An automated machining system and process for fasteners involving multiple machines

Abstract

This invention discloses an automated machining system and process for fasteners involving multiple machines, comprising a feeding and conveying unit, a vision recognition unit, a material transfer unit, a machining execution unit, a workpiece cleaning unit, and a control unit. The vision recognition unit is located directly above the end of the feeding and conveying unit and automatically determines the engraving status of the workpiece. The material transfer unit consists of an articulated robotic arm and a dual-station gripper, which sorts or loads raw materials based on the recognition results. The machining execution unit includes at least one lathe, whose spindle fixture adopts a three-point end-face positioning structure, enabling multiple precision machining processes to be completed in a single clamping operation. The control unit coordinates the loading and unloading of materials from a single robotic arm to multiple machine tools. This invention achieves fully automated closed-loop production from raw material loading, intelligent sorting, precision machining to finished product cleaning and stacking, significantly improving processing efficiency.

Description

Technical Field

[0001] This invention relates to the field of automated machining technology for mechanical parts, specifically to an automated machining system and process for fasteners based on visual recognition and multi-device collaboration. Background Technology

[0002] Fastening rings are common mechanical components for water pumps, and their processing typically involves multiple steps. Currently, the processing of these parts mainly relies on manual visual inspection of the workpiece's engraving and manual clamping and unloading on a lathe. This method is labor-intensive, inefficient, and prone to visual fatigue or misjudgment, leading to processing errors and making it difficult to guarantee consistent product quality.

[0003] Although some production lines have introduced stand-alone automation or simple robotic arms for loading and unloading, they typically lack the ability to intelligently determine the status of workpieces. For example, determining whether the engraved side of a workpiece is facing up still requires manual pre-sorting. At the same time, existing solutions are mostly designed around single equipment, making it difficult to achieve efficient collaborative scheduling and resource sharing between a single handling device (such as a robotic arm) and multiple processing lathes. This results in poor system flexibility and low production efficiency.

[0004] Therefore, there is an urgent need for a system that can achieve intelligent sorting and efficient automated processing of fasteners to solve the above problems. Summary of the Invention

[0005] To solve the above-mentioned technical problems, this application adopts the following technical solution:

[0006] An automated machining system for fasteners, comprising a multi-machine linkage, includes a feeding and conveying unit, a vision recognition unit, a material transfer unit, a machining execution unit, a workpiece cleaning unit, and a control unit. The feeding and conveying unit transports the workpieces. The vision recognition unit is located directly above the end of the feeding and conveying unit and can move vertically relative to it. The material transfer unit includes an articulated robotic arm and a dual-position gripper at its end. The machining execution unit includes at least one lathe, each lathe having a fixture on its spindle for clamping the workpiece. The workpiece cleaning unit cleans the finished workpieces. The control unit is signal-connected to the feeding and conveying unit, the vision recognition unit, the material transfer unit, the machining execution unit, and the workpiece cleaning unit, coordinating the actions of each unit.

[0007] Furthermore, the feeding and conveying unit includes a conveyor belt and a workpiece sensor. The conveyor belt is used to convey the workpiece to the area directly below the vision recognition unit. The workpiece sensor is located at the end of the conveyor belt and is signal-connected to the control unit to detect whether the workpiece has reached the area directly below the vision recognition unit.

[0008] The visual recognition unit includes an industrial camera, a vertically arranged slide rail, a slider that slides with the slide rail, and a control motor that drives the slider. The industrial camera is mounted on the slider so that it moves vertically along the slide rail. Both the industrial camera and the control motor are signal-connected to the control unit.

[0009] Furthermore, the dual-position gripper is located at the end of the articulated robotic arm and includes a first gripper and a second gripper, the gripping positions of the first gripper and the second gripper being perpendicular to each other.

[0010] Furthermore, the fixture includes a chassis and three clamping units evenly distributed along the circumference of the chassis. Each clamping unit includes a clamping base fixed to the chassis and a clamping block disposed on the clamping base and capable of sliding radially along the fixture. The side of the clamping block facing the center of the fixture is an arc-shaped clamping surface with an anti-slip portion that abuts against the circumferential surface of the workpiece during radial clamping, thus providing an anti-slip function. The bottom of the clamping block extends towards the center of the fixture to form a fan-shaped support plate, and a positioning portion is provided at the center of the fan-shaped support plate.

[0011] Furthermore, it also includes a discharge frame for stacking the cleaned workpieces.

[0012] Furthermore, it also includes a recycling bin for storing workpieces that do not meet processing requirements.

[0013] This application also provides a multi-machine linkage automatic processing method for fastening rings, which is based on the above-mentioned automatic processing system and includes the following steps: S1, the workpiece is placed at the starting end of the feeding and conveying unit either individually or in a stacked manner. When the workpiece sensor detects that there is no workpiece directly below the vision recognition unit, i.e. there is no workpiece at the recognition station, the feeding and conveying unit will transport the workpiece to the recognition station. S2, the visual recognition unit acquires an image of the workpiece and determines whether its upper surface has been engraved. If it is identified as not engraved, proceed to step S3; if it is identified as engraved, proceed to step S4. S3, the material transfer unit grabs the unmarked workpiece. The grabbing action triggers the workpiece sensor detection and recognition station. Based on the detection result, it starts material replenishment and image acquisition, or only performs image acquisition, and simultaneously prepares for the next grab. The material transfer unit moves the workpiece to the recycling bin and executes step S3 or S4 according to the instruction. S4: The control unit schedules an idle lathe. The material transfer unit picks up the engraved workpiece. The picking action triggers the workpiece sensor to detect and identify the workstation. Based on the detection result, it starts material replenishment and image acquisition, or only image acquisition, simultaneously preparing for the next picking. At the same time, the material transfer unit clamps the workpiece and starts the processing program. If there is already a finished product on the lathe, the material transfer unit removes it first before clamping it. S5, the material transfer unit transfers the removed finished workpiece to the workpiece cleaning unit for cleaning. After cleaning, the workpiece is stacked in the discharge box. After completion, step S3 or S4 is executed according to the instruction.

[0014] The beneficial effects of this invention are:

[0015] This invention integrates units such as material feeding and conveying, visual recognition, material transfer, processing execution, and workpiece cleaning, all coordinated and scheduled by a control unit. This achieves fully automated closed-loop production from raw material loading, intelligent sorting, precision machining to finished product post-processing. The system significantly reduces manual labor intensity and human intervention, effectively avoiding errors and quality fluctuations caused by human fatigue or negligence, thereby greatly improving production efficiency and product quality stability.

[0016] Building upon this foundation, the present invention employs a single articulated robotic arm to collaboratively provide loading and unloading services for multiple lathes, and utilizes a control unit for real-time task scheduling and path optimization. This "one-to-many" architecture significantly improves the utilization rate of processing equipment, shortens workpiece turnaround and waiting time, thereby increasing overall production capacity.

[0017] Furthermore, the system utilizes industrial vision cameras and image recognition algorithms to automatically, quickly, and accurately identify the engraving status on workpiece surfaces, completely replacing the traditional sorting method that relies on manual visual inspection. This design fundamentally eliminates errors that may result from manual pre-sorting, ensuring the continuity and accuracy of the processing flow. Attached Figure Description

[0018] Figure 1 This is an overall structural diagram of the system of the present invention; Figure 2 This is a top view of the system of the present invention; Figure 3 This is a schematic diagram of the visual recognition unit of the system of the present invention; Figure 4 This is a schematic diagram of the material transfer unit of the system of the present invention; Figure 5 This is a schematic diagram of the lathe fixture of the system of the present invention.

[0019] In the diagram: 1. Feed conveying unit; 2. Vision recognition unit; 21. Industrial camera; 22. Slide rail; 23. Slider; 24. Control motor; 3. Material transfer unit; 31. Articulated robotic arm; 32. Dual-station gripper; 321. First gripper; 322. Second gripper; 4. Machining execution unit; 41. Lathe; 42. Fixture; 421. Clamping base; 422. Clamping block; 4221. Anti-slip part; 4222. Positioning part; 5. Workpiece cleaning unit; 6. Discharge frame; 7. Recycling bin. Detailed Implementation

[0020] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the invention.

[0021] like Figures 1 to 5 As shown, this embodiment provides a multi-machine linkage automatic machining system for fasteners, mainly including a feeding and conveying unit 1, a vision recognition unit 2, a material transfer unit 3, a machining execution unit 4, a workpiece cleaning unit 5, a discharge frame 6, a recycling bin 7, and a control unit. The machining execution unit 4 employs two CNC lathes 41, which are respectively positioned on adjacent sides of the material transfer unit 3, with a 90-degree angle between them on the horizontal plane, allowing the articulated robotic arm 31 to quickly switch between the two lathes through rotational movement. Each lathe 41 has a dedicated fixture 42 mounted on its spindle for one-time clamping and multi-process machining of the fastener workpiece. Each lathe 41 has multiple cutting tools mounted on its turret. During a single clamping process, through precise spindle positioning and automatic tool changing of the turret, the fastener can sequentially complete processes such as end face turning, external diameter turning, internal diameter turning, groove turning, and radial hole machining.

[0022] like Figure 1 As shown, the feeding conveyor unit 1 uses a motor-driven flat belt conveyor, with its end extending directly below the vision recognition unit 2, i.e., the recognition station. A workpiece sensor (not shown in the figure) is installed on one side of the end of the conveyor belt. This sensor is preferably a photoelectric proximity switch, with its detection optical axis facing the recognition station at the end of the conveyor belt. The workpiece sensor is signal-connected to the control unit to detect in real time whether a workpiece is in place at the recognition station. The raw material workpieces to be processed are placed at the beginning of the conveyor belt, either individually or in a stack. Each time the material transfer unit picks up a workpiece from the recognition station, the workpiece sensor immediately checks whether the station is empty. If there is no workpiece, the control unit controls the conveyor belt to start, pushing the next workpiece or a batch of stacked workpieces to the recognition station, ensuring that there are always workpieces to be processed at the recognition station, thus achieving continuous automated production.

[0023] like Figure 3As shown, the visual recognition unit 2 includes an industrial camera 21, a vertically arranged slide rail 22, a slider 23, and a control motor 24. The industrial camera 21 is fixedly mounted on the slider 23, which is connected to the control motor 24 and can move up and down along the vertical slide rail 22. The control motor 24 is preferably a servo motor, which is connected to the control unit and can receive commands to drive the industrial camera 21 to rise and fall. The determination of whether the workpiece surface is engraved uses an AI visual recognition algorithm based on deep learning. Specifically, this embodiment uses a lightweight convolutional neural network model, which has been pre-trained on a large number of engraved and unengraved workpiece samples, and can effectively extract deep features such as texture, edge, and contrast of engraved and unengraved areas. In actual operation, the workpiece image acquired by the industrial camera 21 is pre-processed and input into the neural network model. The model outputs whether the workpiece is "engraved" or "unengraved". The control unit makes a final decision based on a preset confidence threshold and maps the decision result to the execution command of the robotic arm in real time. The specific algorithm content will not be described in detail here.

[0024] like Figure 4 As shown, the material transfer unit 3 includes an articulated robotic arm 31 and a dual-station gripper 32 mounted at its end. The dual-station gripper 32 includes a first gripper 321 and a second gripper 322, which are perpendicular to each other at a 90-degree angle. The first gripper 321 adopts an internal support structure for gripping unprocessed raw material workpieces, and the second gripper 322 also adopts an internal support structure for gripping raw material workpieces that do not meet processing conditions or processed finished workpieces. The internal support gripper is a well-known technology in the art, and its specific structure will not be described in detail here. The articulated robotic arm 31 can quickly switch grippers and complete corresponding actions by rotating 90 degrees around its end-effector axis.

[0025] like Figure 5 As shown, each lathe 41 in the machining execution unit 4 is equipped with a fixture 42 at the front end of its spindle. This fixture 42 completes the entire turning process of the fastening ring in a single clamping operation, eliminating the need for secondary clamping. The fixture 42 includes a disc-shaped base and three clamping units evenly distributed along the circumference of the base. Each clamping unit includes a clamping base 421 fixed to the base and a clamping block 422 disposed on the clamping base 421 and slidable radially along the fixture 42. The side of the clamping block 422 facing the center of the fixture 42 is formed into an arc-shaped clamping surface, and an anti-slip part 4221 is provided on the arc-shaped clamping surface, which can abut against the circumferential surface of the workpiece during radial clamping, thus providing an anti-slip function. The bottom of the clamping block 422 extends towards the center of the fixture 42 to form a fan-shaped support plate, and a positioning part 4222 is provided at the center of the fan-shaped support plate to achieve axial positioning.

[0026] To ensure safe production of equipment and parts, a proximity sensor (not shown in the figure) is also installed on the clamping base 421 of the fixture 42. This sensor is signal-connected to the control unit and is used to automatically detect whether the workpiece is clamped in place after the articulated robotic arm 31 completes the loading action and before the lathe starts the machining program. If the workpiece is detected to be not in place or clamped crookedly, the control unit immediately sends a command to the lathe to prohibit starting and alarms the system.

[0027] To ensure safe production, a door interlock switch (not shown in the figure) is installed on the safety door of the lathe 41. This switch is hard-wired and interlocked with the starting circuit of the lathe 41. When the safety door is open, the door interlock switch contacts are open, and the lathe cannot start any machining program. When the safety door is fully closed, the door interlock switch contacts are closed, and machining can then be started normally.

[0028] The workflow of this system is as follows: S1, the workpiece is placed at the beginning of the feeding conveyor unit in a single or stacked manner. The workpiece sensor detects the end of the feeding conveyor unit 1 in real time, that is, whether there is a workpiece at the identification station. If not, it is transmitted to the control center. The control center controls the conveyor belt to start and transport the workpiece to the end identification station. After the workpiece sensor detects that the workpiece is in place, the control unit commands the conveyor belt to stop. S2, the industrial camera 21 of the vision recognition unit 2 moves to a preset height under the drive of the control motor 24 to acquire images of the workpiece. The AI ​​algorithm determines whether the surface has been engraved. The control unit receives the recognition result of the vision recognition unit 2. If it is recognized that no engraving has been made, step S3 is executed. If it is recognized that engraving has been made, step S4 is executed. S3, the material transfer unit 3 grabs the unmarked workpiece. The grabbing action triggers the workpiece sensor to detect and identify the workstation. Based on the detection result, it starts material replenishment and image acquisition, or only performs image acquisition, simultaneously preparing for the next grabbing by the material transfer unit 3. The control unit instructs the articulated robotic arm 31 to use the second gripper 322 to grab the workpiece and transfer it to the recycling bin 7, and executes step S3 or S4 according to the instructions. S4, the control unit dynamically schedules one of the idle lathes 41 based on the current working status of the two lathes 41. The robotic arm 31 uses its first gripper 321 to grasp the raw workpiece and move it to the spindle position of the target lathe 41. The grasping action triggers the workpiece sensor to detect and identify the workstation. Based on the detection result, it initiates material replenishment and image acquisition, or only performs image acquisition, simultaneously preparing for the next grasping by the material transfer unit 3. At the same time, if there is a finished workpiece already processed on the spindle of the target lathe, the robotic arm 31 first uses its second gripper 322 to remove it, then rotates 90 degrees to switch to the first gripper 321 to clamp the raw workpiece onto the fixture 42. After clamping, the clamping position sensing system automatically verifies the workpiece's position. After confirming that there is no error, the lathe starts the machining program to perform a one-time multi-process turning operation. In step S5, the material transfer unit 3 transfers the removed finished workpiece to the workpiece cleaning unit 5 for cleaning of surface cutting fluid and impurities. After cleaning, the material transfer unit 3 neatly stacks the finished workpiece into the discharge frame 6 according to the stacking path and layer plan preset by the control unit. Subsequently, step S3 or S4 is executed according to the instruction.

[0029] The above steps enable efficient parallel machining by two lathes 41 and full-load collaborative operation by a single robotic arm.

[0030] Although this embodiment uses two lathes as an example, the system can be expanded to the collaborative operation of three or more processing machines according to actual production capacity requirements. Only the installation position of the robotic arm, the working radius, and the scheduling algorithm of the control unit need to be adjusted accordingly. Furthermore, by replacing the clamping block 422 of the fixture 42 and adjusting the visual recognition algorithm, the system can quickly adapt to processing tasks of fastening rings of different specifications and models, demonstrating excellent flexible production capabilities.

[0031] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., based on the present invention should be included within the scope of protection of the present invention.

Claims

1. A multi-machine linkage automatic processing system for fastening rings, characterized in that, include: The feeding conveyor unit (1) is used to convey the workpiece; The visual recognition unit (2) is located directly above the end of the feeding conveying unit (1) and can move up and down relative to the feeding conveying unit (1); The material transfer unit (3) includes an articulated robotic arm (31) and a dual-position gripper (32) located at its end. The machining execution unit (4) includes at least one lathe (41), and each lathe (41) has a fixture (42) for clamping workpieces on its spindle. The workpiece cleaning unit (5) is used to clean the finished workpieces after processing. The control unit is connected to the feeding conveying unit (1), vision recognition unit (2), material transfer unit (3), processing execution unit (4) and workpiece cleaning unit (5) respectively, and is used to coordinate the actions of each unit.

2. The automatic processing system for fastening rings with multi-machine linkage according to claim 1, characterized in that: The feeding and conveying unit (1) includes a conveyor belt and a workpiece sensor. The conveyor belt is used to transport the workpiece to the area directly below the vision recognition unit (2). The workpiece sensor is located at the end of the conveyor belt and is signal-connected to the control unit to detect whether the workpiece has reached the area directly below the vision recognition unit (2).

3. The automatic processing system for fastening rings with multi-machine linkage according to claim 1, characterized in that: The visual recognition unit (2) includes an industrial camera (21), a vertically arranged slide rail (22), a slider (23) that slides with the slide rail (22), and a control motor (24) that drives the slider (23). The industrial camera (21) is mounted on the slider (23) to move vertically along the slide rail (22). Both the industrial camera (21) and the control motor (24) are signal-connected to the control unit.

4. The automatic processing system for fastening rings with multi-machine linkage according to claim 1, characterized in that: The dual-position gripper (32) is located at the end of the articulated robotic arm (31) and includes a first gripper (321) and a second gripper (322), with the gripping positions of the first gripper (321) and the second gripper (322) perpendicular to each other.

5. The automatic processing system for fastening rings with multi-machine linkage according to claim 1, characterized in that: The clamp (42) includes a chassis and three clamping units evenly distributed along the circumference of the chassis. Each clamping unit includes a clamping base (421) fixed on the chassis and a clamping block (422) disposed on the clamping base (421) and slidable radially along the clamp (42). The side of the clamping block (422) facing the center of the clamp (42) is an arc-shaped clamping surface, and an anti-slip part (4221) is provided on the arc-shaped clamping surface. The bottom of the clamping block (422) extends toward the center of the clamp (42) to form a fan-shaped support plate, and a positioning part (4222) is provided at the center of the fan-shaped support plate.

6. The automatic processing system for fastening rings with multi-machine linkage according to claim 1, characterized in that: It also includes a discharge box (6) for stacking the cleaned workpieces.

7. The automatic processing system for fastening rings with multi-machine linkage according to claim 1, characterized in that: It also includes a recycling bin (7) for storing workpieces that do not meet the processing conditions.

8. An automated processing method for fastening rings used in multi-machine linkage, characterized in that, The method uses the automatic fastener processing system for multi-machine linkage as described in any one of claims 1-7, and the method includes: S1, the workpiece is placed at the starting end of the feeding and conveying unit (1) in a single or stacked manner. When the workpiece sensor detects that there is no workpiece at the recognition station, the feeding and conveying unit (1) will transport the workpiece to the recognition station. S2, the visual recognition unit (2) acquires images of the workpiece and determines whether its upper surface has been engraved. If it is identified as not engraved, step S3 is executed; if it is identified as engraved, step S4 is executed. S3, the material transfer unit (3) grabs the workpiece without engraving. The grabbing action triggers the workpiece sensor to detect and identify the station. Based on the detection result, it starts material replenishment and image acquisition, or only performs image acquisition, and prepares for the next grabbing. At the same time, the material transfer unit (3) transfers the workpiece to the recycling bin (7) and executes step S3 or S4 according to the instruction. S4, the control unit schedules an idle lathe (41), the material transfer unit (3) grabs the engraved workpiece, the grabbing action triggers the workpiece sensor to detect and identify the station, and starts material replenishment and image acquisition according to the detection result, or only performs image acquisition, and prepares for the next grabbing at the same time. Meanwhile, the material transfer unit (3) clamps the workpiece and starts the processing program. If there is already a finished product on the lathe, the material transfer unit (3) removes it first and then performs clamping. S5, the material transfer unit (3) transfers the removed finished workpiece to the workpiece cleaning unit (5) for cleaning. After cleaning, the workpiece is placed in the discharge box (6). After completion, step S3 or S4 is executed according to the instruction.

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