Large-scale automatic lifting material feeding and taking furnace charging car and control method thereof

Abstract

The invention discloses a large automatic lifting feeding and taking charging car and a control method thereof.The charging car comprises a bottom skip car, an operation platform and a material platform are arranged on the bottom skip car, a control box is arranged on the operation platform, the control box is in signal connection with an upper computer, the operation platform is located at one end of the material platform, and the material platform is located at the other end of the material platform. The material platform comprises an upper lifting skip car, an up-down lifting mechanism and a left-right translation mechanism, the upper lifting skip car is installed on the bottom skip car through the up-down lifting mechanism and the left-right translation mechanism so as to achieve up-down lifting and front-back translation movement of the bottom skip car, and the method comprises the steps of task receiving and global planning; taking the materials; according to the invention, intrinsic safety is realized, the risk of high-risk manual operation is completely eradicated, the operation efficiency is greatly improved, high precision and strong self-adaptive capability are achieved, and the charging quality is guaranteed.

Description

Technical Field

[0001] This invention relates to the field of advanced manufacturing and automation, specifically to a large-scale automatic lifting and loading furnace car and its control method. Background Technology

[0002] In heat treatment and heavy manufacturing, loading large, heavy workpieces (such as large titanium alloy components) into a high-temperature vacuum annealing furnace is a critical and high-risk process.

[0003] Currently, the commonly used operating methods mainly have the following problems and defects: 1. Manual labor is inefficient and extremely dangerous: Traditional methods rely on operators driving overhead cranes or ordinary forklifts, working in coordination with ground control personnel. This model requires a large workforce, involves numerous coordination steps, and has a long operation cycle, severely restricting production pace.

[0004] Operators are required to be extremely close to the high-temperature furnace opening, facing serious occupational health threats such as burns, high-temperature radiation, and harmful gases. Furthermore, heavy workpieces pose a risk of slipping or impact during hoisting, creating significant hazards to personnel and equipment safety.

[0005] 2. Existing semi-automated equipment has poor versatility: Some factories use simple, fixed loading machines or rail-mounted feeding carts. These devices are extremely inflexible, typically only serving fixed workstations and handling materials of fixed specifications, and cannot adapt to the production needs of diverse and variable-sized workpieces. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention proposes a large-scale automatic lifting and loading furnace trolley and its control method. This not only achieves inherent safety and completely eliminates the risks of high-risk manual operations, but also significantly improves operational efficiency, possesses high precision and strong adaptability, and ensures furnace loading quality.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A large automatic lifting and loading furnace trolley is characterized by comprising a bottom material trolley, on which an operating platform and a material platform are provided. A control box is provided on the operating platform, and the control box is connected to a host computer via a signal. The operating platform is located at one end of the material platform. The material platform includes an upper lifting material trolley, an up-and-down lifting mechanism, and a left-and-right translation mechanism. The upper lifting material trolley is mounted on the bottom material trolley via the up-and-down lifting mechanism and the left-and-right translation mechanism to realize the up-and-down lifting and forward-and-backward translation of the upper lifting material trolley.

[0008] As a preferred embodiment of the present invention, a guardrail is also provided on the side of the operating platform.

[0009] As a preferred technical solution of the present invention: the lifting mechanism includes a screw jack, a first planetary reducer, and a lifting drive servo motor. The lifting drive servo motor is connected to the first planetary reducer, and the first planetary reducer is connected to the screw jack. The screw jack is installed below the upper lifting material trolley. The left and right translation mechanism includes a translation drive motor, a second planetary reducer, and a first transmission gear. The translation drive motor is connected to the second planetary reducer. A transmission rod is installed on the second planetary reducer. The first transmission gear is installed on the transmission rod. The upper lifting material trolley is provided with a first tooth groove, and the first transmission gear meshes with the first tooth groove.

[0010] As a preferred technical solution of the present invention: a second left and right translation mechanism is provided on the bottom material cart. The second left and right translation mechanism includes a translation plate, a material cart drive motor, a third planetary reducer and a second transmission gear. The translation plate is fixed at the bottom center position of the bottom of the bottom material cart and is provided with a second tooth groove. The material cart drive motor is connected to the third planetary reducer. The second transmission gear is installed on the output shaft of the third planetary reducer and meshes with the second tooth groove.

[0011] As a preferred embodiment of the present invention, rollers are installed below the bottom material cart.

[0012] A control method for a large-scale automatic lifting and loading furnace car, characterized by the following steps: S1. Task reception and global planning; S2, Material Retrieval; S3, Material transfer and furnace mouth alignment; S4. Automatic loading and placement of the furnace.

[0013] As a preferred technical solution of the present invention, step S1 is specifically as follows: S11. Instruction Issuance: The factory's manufacturing execution system generates specific furnace loading task instructions based on the production plan, including material ID, target furnace number, and process requirements, and sends them to the control box of the furnace loading car. S12, Path Planning: The loading car plans its route from the current parking position to the material collection point and then to the target furnace opening, according to the loading task instructions.

[0014] As a preferred technical solution of the present invention, step S2 is specifically as follows: S21, Manual Driving: Once the vehicle starts, it autonomously travels along the planned path using sensors on the loading car. The control box compares the actual position of the loading car with the planned path in real time and adjusts the speed and direction of the loading car's drive wheels through the motion controller. S22, Placement Decision: After the charging car identifies the precise location, center point, and orientation of the material, it manually sends a message to the control box via a button. The control box then uploads the information to the host computer, which formulates a placement strategy and then retrieves the material.

[0015] As a preferred technical solution of the present invention, step S3 is as follows: S31. Cargo movement: The upper lifting material cart carries the material and travels safely along the planned path to the designated position in front of the industrial furnace; S32. Furnace opening alignment: Align the material with the guide rails inside the furnace.

[0016] As a preferred technical solution of the present invention, step S4 is specifically as follows: S41. Synchronous loading: Under servo control, the lifting mechanism raises or lowers the material to a height that matches the bottom plate of the furnace. Through the first left and right translation mechanism and the second left and right translation mechanism on the bottom material cart, the material is delivered to the picking range of the picking arm. The picking arm delivers the material smoothly and at a uniform speed into the designated position in the furnace according to the preset anti-collision trajectory. S42. Placement and Release: After confirming that the materials have been placed in place, the loading car safely exits the furnace.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. Achieve inherent safety and completely eliminate the risks of high-risk manual operations: This invention achieves a fundamental shift from "people approaching the furnace opening" to "people moving away from the furnace opening while the equipment operates automatically." Operators no longer need to enter high-temperature, high-risk areas, completely eliminating the direct personal safety risks of burns, radiation damage, and lifting heavy workpieces, meeting the highest safety standards for industrial production.

[0018] 2. Significantly improves work efficiency: It significantly shortens the material turnover cycle and improves overall production efficiency.

[0019] 3. Possesses high precision and strong self-adaptive capabilities, ensuring furnace charging quality: By integrating high-precision positioning and motion control technologies, it can achieve high-precision alignment, ensuring that the workpiece is put into the furnace smoothly and accurately, avoiding collisions and damage to the furnace chamber, and improving heating uniformity and product quality. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is the front view of the present invention; Figure 3This is a top view of the present invention; Figure 4 This is a side view of the present invention; Figure 5 This is a bottom view of the present invention.

[0021] List of reference numerals in the attached diagram: 1. Operating platform; 2. Guardrail; 3. Control box; 4. Bottom material cart; 5. Upper lifting material cart; 6. Up and down lifting mechanism; 61. Lifting drive servo motor; 62. Screw jack; 7. First left and right translation mechanism; 71. Translation drive motor; 72. Transmission rod; 73. First transmission gear; 74. First tooth groove; 8. Roller; 9. Material cart drive motor; 10. Translation plate; 11. Second tooth groove; 12. Second transmission gear. Detailed Implementation

[0022] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments: like Figure 1-5 As shown, the large-scale automatic lifting and loading furnace trolley proposed in this invention includes a bottom material trolley 4, on which an operating platform 1 and a material platform are mounted. A control box 3 is mounted on the operating platform 1 and is connected to a host computer via signals. The operating platform 1 is located at one end of the material platform. The material platform includes an upper lifting material trolley 5, a vertical lifting mechanism 6, and a horizontal translation mechanism. The upper lifting material trolley 5 is mounted on the bottom material trolley 4 via the vertical lifting mechanism 6 and the horizontal translation mechanism to realize the vertical lifting and horizontal movement of the upper lifting material trolley 5. A guardrail 2 is also provided on the side of the operating platform 1. The vertical lifting mechanism 6 includes a screw jack 62, a first planetary reducer, and a lifting drive servo motor 61. The lifting drive servo motor 61 is connected to the first planetary reducer, and the first planetary reducer is connected to the screw jack 62. The screw jack 62 is installed below the upper lifting trolley 5. The horizontal translation mechanism includes a translation drive motor 71, a second planetary reducer, and a first transmission gear 73. The translation drive motor 71 is connected to the second planetary reducer. A transmission rod 72 is installed on the second planetary reducer, and the first transmission gear 73 is installed on the transmission rod 72. The upper lifting trolley 5 is provided with a first tooth groove 74, and the first transmission gear 73 meshes with the first tooth groove 74. The bottom material cart 4 is equipped with a second left-right translation mechanism, which includes a translation plate 10, a material cart drive motor 9, a third planetary reducer, and a second transmission gear 12. The translation plate 10 is fixed at the bottom center of the bottom of the bottom material cart 4 and has a second toothed groove 11. The material cart drive motor 9 is connected to the third planetary reducer, and the second transmission gear 12 is mounted on the output shaft of the third planetary reducer, meshing with the second toothed groove 11. Rollers 8 are installed below the bottom material cart 4.

[0023] Specifically: Lifting mechanism 6: 1. Model of lifting drive servo motor 61 and controller: Servo drive: SV630NT012I; Lifting drive servo motor 61: MS1H3-29C15CD-T334R; PLC controller: Easy-521 0808TN.

[0024] 2. The model of the first planetary reducer is AB-180-L1, and the speed ratio is 4.

[0025] 3. Screw jack model 62: JWM025-UM-6-60-FZ, speed ratio is 6.

[0026] 4. Overview: Sixteen lifting drive servo motors 61 are set up. The sixteen lifting drive servo motors 61 run synchronously at a speed of 1440 r / min. After being reduced by the first planetary reducer, they meet the operating speed of the screw jack 62 of 300 mm / min. Every three screw jacks 62 are connected in series and a top plate is installed to bear a weight of 1.5 tons. The eight groups bear a total weight of 24 tons.

[0027] To improve the service life of the lead screw lifting machine, the worm gear is made of high wear-resistant tin bronze, and the worm material is changed to hardened tooth surface with a hardness of HRC58-62. In addition to precise synchronous control of the lifting drive servo motor 61 and the first planetary reducer, all mounting surfaces are simultaneously milled to ensure installation accuracy.

[0028] Left and right translation mechanism: 1. Model of the second planetary reducer: K97R57-Y1.5KW-4P-573-M1, speed ratio is 573, rated motor speed is 1400r / min, and the output speed of the second planetary reducer is 2.4r / min.

[0029] 2. First transmission gear 73: M=8 Z=40 3. Translation speed per minute: ~2411 mm / min 4. Overview: To ensure installation and operational accuracy, all mounting surfaces are milled simultaneously. Travel position is controlled by limit switches.

[0030] Bottom material cart 4: 1. The model of the third planetary reducer is K107R77-YEJ2.2KW-4P-515-M1, with a speed ratio of 515, a rated motor speed of 1410r / min, and an output speed of 2.74r / min for the third planetary reducer.

[0031] 2. Second transmission gear 12: M=12, Z=28 3. Movement speed per minute: ~2890mm / min 4. Overview: To ensure installation and operational accuracy, all mounting surfaces are milled simultaneously. Travel position is controlled by limit switches.

[0032] This invention also proposes a control method for large-scale automatic lifting and loading furnace cars, which specifically includes the following steps: S1. Task reception and global planning; S11. Instruction Issuance: The factory's manufacturing execution system generates specific furnace loading task instructions based on the production plan, including material ID, target furnace number, and process requirements, and sends them to the control box 3 of the furnace loading car; S12, Path Planning: The loading car plans its route from the current parking position to the material collection point and then to the target furnace opening, according to the loading task instructions.

[0033] S2, Material Retrieval; S21, Manual Driving: Once the vehicle starts, it autonomously travels along the planned path using sensors on the loading car. The control box 3 compares the actual position of the loading car with the planned path in real time and adjusts the speed and direction of the loading car's drive wheels through the motion controller. S22, Placement Decision: After the charging car identifies the precise location, center point, and orientation of the material, it sends a manual button to control box 3. Control box 3 then uploads this information to the host computer, which formulates a placement strategy and then retrieves the material.

[0034] S3, Material transfer and furnace mouth alignment; S31. Cargo movement: The upper lifting material cart 5 carries the material and travels safely to the designated position in front of the industrial furnace according to the planned path; S32. Furnace opening alignment: Align the material with the guide rails inside the furnace.

[0035] S4. Automatic loading and placement of the furnace.

[0036] S41. Synchronous loading: Under servo control, the lifting mechanism 6 lifts or lowers the material to a height that matches the bottom plate of the furnace. Through the first left and right translation mechanism 7 and the second left and right translation mechanism on the bottom material cart 4, the material is delivered to the picking range of the picking arm. The picking arm delivers the material smoothly and at a uniform speed into the designated position in the furnace according to the preset anti-collision trajectory. S42. Placement and Release: After confirming that the materials have been placed in place, the loading car safely exits the furnace.

[0037] Based on the above technical solution, the present invention achieves inherent safety and completely eliminates the risks of high-risk manual operations: This achieves a fundamental shift from "people near the furnace opening" to "people away from the furnace opening, with equipment operating automatically." Operators no longer need to enter high-temperature, high-risk areas, completely eliminating the direct personal safety risks of burns, radiation damage, and lifting heavy workpieces, meeting the highest safety standards for industrial production.

[0038] This invention can significantly improve work efficiency: It significantly shortens the material turnover cycle and improves overall production efficiency.

[0039] This invention features high precision and strong adaptability, ensuring furnace charging quality: By integrating high-precision positioning and motion control technologies, it can achieve high-precision alignment, ensuring that the workpiece is smoothly and accurately placed into the furnace, avoiding damage to the furnace chamber, and improving heating uniformity and product quality. The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any other way. Any modifications or equivalent changes made based on the technical essence of the present invention shall still fall within the scope of protection claimed by the present invention.

Claims

1. A large-scale automatic lifting and loading furnace trolley, characterized in that, Includes a bottom material cart (4), on which an operating platform (1) and a material platform are provided. The operating platform (1) is equipped with a control box (3), which is connected to the host computer via signal. The operating platform (1) is located at one end of the material platform. The material platform includes an upper lifting material cart (5), an up-and-down lifting mechanism (6), and a left-and-right translation mechanism. The upper lifting material cart (5) is installed on the bottom material cart (4) through the up-and-down lifting mechanism (6) and the left-and-right translation mechanism to realize the up-and-down lifting and forward-and-backward translation of the upper lifting material cart (5).

2. The large automatic lifting and loading furnace car according to claim 1, characterized in that, The operating platform (1) is also equipped with a guardrail (2) on its side.

3. The large automatic lifting and loading furnace car according to claim 1, characterized in that, The lifting mechanism (6) includes a screw jack (62), a first planetary reducer, and a lifting drive servo motor (61). The lifting drive servo motor (61) is connected to the first planetary reducer, and the first planetary reducer is connected to the screw jack (62). The screw jack (62) is installed below the upper lifting trolley (5). The left and right translation mechanism includes a translation drive motor (71), a second planetary reducer, and a first transmission gear (73). The translation drive motor (71) is connected to the second planetary reducer. A transmission rod (72) is installed on the second planetary reducer. The first transmission gear (73) is installed on the transmission rod (72). The upper lifting trolley (5) is provided with a first tooth groove (74), and the first transmission gear (73) meshes with the first tooth groove (74).

4. The large automatic lifting and loading furnace car according to claim 1, characterized in that, The bottom material cart (4) is provided with a second left and right translation mechanism. The second left and right translation mechanism includes a translation plate (10), a material cart drive motor (9), a third planetary reducer and a second transmission gear (12). The translation plate (10) is fixed at the bottom center of the bottom of the bottom material cart (4) and is provided with a second tooth groove (11). The material cart drive motor (9) is connected to the third planetary reducer. The second transmission gear (12) is installed on the output shaft of the third planetary reducer and meshes with the second tooth groove (11).

5. The large automatic lifting and loading furnace car according to claim 1, characterized in that, Rollers (8) are installed below the bottom trolley (4).

6. The control method for a large-scale automatic lifting and loading furnace car according to any one of claims 1-5, characterized in that, Includes the following steps: S1. Task reception and global planning; S2, Material Retrieval; S3, Material transfer and furnace mouth alignment; S4. Automatic loading and placement of the furnace.

7. The control method for a large-scale automatic lifting and loading furnace car according to claim 6, characterized in that, Step S1 is as follows: S11. Instruction Issuance: The factory's manufacturing execution system generates specific furnace loading task instructions based on the production plan, including material ID, target furnace number, and process requirements, and sends them to the control box of the furnace loading car (3); S12, Path Planning: The loading car plans its route from the current parking position to the material collection point and then to the target furnace opening, according to the loading task instructions.

8. The control method for a large-scale automatic lifting and loading furnace car according to claim 6, characterized in that, Step S2 is as follows: S21, Manual Driving: The vehicle starts and autonomously travels along the planned path using the sensors on the loading car. The control box (3) compares the actual position of the loading car with the planned path in real time and adjusts the speed and direction of the driving wheels of the loading car through the motion controller. S22, Placement Decision: After the loading car identifies the precise location, center point and attitude of the material, it sends the information to the control box (3) via a manual button. The control box (3) then uploads the information to the host computer, which then formulates a placement strategy and retrieves the material.

9. The control method for a large-scale automatic lifting and loading furnace car according to claim 6, characterized in that, Step S3 is as follows: S31. Cargo movement: The upper lifting material cart (5) carries the material and travels safely to the designated location in front of the industrial furnace according to the planned path; S32. Furnace opening alignment: Align the material with the guide rails inside the furnace.

10. The control method for a large-scale automatic lifting and loading furnace car according to claim 6, characterized in that, Step S4 is as follows: S41. Synchronous loading: Under servo control, the lifting mechanism (6) lifts or lowers the material to a height that matches the bottom plate of the furnace. Through the first left and right translation mechanism (7) and the second left and right translation mechanism on the bottom material cart (4), the material is sent to the picking range of the picking arm. The picking arm sends the material smoothly and at a constant speed into the designated position in the furnace according to the preset anti-collision trajectory. S42. Placement and Release: After confirming that the materials have been placed in place, the loading car safely exits the furnace.

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