Ceramic insulator automatic rolling forming machine and forming method thereof

Abstract

The invention discloses a ceramic insulator automatic rolling forming machine and a forming method thereof, and relates to the technical field of forming machines. According to the automatic rolling forming machine for the ceramic insulator, the blank pretreatment unit is arranged and is in signal connection with the control unit of the self-adaptive leveling mechanism, blank state sensing is achieved, meanwhile, dynamic adjustment of forming process parameters is further conducted subsequently, the blank pretreatment unit can detect the initial state of a blank on line, and the automatic rolling forming machine for the ceramic insulator is achieved. The blank pretreatment unit performs targeted adjustment through a pretreatment actuator, so that blanks entering a rolling station reach an ideal and uniform state, the blank pretreatment unit transmits final state parameters of the treated blanks to the control unit, and parameters of a rolling head and a die rotary disc are adjusted in a linkage mode according to the final state parameters. The forming process can adapt to the characteristics of each blank, and the consistency and the qualified rate of products are ensured.

Description

Technical Field

[0001] This invention relates to the field of molding machine technology, specifically to an automated roll forming machine for ceramic insulators and its forming method. Background Technology

[0002] Ceramic insulators are fundamental components of power systems. The performance and reliability of ceramic insulators largely depend on the quality of the blank forming stage. Roll forming is one of the common processes for producing ceramic insulator blanks. Its basic principle is to use a rotating rolling head to roll the plastic ceramic clay placed in a rotating mold to form the desired umbrella shape. Existing automated roll forming machines typically include a frame, a mold rotary table, a rolling head, and a feeding mechanism that drives the rolling head. The mold rotary table realizes the cyclic switching of the workstation, and the feeding mechanism controls the pressing and lifting of the rolling head. This structure realizes the continuity and automation of production.

[0003] However, in actual production, there are still problems affecting the consistency and pass rate of molding quality. First, during the aging, transportation, and filling process of ceramic clay blanks, the distribution of moisture and temperature inside and on the surface may be uneven. This difference in initial state directly affects the plasticity and deformation resistance of the blank. Direct rolling is not feasible because the rolling process parameters (such as pressure, temperature, and speed) can usually only be set according to fixed values ​​or experience, which cannot be adapted to the actual state of each blank. This can easily lead to defects such as blank cracking, uneven density, or out-of-tolerance dimensions. Moreover, during the rolling process, the installation error of the mold, the levelness deviation of the mold plate, and the irregularity of the initial shape of the blank itself can cause the working surface of the rolling head and the bearing surface of the mold to be non-parallel. Although some equipment uses floating heads or simple spring buffer structures, these are passive responses with limited leveling capabilities, resulting in uneven rolling pressure distribution, affecting the uniformity of the blank wall thickness and the density of the internal structure. In view of the shortcomings of the existing technology, this invention provides an automated rolling forming machine for ceramic insulators and its forming method to solve the above problems. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an automated ceramic insulator roll forming machine and its forming method. By setting up a blank pretreatment unit and connecting it with the control unit of the adaptive leveling mechanism, the blank state is perceived. Simultaneously, the forming process parameters are dynamically adjusted. The blank pretreatment unit can detect the initial state of the blank online and make targeted adjustments through its pretreatment actuator, ensuring that the blank entering the roll forming station reaches an ideal and uniform state. The blank pretreatment unit transmits the final state parameters of the processed blank to the control unit, which then adjusts the parameters of the roll forming head and the mold rotary table based on these final state parameters. The forming process can adapt to the characteristics of each blank, solving the problem of unstable forming quality caused by fluctuations in the initial state of the blank, and ensuring product consistency and pass rate.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an automated ceramic insulator roll forming machine, comprising a frame, a mold rotary table mounted on the frame, a roll forming head, and a feeding mechanism for driving the roll forming head to feed, and further comprising: An adaptive leveling mechanism is connected between the rolling head and the feeding mechanism to dynamically maintain the parallelism between the rolling head and the mold surface during the rolling process. The billet pretreatment unit is located above the mold rotary table and before the rolling station, and is used to adjust the state of the billet before it enters the rolling station. The pre-treatment unit of the billet is connected to the control unit of the adaptive leveling mechanism to adjust the rolling forming parameters in conjunction with the state parameters of the pre-treated billet.

[0006] Preferably, the adaptive leveling mechanism includes: A pressure sensing unit is installed between the rolling head and the feeding mechanism to detect the contact pressure distribution between the rolling head and the ceramic blank in real time. The leveling execution unit includes at least three independently driven electric push rods arranged circumferentially along the rolling head, with the end of each electric push rod connected to the rolling head. The control unit is connected to the pressure sensing unit and the leveling execution unit respectively, and is used to dynamically control the extension and retraction of each electric push rod according to the pressure distribution data.

[0007] Preferably, the pressure sensing unit is a plurality of pressure sensors arranged in a ring array, and the plurality of pressure sensors are evenly distributed on the connection interface on the back of the rolling head.

[0008] Preferably, the electric push rod of the leveling execution unit is a servo electric cylinder, and its end is connected to the rolling head through a universal joint.

[0009] Preferably, the billet pretreatment unit includes: The sensor module is used to detect at least the moisture and temperature parameters of the blank inside the mold in real time. The pretreatment actuator is a multi-axis adjustable microwave or infrared heating and humidity control module used to pretreat the billet; The linkage control module is connected to the control unit of the sensor module, the preprocessing actuator, and the adaptive leveling mechanism, respectively.

[0010] Preferably, the sensor module includes a non-contact infrared moisture sensor and a temperature sensor integrated in the mold base of the mold rotary table, and an ambient temperature and humidity sensor mounted on the frame.

[0011] Preferably, the linkage control module has a built-in preprocessing algorithm and parameter matching algorithm; The preprocessing algorithm is used to calculate and generate adjustment instructions for the heating power, action time and action area of ​​the preprocessing actuator based on the initial state of the billet and environmental parameters detected by the sensor module. The parameter matching algorithm is used to generate linkage adjustment commands for the heating temperature of the rolling head, the reference pressure setting value of the adaptive leveling mechanism, and the rotation speed of the mold rotary table based on the final state parameters of the pre-processed billet.

[0012] Preferably, the rolling head is equipped with a heating device that is linked to the control unit signal.

[0013] Preferably, the mold rotary table is an indexing rotary table structure, and its rotation axis intersects perpendicularly with the feed axis of the rolling head; the control unit is also connected to a human-machine interface for displaying real-time process parameters and equipment status.

[0014] This invention also discloses an automated roll forming method for ceramic insulators, which uses the aforementioned automated roll forming machine for ceramic insulators and includes the following steps: Step S1: Perform billet condition detection. When the mold carrying the billet rotates to the pre-processing station, the surface moisture and temperature of the billet are scanned non-contactly by the sensor module, and the ambient temperature and humidity parameters are obtained. Step S2: Calculate the pretreatment scheme. Based on the data obtained in step S1 and the target billet state model, the linkage control module calculates the pretreatment scheme required to make the billet reach the ideal state before rolling. Step S3: Perform adaptive pretreatment of the billet, drive the pretreatment actuator to perform local or overall heating and humidity adjustment of the billet according to the pretreatment scheme in step S2; Step S4: Dynamic matching of forming parameters is performed. The final state parameters of the blank processed in step S3 are transmitted to the control unit of the adaptive leveling mechanism. The control unit dynamically adjusts the heating temperature of the rolling head, the reference pressure setting value of the adaptive leveling mechanism, and the rotation speed of the mold rotary table accordingly. Step S5: Adaptive roll forming is performed. The feed mechanism is driven to make the roll head contact the blank. The pressure sensing unit monitors the pressure distribution in real time. The control unit dynamically adjusts each electric push rod of the leveling execution unit to keep the roll head parallel to the mold surface during the forming process until the forming is completed.

[0015] The technical effects and advantages of this invention are as follows: 1. This automated ceramic insulator roll forming machine achieves blank state perception by setting up a blank pretreatment unit and connecting it with the control unit of the adaptive leveling mechanism. Simultaneously, it dynamically adjusts the forming process parameters. The blank pretreatment unit can detect the initial state of the blank online and make targeted adjustments through its pretreatment actuator, ensuring that the blank entering the roll forming station reaches an ideal and uniform state. The blank pretreatment unit transmits the final state parameters of the processed blank to the control unit, which then adjusts the parameters of the roll forming head and mold rotary table based on these final state parameters. The forming process can adapt to the characteristics of each blank, solving the problem of unstable forming quality caused by fluctuations in the initial state of the blank, and ensuring product consistency and pass rate.

[0016] 2. This automated ceramic insulator roll forming machine features an adaptive leveling mechanism. The pressure sensing unit monitors the pressure distribution between the rolling head and the blank in real time. Based on the pressure distribution data, the control unit precisely drives the leveling execution unit for compensation. This design allows the rolling head to actively adapt to and compensate for skewing caused by factors such as mold installation errors and irregular blank shapes. During the forming process, the working end face of the rolling head remains parallel to the mold surface, ensuring that the rolling pressure is applied evenly to the blank. This solves the problems of uneven blank wall thickness, local overpressure, or underpressure caused by the difficulty in ensuring parallelism in traditional equipment, thus improving the forming accuracy and uniformity of the blank structure.

[0017] 3. This automated ceramic insulator roll forming machine links the billet pretreatment unit with the adaptive leveling mechanism, forming a combination of feedforward compensation and feedback correction. The billet pretreatment unit acts as a feedforward link, actively eliminating most of the interference from the initial state of the billet. The adaptive leveling mechanism acts as a real-time feedback link, continuously correcting deviations during the forming process. This composite control is achieved through the coordinated operation of the linkage control module and the control unit, which not only enhances the effects of pretreatment and leveling respectively, but also enables the equipment to cope with more complex working condition changes. It has low dependence on operator experience and is conducive to improving the quality and reliability of ceramic insulators. Attached Figure Description

[0018] 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 these drawings without creative effort.

[0019] 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 3 This is a side view of the present invention; Figure 4 This is a top view of the present invention; Figure 5 This is a schematic diagram of the sensor module of the present invention; Figure 6 This is a schematic diagram of the adaptive leveling mechanism of the present invention; Figure 7 For the present invention Figure 6 Enlarged diagram of part A in the middle; Figure 8 This is a schematic diagram of the structure of the control unit and the linkage control module of the present invention; Figure 9 This is a flowchart of the roll forming method of the present invention.

[0020] In the diagram: 1. Frame; 2. Die turntable; 3. Rolling head; 31. Heating device; 4. Feeding mechanism; 5. Adaptive leveling mechanism; 51. Pressure sensing unit; 511. Pressure sensor; 52. Leveling actuator; 521. Electric push rod; 522. Universal joint; 53. Control unit; 6. Billet pretreatment unit; 61. Sensor module; 611. Non-contact infrared moisture sensor; 612. Temperature sensor; 613. Ambient temperature and humidity sensor; 62. Pretreatment actuator; 63. Linkage control module; 7. Human-machine interface. Detailed Implementation

[0021] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0022] This embodiment discloses an automated roll forming machine for ceramic insulators, according to the attached... Figure 1 To be continued Figure 9As shown, the device includes a frame 1, a mold rotary table 2 mounted on the frame 1, a rolling head 3, and a feeding mechanism 4 that drives the rolling head 3 to feed vertically. The mold rotary table 2 is an indexing turntable structure, and multiple molds for carrying ceramic blanks are evenly arranged circumferentially on the mold rotary table 2. In the conventional rolling forming process, the molds sequentially pass through the loading station, pretreatment station, rolling forming station, and unloading station. The improvement of this invention is that it also includes an adaptive leveling mechanism 5 and a blank pretreatment unit 6. The adaptive leveling mechanism 5 is connected between the rolling head 3 and the output end of the feeding mechanism 4, and is used to dynamically adjust the leveling mechanism during the rolling process. To maintain the parallelism between the rolling head 3 and the mold surface, the effects of mold installation errors and uneven initial shape of the blank are compensated. The blank pretreatment unit 6 is set above the mold rotary table 2 and before the rolling forming station, i.e., at the pretreatment station position. The blank pretreatment unit 6 is used to adjust the state of the blank, such as moisture and temperature, before it enters the rolling station. The blank pretreatment unit 6 is connected to the control unit 53 of the adaptive leveling mechanism 5, so that the parameters of the subsequent rolling forming can be adjusted in linkage according to the final state parameters of the pretreated blank, so as to realize intelligent processing and forming from the blank state to the forming process.

[0023] According to the appendix Figure 1 To be continued Figure 7As shown, the adaptive leveling mechanism 5 includes a pressure sensing unit 51, a leveling execution unit 52, and a control unit 53. The pressure sensing unit 51 is located between the rolling head 3 and the feeding mechanism 4. The pressure sensing unit 51 is used to detect the contact pressure distribution between the rolling head 3 and the ceramic blank in real time. Furthermore, the pressure sensing unit 51 consists of multiple pressure sensors 511 arranged in a ring array. The multiple pressure sensors 511 are evenly distributed on the connection interface on the back of the rolling head 3. This ring array distribution can measure the pressure difference at different positions on the bottom surface of the rolling head 3, providing accurate feedback signals for leveling control. The leveling execution unit 52 includes at least three independently driven electric push rods 521 arranged circumferentially along the rolling head 3. The ends of each electric push rod 521 are connected to the back of the rolling head 3 through universal joints 522. The universal joints 522 allow the angle of the electric push rods 521 to change obliquely during the leveling process, ensuring that the force transmission and the movement of the output end are not restricted. Furthermore, the electric... The push rod 521 is preferably a servo electric cylinder, which has high-precision position and speed control capabilities. The control unit 53 is connected to the pressure sensing unit 51 and the leveling execution unit 52 respectively. The control unit 53 integrates a high-speed processor and a motion control card. The control unit 53 reads the pressure values ​​of each pressure sensor 511 in real time and calculates the center and uniformity of the pressure distribution. When uneven pressure distribution is detected, the control unit 53 dynamically calculates and outputs control commands according to the preset closed-loop control algorithm, and independently adjusts the extension and retraction of each electric push rod 521, thereby changing the relative height of the local part of the rolling head 3, making the pressure distribution tend to be uniform, and finally achieving dynamic parallelism between the working end face of the rolling head 3 and the mold bearing surface. In addition, the rolling head 3 is equipped with a heating device 31, which is linked to the control unit 53. The temperature of the heating device 31 can be set and adjusted according to the process requirements to reduce the friction between the blank and the rolling head 3 and improve the forming quality.

[0024] According to the appendix Figure 5 and attached Figure 8As shown, the billet pretreatment unit 6 includes a sensor module 61, a pretreatment actuator 62, and a linkage control module 63. The sensor module 61 is used to detect at least the moisture and temperature state parameters and environmental parameters of the billet inside the mold in real time. Further, the sensor module 61 includes a non-contact infrared moisture sensor 611 and a temperature sensor 612 integrated above the mold base of the mold rotary table 2, and an ambient temperature and humidity sensor 613 installed near the pretreatment station on the frame 1. When the mold rotates to the pretreatment station, the non-contact infrared moisture sensor 611 and temperature sensor 612 can quickly scan the surface of the billet that it has rotated through, obtaining the surface moisture content and temperature distribution. The ambient temperature and humidity sensor 613 provides reference parameters for the workshop environment. The pretreatment actuator 62 is a multi-axis adjustable microwave or infrared heating and humidity control module. The pretreatment actuator 62 is suspended above the pretreatment station by a robotic arm or a multi-degree-of-freedom slide table. It can move in the X, Y, and Z directions according to instructions and can adjust the irradiation angle. The pretreatment actuator 62 is used to perform directional and quantitative heating and humidity control on the billet, such as local humidification and preheating of areas with low moisture content, or uniform heating of the entire billet. The linkage control module 63 can be an independent industrial computer or a software module integrated into the main control system. It is connected to the sensor module 61, the pretreatment actuator 62, and the control unit 53 of the adaptive leveling mechanism 5 via industrial Ethernet or fieldbus. Preferably, the present invention is integrated on the same circuit board and electrically connected.

[0025] Furthermore, the linkage control module 63 incorporates a preprocessing algorithm and a parameter matching algorithm. The preprocessing algorithm is used to calculate based on the initial state of the billet and the ambient temperature and humidity parameters detected by the sensor module 61, combined with the target billet state model corresponding to the product model. The target billet state model presets the ideal moisture and temperature range and uniformity requirements of the billet before entering the rolling station. The algorithm generates adjustment instructions for the preprocessing actuator 62 by comparing the difference between the detected values ​​and the target values, including heating power, action time, action area, and whether to activate auxiliary spray humidification. The parameter matching algorithm is used to generate linkage adjustment instructions for the core parameters of subsequent rolling forming based on the final state parameters of the billet detected again by the sensor module 61 after preprocessing, i.e., the actual state upon entering the rolling station. These instructions are sent to the control unit 53 of the adaptive leveling mechanism 5 via the network, including: adjustment... The temperature setting of the internal heating device 31 of the rolling head 3 is adjusted, for example, when the billet is too dry, the temperature of the rolling head 3 is appropriately increased to reduce adhesion; the reference pressure setting of the adaptive leveling mechanism 5 is adjusted, for example, when the plasticity of the billet changes due to changes in moisture and temperature, the molding pressure needs to be adjusted; the rotation speed of the mold rotary table 2 during rolling is adjusted, for example, when the billet is soft, the rotation speed is appropriately increased to reduce deformation. This linkage ensures that the molding process parameters can adapt to the actual state of each billet, improving product consistency and pass rate. The control unit 53 is also connected to a human-machine interface 7, which is installed in a position on the frame 1 that is easy to observe and operate. It is used to display real-time process parameters and equipment status, and allows operators to select formulas, fine-tune parameters, and control start and stop. Process parameters include pressure values ​​at various points, billet moisture and temperature, rolling head 3 temperature, mold rotary table 2 rotation speed, etc. Equipment status includes the position of each mechanism, alarm information, etc.

[0026] According to the appendix Figure 1 To be continued Figure 8 As shown, the working principle of the adaptive leveling mechanism 5, which is specifically disclosed, is not limited to correcting static deviations, but more importantly, it is designed to cope with dynamic changes during the rolling process. In the early stage of rolling, the billet shape is irregular and the pressure distribution may be severely uneven. The control unit 53 will respond quickly and drive the leveling execution unit 52 to make the rolling head 3 quickly conform to the outline of the billet. In the middle stage of rolling, as the billet is squeezed and stretched, the shape and resistance of the billet change continuously. The pressure sensing unit 51 continuously monitors and the control unit 53 makes fine adjustments to keep the rolling pressure balanced at all times, avoiding single-point overpressure that could cause the billet to crack or have uneven thickness. Compared with the traditional rigid feed or simple floating head, this dynamic leveling process improves the forming accuracy and adaptability to the billet.

[0027] According to the appendix Figure 2 To be continued Figure 8 As shown, the linkage between the billet pretreatment unit 6 and the adaptive leveling mechanism 5, as specifically disclosed, realizes a two-stage feedforward feedback composite control: First-level feedback: The billet pretreatment unit 6 senses and adjusts to ensure that each billet reaches the standard state before entering the rolling process. This is feedforward compensation, which aims to eliminate most of the interference caused by the difference in the initial state of the billet. Second-level feedback: Even after preprocessing, minor state fluctuations and dynamic disturbances during the molding process still exist. The adaptive leveling mechanism 5, as a subsequent feedback process, senses the molding pressure distribution, a variable that directly reflects the molding state, in real time and makes dynamic adjustments and real-time corrections. The two-level feedback control works together to ensure that the molding process is always within the optimal range under changing internal and external conditions.

[0028] According to the appendix Figure 1 To be continued Figure 8 As shown, it is particularly important to emphasize that this invention has a high degree of integration. The precise indexing and positioning of the mold rotary table 2, the stable pressing of the feeding mechanism 4, the multi-axis motion of the pre-processing actuator 62, the precise extension and retraction of the electric push rod 521, and the data acquisition of all sensors are all controlled by a unified control unit 53 and a linkage control module 63. The action sequence, speed, and position of each actuator are all determined and executed according to a preset algorithm, and visual monitoring is achieved through the human-machine interface 7. This realizes the development of ceramic insulator rolling forming from experience-based manual to automated.

[0029] According to the appendix Figure 1 To be continued Figure 9 As shown, it is particularly important to emphasize that the structure disclosed in this invention provides the foundation for subsequent methods. The state information of the billet is related to the control commands of the equipment. From the sensor module 61 collecting raw data, to the linkage control module 63 making preprocessing decisions and executing them, to the processing state information being transmitted to the control unit 53 for matching molding parameters, and finally to the pressure sensing unit 51 achieving real-time dynamic leveling during the molding process, driving the material to undergo precise shape and performance transformation. This data-driven automated equipment realizes intelligent manufacturing.

[0030] Example 1: This example uses the automated roll forming of standard umbrella-skirt ceramic insulator blanks as an example, combined with the attached... Figure 1 To be continued Figure 9 The workflow is explained in detail below: Step S1, billet state detection: The mold carrying the plastic clay billet rotates with the mold turntable 2 to the pretreatment station and is precisely positioned. The sensor module 61 installed at this station is immediately activated. The non-contact infrared moisture sensor 611 and temperature sensor 612 integrated on the mold base perform a ring scan on the surface of the stationary or slowly rotating billet to obtain the moisture content and temperature values ​​of multiple points on the surface of the billet, forming a preliminary distribution map. At the same time, the ambient temperature and humidity sensor 613 records the environmental parameters of the current workshop. All of these data are transmitted to the linkage control module 63 in real time.

[0031] Step S2: Preprocessing scheme calculation. After receiving the data, the linkage control module 63 starts the built-in preprocessing algorithm. The algorithm inputs the average moisture and temperature of the blank obtained by scanning along with the current environmental parameters, and retrieves the target blank state model of the insulator of this type from the database. For example, it requires that the surface moisture of the blank be uniform and within 12% ± 0.5% and the temperature be within 25℃ ± 2℃ before rolling. The algorithm calculates the difference between the current state and the target state, and combines it with the blank moisture distribution map to determine whether overall adjustment or local compensation is needed. For example, if the detection finds that the blank is generally too dry and the moisture in the central area is slightly lower than that at the edge, the algorithm will generate a preprocessing scheme: instruct the preprocessing actuator 62 to move directly above the blank and gently heat the blank with medium power for 30 seconds. At the same time, in the last 10 seconds, the actuator will slightly shift the focus to the central area to balance the moisture distribution. The scheme clearly specifies the movement trajectory, dwell time, and heating power level of the preprocessing actuator 62.

[0032] In step S3, the billet undergoes adaptive pretreatment. The linkage control module 63 sends the decomposed action instructions to the driver of the pretreatment actuator 62. The robotic arm of the pretreatment actuator 62 drives the infrared heating head to move precisely to the predetermined position and irradiates and heats the billet according to the set power and time. During the heating process, some moisture may be gently evaporated, but the main purpose is to increase the billet temperature, enhance its plasticity, and promote the uniform migration of internal moisture. After the pretreatment is completed, the sensor module 61 can perform rapid detection again to confirm the final state of the billet.

[0033] Step S4, dynamic matching of molding parameters: The linkage control module 63 converts the final state parameters of the billet after step S3 through a parameter matching algorithm. For example, the final billet temperature is raised to 26℃ and the moisture is uniform. The parameter matching algorithm calculates that the appropriate reference pressure of the rolling head 3 should be set to 105% of the standard value according to the preset temperature, pressure and speed matching relationship curve. Because the temperature is slightly higher and the plasticity is better, the pressure can be slightly increased to improve the density. The heating temperature of the rolling head 3 itself can be set to the standard value. The speed of the mold rotary table 2 can be set to 98% of the standard value. The billet is relatively soft, so the speed is slightly reduced to prevent centrifugal deformation. These adjustment instructions are sent to the control unit 53 of the adaptive leveling mechanism 5 in real time.

[0034] Step S5, adaptive roll forming: The mold rotary table 2 rotates the pre-treated blank to the roll forming station. The control unit 53 first sets the temperature of the heating device 31 of the roll head 3 and the reference pressure target value of the leveling system according to the received instructions. Then, it starts the feeding mechanism 4, driving the entire adaptive leveling mechanism 5 and the roll head 3 to descend rapidly. When the pressure sensing unit 51 at the bottom of the roll head 3 detects a contact pressure signal, the feeding mechanism 4 switches to force control or slow feed mode, and the roll head 3 begins to contact and press into the blank. The mold rotary table 2 rotates synchronously at the set speed. During this process, multiple pressure sensors 511 of the pressure sensing unit 51 continuously collect data. The pressure data is monitored in real time by the control unit 53. Once uneven pressure distribution is detected, such as a pressure in a certain quadrant that is consistently higher than the average value, it is determined that the rolling head 3 is pressing too deeply at that point and is not parallel. The control unit 53 immediately sends a command to the leveling execution unit 52 to slightly retract the electric push rod 521 at the corresponding position and slightly extend the push rod at the diagonal position, thereby adjusting the posture of the rolling head 3. This dynamic adjustment continues throughout the entire rolling forming cycle to ensure uniform pressure distribution. When the forming depth or time reaches the set value, the rolling is completed, the feeding mechanism 4 lifts the rolling head 3 to reset, the mold rotary table 2 rotates to the next cycle, and the formed part is transferred to the unloading station.

[0035] Example 2: This example takes the processing of a batch of irregularly shaped ceramic insulator blanks with uneven initial moisture content as an example, combined with the attached... Figure 1 To be continued Figure 9 The workflow is explained in detail, with a focus on demonstrating the system's adaptive and interconnected capabilities under non-ideal conditions. The workflow is as follows: Suppose that due to varying aging times, some blanks dry faster at the edges but remain damp in the center. The mold rotary table 2 sends the first such blank to the pre-processing station.

[0036] In step S1, after scanning, the sensor module 61 found that the moisture distribution on the surface of the billet was severely uneven, with only 10% moisture in the edge area and 14% in the center area, and there was also a gradient difference in the average temperature.

[0037] In step S2, the preprocessing algorithm of the linkage control module 63 identifies the need for local compensation and generates a preset complex preprocessing scheme: the instruction preprocessing executor 62 first performs short-term low-power preheating on the whole, and then focuses on heating the dry edge area while avoiding the overly humid central area. The purpose of heating is not to directly humidify, but to accelerate the migration of moisture inside the billet from the center to the edge by increasing the edge temperature, thereby achieving balance. If the humidity in the workshop allows, auxiliary humidifying mist can be turned on to make slight auxiliary adjustments to the edge.

[0038] In step S3, the preprocessing actuator 62 strictly follows the scheme. Through complex multi-axis linkage, the microwave focusing point moves precisely along the edge path of the billet, and the action time and power are dynamically fine-tuned according to the real-time scanning model.

[0039] Step S4: After pretreatment, if the uniformity of the billet's moisture content is improved, but the edge plasticity is still slightly lower than that of the center, the parameter matching algorithm calculates accordingly and generates a linkage command to be sent to the control unit 53. The command includes: slightly increasing the heating temperature of the rolling head 3 to reduce the overall forming resistance; appropriately lowering the reference pressure setting value of the adaptive leveling mechanism 5 to prevent impact on the relatively hard edges during initial contact; and simultaneously, in the initial stage of rolling, the mold rotary table 2 uses a lower speed, which is increased to the normal speed after the billet is initially shaped.

[0040] Step S5: Entering the roll forming stage. Since the initial state of the blank has been specifically pre-treated and the forming parameters have been matched and adjusted, the initial contact between the roll head 3 and the blank is smoother. During the roll forming process, the pressure sensing unit 51 will continuously monitor. Since there are still micro-inhomogeneities in the blank material, the pressure distribution may fluctuate slightly. The control unit 53, based on the dynamic leveling algorithm, makes high-frequency micro-adjustments through the electric push rod 521 of the leveling execution unit 52 to ensure that the roll head 3 always rolls the blank evenly in the best posture, and finally forms an insulator blank with uniform wall thickness and consistent density. Through this embodiment, it can be seen that the present invention can effectively deal with complex initial conditions of blanks. Through the combination of pre-treatment correction and adaptive forming process, the quality stability of the final product is guaranteed.

[0041] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. 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 roll forming machine for ceramic insulators, comprising a frame (1), a mold rotary table (2) mounted on the frame (1), a roll forming head (3), and a feeding mechanism (4) for driving the roll forming head (3) to feed, characterized in that, Also includes: An adaptive leveling mechanism (5) is connected between the rolling head (3) and the feeding mechanism (4) to dynamically maintain the parallelism between the rolling head (3) and the mold surface during the rolling process; The billet pretreatment unit (6) is located above the mold rotary table (2) and before the rolling station, and is used to adjust the state of the billet before it enters the rolling station. The pre-treatment unit (6) of the billet is connected to the control unit (53) of the adaptive leveling mechanism (5) to adjust the rolling forming parameters in conjunction with the pre-treated billet state parameters.

2. The automated roll forming machine for ceramic insulators according to claim 1, characterized in that, The adaptive leveling mechanism (5) includes: The pressure sensing unit (51) is set between the rolling head (3) and the feeding mechanism (4) to detect the contact pressure distribution between the rolling head (3) and the ceramic blank in real time. The leveling execution unit (52) includes at least three electric push rods (521) arranged circumferentially along the rolling head (3) and driven independently, with the end of each electric push rod (521) connected to the rolling head (3); The control unit (53) is connected to the pressure sensing unit (51) and the leveling execution unit (52) respectively, and is used to dynamically control the extension and retraction of each electric push rod (521) according to the pressure distribution data.

3. The automated roll forming machine for ceramic insulators according to claim 2, characterized in that, The pressure sensing unit (51) consists of multiple pressure sensors (511) arranged in a ring array, and the multiple pressure sensors (511) are evenly distributed on the connection interface on the back of the rolling head (3).

4. The automated roll forming machine for ceramic insulators according to claim 3, characterized in that, The electric push rod (521) of the leveling execution unit (52) is a servo electric cylinder, and its end is connected to the rolling head (3) through a universal joint (522).

5. The automated roll forming machine for ceramic insulators according to claim 2, characterized in that, The billet pretreatment unit (6) includes: Sensor module (61) is used to detect at least the moisture and temperature state parameters of the blank in the mold in real time; The pretreatment actuator (62) is a multi-axis adjustable microwave or infrared heating and humidity control module used to pretreat the billet; The linkage control module (63) is connected to the sensor module (61), the preprocessing actuator (62), and the control unit (53) of the adaptive leveling mechanism (5) respectively.

6. The automated roll forming machine for ceramic insulators according to claim 5, characterized in that, The sensor module (61) includes a non-contact infrared moisture sensor (611) and a temperature sensor (612) integrated in the mold base of the mold turntable (2), and an ambient temperature and humidity sensor (613) mounted on the frame (1).

7. The automated roll forming machine for ceramic insulators according to claim 6, characterized in that, The linkage control module (63) has a built-in preprocessing algorithm and parameter matching algorithm; The preprocessing algorithm is used to calculate and generate adjustment instructions for the heating power, action time and action area of ​​the preprocessing actuator (62) based on the initial state of the billet and environmental parameters detected by the sensor module (61). The parameter matching algorithm is used to generate linkage adjustment commands for the heating temperature of the rolling head (3), the reference pressure setting value of the adaptive leveling mechanism (5), and the rotation speed of the mold rotary table (2) based on the final state parameters of the pre-treated blank.

8. The automated roll forming machine for ceramic insulators according to claim 1, characterized in that, The rolling head (3) is equipped with a heating device (31) that is linked to the control unit (53) via signal.

9. The automated roll forming machine for ceramic insulators according to claim 1, characterized in that, The mold turntable (2) is an indexing turntable structure, and its rotation axis is perpendicular to the feed axis of the rolling head (3); the control unit (53) is also connected to a human-machine interface (7) for displaying real-time process parameters and equipment status.

10. An automated roll forming method for ceramic insulators, using the automated roll forming machine for ceramic insulators as described in any one of claims 1-9, characterized in that, Includes the following steps: Step S1: When the mold carrying the billet rotates to the pretreatment station, the surface moisture and temperature of the billet are scanned non-contactly by the sensor module (61), and the ambient temperature and humidity parameters are obtained. Step S2, the linkage control module (63) calculates the pretreatment scheme required to make the billet reach the ideal state before rolling based on the data obtained in step S1 and the target billet state model. Step S3, drive the pretreatment actuator (62) to perform local or overall heating and humidity adjustment on the billet according to the pretreatment scheme in step S2; In step S4, the final state parameters of the billet after step S3 are transmitted to the control unit (53) of the adaptive leveling mechanism (5). The control unit (53) dynamically adjusts the heating temperature of the rolling head (3), the reference pressure setting value of the adaptive leveling mechanism (5), and the rotation speed of the mold turntable (2) accordingly. Step S5, drive the feeding mechanism (4) to make the rolling head (3) contact the blank, the pressure sensing unit (51) monitors the pressure distribution in real time, and the control unit (53) dynamically adjusts each electric push rod (521) of the leveling execution unit (52) to keep the rolling head (3) parallel to the mold surface during the forming process until the forming is completed.

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