning the external cylindrical part, the machine tool speed n=600r / min and the feed rate f=0.05mm / r.

[0088] S24, finish machining the outer diameter to size, with a cutting depth of approximately 0.05 mm per cut in the length direction and approximately 0.1 mm per cut in the diameter direction. The machine tool speed is n = 600 r / min and the feed rate is f = 0.05 mm / r when turning the outer diameter.

[0089] S25, clean the roots, ensuring root R0.1max.

[0090] During machining, an in-machine probe is used to measure the dimensions of the parts, enabling real-time automatic tool compensation. Simultaneously, the tool change frequency is fixed based on the part characteristics to prevent machining cracks in soft magnetic alloy parts caused by tool dulling.

[0091] S3, after the first precision CNC lathe finishes machining, the robot arm grabs the outer circle of the workpiece and puts it into the flipping mechanism to realize the workpiece rotation.

[0092] S4 picks up parts and places them in the buffer and sampling inspection area, balancing the cycle time of different batches of parts on two precision CNC lathes. At the same time, random manual sampling can be performed on the buffer tray to monitor the processing quality of the parts.

[0093] S5: Grab the unprocessed outer cylindrical surface and send it to the cleaning mechanism for ultrasonic cleaning. This removes excess material from the processed surface, which will serve as the positioning surface in subsequent processes. This prevents scratches on the part surface and misalignment during clamping due to the presence of excess material. After cleaning, air is blown to dry the part surface to ensure it is free of water stains.

[0094] S6, the robotic arm grasps the outer diameter of the part and moves it to the second precision CNC lathe. The robotic arm then delivers the part to be processed to the machine tool chuck. Excess material on the clamping surface is cleaned by air blowing from the spindle. Subsequently, a spring built into the robotic gripper springs the part into the diaphragm chuck and clamps the outer diameter. The spindle then continues air blowing while simultaneously performing an airtightness test. The second precision CNC lathe then processes the remaining dimensions.

[0095] S61, rough machining of the outer diameter, using the cutting tool used for finishing to remove the machining allowance in the direction of the moving iron core end face and the outer diameter, wherein the depth of cut per cut in the length direction is about 0.1mm and the depth of cut per cut in the diameter direction is about 0.2mm.

[0096] S62, rough machining of the inner hole, removing the inner hole allowance, with a cutting depth of approximately 0.2mm per cut in the diameter direction.

[0097] S63, finish machining of the inner hole to size, with a cutting depth of approximately 0.05 mm per cut in the length direction and approximately 0.1 mm per cut in the diameter direction. When turning the outer diameter, the machine tool speed is n=600 r / min and the feed rate is f=0.05 mm / r.

[0098] S64, finish machining the outer diameter to size, with a cutting depth of approximately 0.05 mm per cut in the length direction and approximately 0.1 mm per cut in the diameter direction. The machine tool speed is n = 600 r / min and the feed rate is f = 0.05 mm / r when turning the outer diameter.

[0099] S65, clear the roots, ensuring the root radius R0.1max.

[0100] S7. After processing is completed, the robotic arm picks up the parts and places them on the unloading tray.

[0101] Example 4 This invention discloses an automated processing line for rotating soft magnetic alloy parts, including a gantry robot, two precision CNC lathes, loading / unloading bins, a flipping mechanism, a cleaning mechanism, a buffer and sampling mechanism. The motion execution commands of each mechanism are controlled by the onboard computers of the two precision CNC lathes through NC programs. Each onboard computer can independently issue control commands. When the same mechanism receives multiple operation commands, it completes the actions in the order of receipt.

[0102] The processing flow is as follows: loading - CNC lathe - flipping - buffering and sampling inspection - cleaning - CNC lathe - unloading.

[0103] The robotic arm consists of a 180-degree swing cylinder and two three-jaw grippers. The gripper fingers are made of steel, and copper sheets are attached to the contact surfaces with the parts to prevent damage to the soft magnetic alloy parts.

[0104] The flipping mechanism consists of a 90-degree rotating cylinder, a workpiece clamping gripper, and a material table. The gripper fingers are also made of steel, and copper sheets are attached to the contact surface with the workpiece.

[0105] Before machining on a CNC lathe, remove excess material from the clamping surface by blowing air through the spindle. The first precision CNC lathe uses a common chuck for clamping parts. During clamping, the aluminum top block of the turret on the machine tool pushes the part into the chuck. The second precision CNC lathe uses a membrane chuck to clamp parts. During clamping, the springs on the mechanical jaws gently spring the parts into the chuck, ensuring the coaxiality and perpendicularity requirements of both ends after the parts are turned over, without damaging the already machined surfaces.

[0106] To prevent excessive machining stress on the surface of the parts from causing cracking and slag shedding of the soft magnetic alloy material, the amount of material removed per cut in the length direction during rough machining on a CNC lathe should not exceed 0.1 mm, and the amount of material removed per cut in the diameter direction should not exceed 0.2 mm.

[0107] When machining different parts containing annular grooves of different sizes on a CNC lathe, a CNC machining error prevention program is added before grooving to prevent incorrect or confused installation of the grooving tool type in the turret.

[0108] This invention proposes an automated machining method for soft magnetic alloy rotary parts, used in the aforementioned automated machining line. The machining method includes the following steps: The truss moves to the top of the loading bin, and the robotic arm grabs the parts to be processed in the bin in sequence. Then it moves to the top of the first precision CNC lathe. The CNC lathe opens the upper protective door and sends the parts to the chuck of the CNC lathe. The parts are pushed into the chuck by the clamping device installed on the turret, and then the chuck is locked.

[0109] Automatic tool setting is performed using an in-machine tool setting instrument. Then, all dimensions of the non-clamping end of the rotating body are machined. During this process, an in-machine probe is used to compare and measure the machined dimensions of the part, achieving real-time automatic tool compensation.

[0110] After the first precision CNC lathe finishes machining, the part is picked up and placed into the flipping mechanism, and then placed into the buffer and sampling inspection area. This can be used to balance the cycle time of different batches of parts on two precision CNC lathes. At the same time, random manual sampling can be performed on the buffer tray to monitor the machining quality of the parts.

[0111] The robotic arm picks up the unprocessed surface and sends it to the cleaning unit for ultrasonic cleaning to remove excess material from the processed surface, which will serve as the positioning surface for subsequent processes. After cleaning, the surface of the part is air-dried to ensure that there are no water stains.

[0112] The robotic arm sequentially picks up parts from the buffer tray and moves them above the second precision CNC lathe. The CNC lathe opens its upper protective door, and the robotic arm uses a spring to eject the parts into the machine tool's diaphragm chuck, ensuring reliable and accurate automatic clamping and positioning. The second precision CNC lathe then processes the remaining dimensions.

[0113] After processing is completed, the robotic arm picks up the parts and places them on the unloading tray.

[0114] Using this method to process soft magnetic alloy rotating parts, the automated line can operate continuously around the clock, increasing processing efficiency by more than 2 times. At the same time, it avoids the problem of cracks in soft magnetic alloy materials caused by differences in human operating experience and skill level, and the part qualification rate can be controlled at over 99.8%.

[0115] Thus, the objective of this invention has been achieved.

[0116] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automated processing line for rotating soft magnetic alloy parts, characterized in that, include: Gantry robots are used to transfer parts between different workstations on an automated production line. The first and second precision CNC lathes are used for roughing and finishing parts; The loading bin and unloading bin are used to store parts to be processed and parts that have been processed, respectively; A flipping mechanism, located after the first precision CNC lathe, is used to change the machining posture of the part; A cleaning unit is used to clean the parts that have completed the first machining on the lathe. A buffer and sampling inspection mechanism is provided between or after the flipping mechanism and the cleaning mechanism to temporarily store parts and provide them for manual sampling inspection. The gantry robot, the first precision CNC lathe, the second precision CNC lathe, the flipping mechanism, the cleaning mechanism, and the buffer and sampling mechanism are controlled by the CNC system and work together to realize the automatic flow of parts from loading to unloading. The processing flow is as follows: loading → machining on the first CNC lathe → flipping → buffer and sampling → cleaning → machining on the second CNC lathe → unloading.

2. The automated processing line for soft magnetic alloy rotary parts according to claim 1, characterized in that, The gantry robot is equipped with a 180-degree swing cylinder and two three-jaw grippers, which are used for loading and unloading respectively; the fingers of the grippers are made of steel and copper sheets are attached to the outer surface of the parts they contact.

3. The automated processing line for soft magnetic alloy rotary parts according to claim 1, characterized in that, The flipping mechanism includes a 90-degree rotating cylinder, a workpiece clamping gripper, and a material table; the fingers of the workpiece clamping gripper are made of steel, and copper sheets are attached to the outer surface used to contact the parts.

4. The automated machining line for soft magnetic alloy rotary parts according to claim 1, characterized in that, The first precision CNC lathe uses a conventional chuck to clamp parts, and an aluminum top block mounted on the lathe turret pushes the parts into the chuck for positioning and clamping. The second precision CNC lathe uses a diaphragm chuck to clamp parts, and a spring device on the robotic gripper gently springs the parts into the chuck for positioning and clamping.

5. The automated machining line for soft magnetic alloy rotary parts according to claim 1, characterized in that, The automated line also includes a fault prevention control unit, which is configured to: detect the actual width of the grooving tool by an in-machine probe before grooving and compare it with the preset width range of the program; if it is not within the preset range, trigger an alarm and interrupt the processing program.

6. The automated processing line for soft magnetic alloy rotary parts according to any one of claims 1-5, characterized in that, The automated line is also equipped with a spindle air blowing device for cleaning the positioning surfaces of parts before they are clamped.

7. A method for machining soft magnetic alloy rotary parts based on an automated machining line according to any one of claims 1-6, characterized in that, Includes the following steps: S1: The gantry robot grabs the parts to be processed from the loading bin and transfers them to the first precision CNC lathe; S2: The first precision CNC lathe performs the initial machining on the non-clamping end of the part; S3: The gantry robot moves the part after the first processing to the flipping mechanism for attitude conversion; S4: The flipped parts are transferred to the buffer and sampling inspection mechanism for temporary storage, where quality sampling inspection can be carried out. S5: The gantry robot moves the parts from the buffer and sampling mechanism to the cleaning mechanism for cleaning and drying; S6: The gantry robot transfers the cleaned parts to the second precision CNC lathe; S7: The second precision CNC lathe performs secondary machining on the remaining parts of the part to complete all turning features; S8: The gantry robot moves the processed parts to the unloading bin.

8. The method for machining soft magnetic alloy rotary parts on an automated machining line according to claim 7, characterized in that, In the CNC lathe machining process of step S2 and / or step S7, for soft magnetic alloy materials, the single cutting amount in the roughing stage is controlled to be no more than 0.1 mm in the length direction and no more than 0.2 mm in the diameter direction.

9. The method for machining soft magnetic alloy rotary parts on an automated machining line according to claim 7, characterized in that, During the machining processes in steps S2 and S7, an in-machine tool setter is used for automatic tool setting, and an in-machine probe is used to measure and compare the dimensions of the parts being machined in real time. Tool compensation is automatically performed based on the comparison results.

10. The method for machining soft magnetic alloy rotary parts on an automated machining line according to claim 7, characterized in that, The cleaning in step S5 is ultrasonic cleaning, which aims to remove excess material from the machined positioning surface of the part. After cleaning, compressed air is used to dry the surface of the part. The clamping process of the part on the second precision CNC lathe in step S6 includes: cleaning the clamping surface by blowing air through the spindle; gently flicking the part into the diaphragm chuck by the spring built into the robotic gripper; and after clamping, performing an airtightness test to ensure the reliability and accuracy of the clamping and positioning.

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