Photovoltaic support main shaft online automatic flow punching system

Abstract

The application discloses a kind of photovoltaic support main shaft online automatic flow punch system, comprising: material continuous conveying roller way, feed reversing guide mechanism, beat feeding conveying mechanism, jacking positioning clamping mechanism, double-end punch executing mechanism and intelligent adaptive control module, each mechanism is sequentially linked and with control module closed loop control is established.The system links main shaft forming process to realize online flow, and the main shaft is accurately transferred by reversing guide and beat feeding, and the jacking clamping mechanism completes vertical lifting and horizontal limiting, and the double-end punch executing mechanism executes punching action after position calibration, and the control module controls the collaborative operation of each mechanism and adapts to different specifications of main shaft.The matched punching method realizes full-process automation through information collection, parameter control, accurate transfer, positioning clamping, synchronous punching and resetting transportation.The system improves processing precision and efficiency, reduces damage risk and labor cost, and is suitable for large-scale production of photovoltaic support main shaft.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic bracket punching technology, and in particular to an online automatic rotary punching system for photovoltaic bracket spindles. Background Technology

[0002] As the core load-bearing component of the photovoltaic (PV) bracket structure, the machining accuracy of the holes used for bolt connections on the PV bracket's surface directly affects the fit and overall structural stability of the bracket installation, making it one of the key processing steps in PV power plant construction. With the large-scale development of the PV industry, higher demands are placed on the production efficiency, machining accuracy, and batch adaptability of PV bracket spindles. Traditional processing methods can no longer meet the pace requirements of modern production. Against this backdrop, an automated system capable of continuous online spindle rotation, precise punching, and adaptability to multiple product specifications has become an urgent need for the industry. This system not only needs to integrate the spindle forming process for unified production but also needs to ensure processing consistency through intelligent control methods, laying the foundation for efficient assembly of PV brackets.

[0003] In existing technologies, the punching of photovoltaic bracket spindles mostly adopts a segmented manual operation mode, which has two prominent drawbacks: First, after the spindle is formed, it needs to be manually stacked and hoisted to the punching section. The multiple loading, unloading and handling during the transfer process can easily cause scratches and bumps on the surface of the spindle, and even cause slight deformation of the profile, affecting the sealing and structural strength of the subsequent installation. At the same time, the cumbersome turnover process also prolongs the production cycle. Second, the punching operation relies on manual pushing of the spindle to the punching die and positioning. The subjectivity and uncertainty of manual operation lead to deviations in the spindle pushing position, making it difficult to maintain uniformity in hole spacing and hole diameter accuracy. Moreover, the entire process of manual loading, positioning and unloading requires multiple operators, which not only limits the processing quantity per unit time, but also increases labor costs, making it unsuitable for the actual needs of large-scale mass production. Summary of the Invention

[0004] In order to overcome the shortcomings and deficiencies of the existing technology, the present invention provides an online automatic rotary punching system for photovoltaic support spindle.

[0005] The technical solution adopted in this invention is an online automatic rotary punching system for photovoltaic bracket main shafts, comprising: a continuous material conveying roller conveyor, a feeding and diverting flow guide mechanism, a cycle-type feeding conveyor mechanism, a lifting, positioning, and clamping mechanism, a double-end punching actuator, and an intelligent adaptation control module. The input end of the continuous material conveying roller conveyor is connected to the output end of the main shaft forming process, and its output end is correspondingly set to the input end of the feeding and diverting flow guide mechanism. The output end of the feeding and diverting flow guide mechanism is rigidly connected to the input end of the cycle-type feeding conveyor mechanism. A lifting, positioning, and clamping mechanism is set below the output end of the cycle-type feeding conveyor mechanism. Double-end punching actuators are symmetrically arranged on both sides of the lifting, positioning, and clamping mechanism. The double-end punching actuators are signal-connected to the intelligent adaptation control module. The adaptive control module establishes a closed-loop control link with the drive units of the continuous material conveying roller conveyor, the feeding diversion guide mechanism, the cycle feeding conveyor mechanism, the lifting and positioning clamping mechanism, and the double-end punching actuator. The continuous material conveying roller conveyor carries the spindle to be punched and conveys it along a preset trajectory. After receiving a trigger signal, the feeding diversion guide mechanism guides the spindle to the cycle feeding conveyor mechanism. The cycle feeding conveyor mechanism moves the spindle to the lifting and positioning clamping mechanism according to the set rhythm. The lifting and positioning clamping mechanism lifts the spindle vertically and limits it laterally. Under the control of the intelligent adaptive control module, the double-end punching actuator moves to the set position and completes the punching action. After punching, each mechanism resets in sequence, and the spindle is transferred to the next workstation via the conveying unit.

[0006] Furthermore, the cycle-type feeding and conveying mechanism includes a roller conveyor drive unit, a cycle detection unit, a stroke adjustment unit, and a synchronous linkage unit. The roller conveyor drive unit is connected to the conveyor roller shaft via a coupling. The sensor assembly of the cycle detection unit is mounted on the supports on both sides of the conveyor roller conveyor. The screw and nut mechanism of the stroke adjustment unit is slidably connected to the conveyor roller conveyor frame. The gear transmission assembly of the synchronous linkage unit meshes with the output shaft of the roller conveyor drive unit and the input end of the stroke adjustment unit, respectively. The roller conveyor drive unit receives the speed signal from the intelligent adaptation control module to drive the conveyor roller shaft to rotate. The cycle detection unit collects the main shaft conveying position signal in real time and feeds it back to the intelligent adaptation control module. The stroke adjustment unit adjusts the effective conveying length of the conveyor roller conveyor according to the main shaft length parameter. The synchronous linkage unit ensures that the roller conveyor drive and stroke adjustment actions operate in coordination.

[0007] Furthermore, the lifting, positioning, and clamping mechanism includes: a vertical lifting unit, a horizontal limiting unit, a pressure detection unit, and a reset buffer unit. The hydraulic push rod of the vertical lifting unit is vertically installed on the base. The cylinder-driven clamping plates of the horizontal limiting unit are symmetrically arranged on both sides of the lifting platform. The pressure sensor of the pressure detection unit is embedded inside the clamping plate. The spring assembly of the reset buffer unit is elastically connected to the bottom of the lifting platform. After receiving the command, the vertical lifting unit pushes the lifting platform to move upward to lift the main shaft. After the main shaft is in place, the horizontal limiting unit drives the clamping plates to move in opposite directions to clamp the main shaft. The pressure detection unit monitors the clamping force signal in real time and transmits it to the intelligent adaptation control module. After punching is completed, the reset buffer unit assists the lifting platform to fall back smoothly.

[0008] Furthermore, the double-ended punching actuator includes: a moving support unit, a mold mounting unit, a punching drive unit, and a position calibration unit. The linear guide rail of the moving support unit is fixedly connected to the frame. The quick-change bracket of the mold mounting unit is rigidly connected to the slider of the moving support unit. The electric hydraulic cylinder of the punching drive unit is connected to the mold mounting unit for transmission. The laser rangefinder of the position calibration unit is installed at the end of the moving support unit. The moving support unit moves along the linear guide rail under the drive of a servo motor. The mold mounting unit quickly assembles molds of different hole types through the quick-change bracket. The punching drive unit outputs axial force to drive the mold to complete the punching action. The position calibration unit detects the relative position between the mold and the end of the spindle in real time and feeds back a calibration signal.

[0009] Furthermore, the intelligent adaptation control module has a built-in spindle length adaptation model, the model expression of which is: ,in, Adjust the length of the mechanism. Main spindle detection length The length occupied by the clamping mechanism, This is the transmission efficiency coefficient. This is the temperature compensation amount. To calibrate the angle, The wear coefficient of the component. The standard installation length is used.

[0010] Furthermore, the double-ended punching actuator is equipped with a punching position calculation model, the model expression of which is: ,in, This refers to the actual punching location. For reference base position, Design parameters for the i-th hole position. This is the position correction factor. The cumulative deviation for the i-th hole position, For feeding speed, For acceleration, This is the signal delay time.

[0011] Furthermore, the lifting, positioning, and clamping mechanism is equipped with a clamping force control model, the model expression of which is: ,in, To output clamping force, To minimize the required clamping force, The coefficient of friction, The angle of inclination of the clamping plate. The elastic coefficient, For contact area, For preload, The attenuation coefficient is... The clamping and holding time.

[0012] Furthermore, the continuous material conveying roller conveyor is equipped with a conveying speed adaptation model, the model expression of which is: ,in, For roller conveyor speed, Main axis length, To produce the cycle frequency, For synchronization correction coefficients, For the delivery time constant, The waiting time constant, The number of spindles to be transported simultaneously.

[0013] Furthermore, the feeding and diverting guide mechanism is equipped with a diversion angle control model, the model expression of which is: ,in, The rotation angle of the reversing mechanism, As the initial angle, To guide travel deviation, As the guiding coefficient, For conveying speed deviation, For response time, For rotational inertia, For driving torque.

[0014] An online automatic punching system for photovoltaic bracket spindles includes the following steps: First, the sensor components of the continuous material conveying roller conveyor collect the external dimensions and position information of the spindle to be punched, and transmit the collected information to an intelligent adaptation control module for data analysis and processing. Second, the intelligent adaptation control module calls a preset parameter library based on the analysis results and sends a reversing angle command to the feeding and diverting guide mechanism, while simultaneously adjusting the conveying speed of the continuous material conveying roller conveyor to match the process rhythm. Third, the spindle is guided by the feeding and diverting guide mechanism into a cycle-type feeding conveyor mechanism, which gradually moves the spindle to the working area of ​​the lifting, positioning, and clamping mechanism according to the cycle parameters set by the intelligent adaptation control module. Fourth, the lifting, positioning, and clamping mechanism... After receiving the positioning signal, the clamping mechanism initiates a vertical lifting action. Once the main shaft is disengaged from the conveyor rollers, the lateral limiting unit performs precise positioning and clamping of the main shaft, and the pressure detection unit provides real-time feedback on the clamping status data. In the fifth step, the intelligent adaptation control module sends a movement command to the double-end punching actuator according to the hole design parameters. The double-end punching actuator moves along the guide rail to the set position, and the punching drive unit drives the mold to complete the double-end synchronous punching. The position calibration unit calibrates the punching position deviation in real time. In the sixth step, after the punching action is completed, the double-end punching actuator first resets, the lifting positioning clamping mechanism loosens and falls back, and the cycle-type feeding conveyor moves the punched main shaft to the discharge end. It is then transferred to the next workstation via the conveying unit, while the system prepares to receive the next main shaft to be punched.

[0015] Beneficial Effects: This invention proposes an online automatic punching system for photovoltaic bracket spindles. The system uses a continuous material conveyor roller to connect the spindle forming process, eliminating manual stacking and hoisting. Through the automated flow of the feeding diversion guide mechanism and the cycle-type feeding conveyor mechanism, the risk of contact damage and deformation during spindle transport is reduced, completely solving the problems of product scratches and deformation in traditional segmented operations. Utilizing the vertical lifting and lateral limiting of the lifting, positioning, and clamping mechanism, combined with the precise displacement and position calibration function of the double-end punching actuator, manual positioning and pushing operations are replaced. Through the closed-loop control of the intelligent adaptive control module and the coordinated linkage of various mechanisms, the consistency and accuracy of hole processing are ensured, compensating for the instability of hole position data caused by manual operation. Meanwhile, the fully automated operation mode greatly reduces manual intervention. Each mechanism operates efficiently according to the set rhythm. With the quick-change mold and adaptive adjustment function, it can adapt to the processing needs of different specifications of spindles. This not only improves the processing efficiency per unit time, but also reduces the input of labor costs. It successfully breaks through the limitations of low efficiency and high cost of traditional manual operation, and provides reliable technical support for the large-scale and high-precision production of photovoltaic bracket spindles. Attached Figure Description

[0016] Figure 1 This is a diagram showing the system module composition of the present invention; Figure 2 This is a flowchart of the system operation steps of the present invention; Figure 3 This is a three-dimensional schematic diagram of the system structure of the present invention. Detailed Implementation

[0017] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0018] like Figure 1 As shown, an online automatic rotary punching system for photovoltaic bracket spindles includes: a continuous material conveying roller conveyor, a feeding and diverting flow guide mechanism, a cycle-type feeding conveyor mechanism, a lifting, positioning, and clamping mechanism, a double-end punching actuator, and an intelligent adaptation control module. The input end of the continuous material conveying roller conveyor is connected to the output end of the spindle forming process, and its output end is correspondingly set with the input end of the feeding and diverting flow guide mechanism. The output end of the feeding and diverting flow guide mechanism is rigidly connected to the input end of the cycle-type feeding conveyor mechanism. A lifting, positioning, and clamping mechanism is set below the output end of the cycle-type feeding conveyor mechanism. Double-end punching actuators are symmetrically arranged on both sides of the lifting, positioning, and clamping mechanism. The double-end punching actuators are signal-connected to the intelligent adaptation control module. The block establishes a closed-loop control link with the drive units of the continuous material conveying roller conveyor, the feeding diversion guide mechanism, the cycle feeding conveyor mechanism, the lifting positioning and clamping mechanism, and the double-end punching actuator. The continuous material conveying roller conveyor carries the spindle to be punched and conveys it along a preset trajectory. After receiving the trigger signal, the feeding diversion guide mechanism guides the spindle to the cycle feeding conveyor mechanism. The cycle feeding conveyor mechanism moves the spindle to the lifting positioning and clamping mechanism according to the set rhythm. The lifting positioning and clamping mechanism lifts the spindle vertically and limits it laterally. Under the control of the intelligent adaptation control module, the double-end punching actuator moves to the set position and completes the punching action. After punching, each mechanism resets in sequence, and the spindle is transferred to the next workstation via the conveying unit.

[0019] The continuous material conveyor roller conveyor serves as the system's initial feeding unit. It utilizes a one-piece molded roller shaft made of Q235 carbon steel, with a diameter of 85 mm and a length of 6500 mm. The roller shaft surface undergoes high-frequency quenching treatment, achieving a hardness of HRC48-52 to ensure wear resistance and load-bearing strength. The roller shaft spacing is uniformly set at 320 mm, supported by a 12 mm thick steel plate welded frame. The frame bottom is equipped with M24 adjustable anchor bolts, with an adjustment stroke of 50 mm, ensuring the roller conveyor's levelness error does not exceed 0.15 mm / m. Its input end is rigidly connected to the output end of the main shaft forming process via a flange, with the connection gap controlled within 2 mm. The alignment deviation between the output end and the input end of the feeding diversion guide mechanism does not exceed 3 mm. The roller conveyor is driven by a 7.5 kW variable frequency motor with a speed range of... With a conveyor speed of 50-300 rpm, the rollers are driven synchronously by chain transmission, achieving stepless adjustment of the conveying speed from 0.8-4 m / s. Guide baffles with a height of 120 mm are set on both sides of the roller conveyor, and the parallelism error between the baffles and the roller axis does not exceed 0.3 mm. It can carry a main shaft to be punched with a weight of not less than 600 kg, conveying it along a preset straight trajectory with lateral offset controlled within ±1.5 mm. Infrared position sensors are installed below the roller conveyor at 500 mm intervals to collect the main shaft conveying position signal in real time and transmit it to the intelligent adaptation control module to ensure that the main shaft is continuously and smoothly conveyed to the next mechanism. This structure reduces transfer links and improves feeding efficiency through integrated connection design. Its rigid frame and precise guiding design ensure the stability of the main shaft conveying, laying the foundation for subsequent processing accuracy.

[0020] The feeding diversion guide mechanism, serving as the material deflection and connection unit, consists of a 15mm thick 304 stainless steel guide plate, a pneumatic push rod (model SC125×200), and a diffuse reflection infrared sensor. The guide plate is 500mm wide and 800mm long, with R5 rounded edges to prevent scratching the main shaft surface. The pneumatic push rod has a working pressure of 0.65-0.85 MPa, a maximum thrust of 3000 N, a stroke of 200mm, and a response time of no more than 0.25 seconds. The guide plate has a maximum rotation angle of 35 degrees and is hinged to the frame via a 30mm diameter shaft, using a copper bushing bearing to reduce rotational resistance. The infrared sensor is installed on one side of the guide plate's input end, 100mm from the roller conveyor surface, with a detection distance of 0-5... When the sensor detects that the front end of the main shaft has reached the set position, it immediately sends a trigger signal to the intelligent adaptation control module. The control module outputs a command to drive the pneumatic push rod to extend and retract, causing the guide plate to rotate around the shaft to a preset angle, precisely guiding the main shaft to the cycle-type feeding conveyor mechanism. The output end of the mechanism and the input end of the cycle-type feeding conveyor mechanism are rigidly connected by M16 bolts. A 5 mm thick rubber buffer pad is set at the joint to reduce the impact of vibration. This mechanism achieves rapid reversal through pneumatic drive. The infrared sensor accurately triggers to ensure accurate turning timing. The guide plate angle can be preset and adjusted according to the main shaft specifications through the control module to adapt to different conveying needs. Its rigid connection and buffer design ensure a smooth transition of the main shaft during the turning process and avoid collision damage.

[0021] The cycle-type feeding conveyor mechanism serves as a precision feeding unit. The rollers are made of 45# steel, with a diameter of 65 mm and an adjustable length ranging from 3500-6500 mm. The roller surfaces are coated with a 5 mm thick polyurethane wear-resistant coating, achieving a friction coefficient ≥0.8. The roller spacing is 280 mm. Driven by a servo motor (model 130STM-07520), with a power of 4.5 kW and a rated speed of 3000 rpm, the positioning accuracy reaches ±0.08 mm. The roller conveyor frame is constructed from aluminum profiles, making it lightweight yet rigid. The bottom is fixed to the ground via adjustable brackets, with a height adjustment range of 800-1000 mm. The mechanism is equipped with a roller conveyor drive unit, a cycle detection unit, a stroke adjustment unit, and a synchronous linkage unit. The drive unit connects to the conveyor rollers via couplings, achieving a transmission efficiency ≥98%. The laser displacement sensors of the cycle detection unit are mounted on brackets on both sides of the roller conveyor, spaced 800 mm apart, with a detection accuracy of ±0.02 mm. The system collects the main shaft conveying position signal in real time and feeds it back to the intelligent adaptation control module. The ball screw nut mechanism of the stroke adjustment unit has a lead of 10 mm and is driven by a stepper motor with an adjustment speed of 5 mm / s. It adjusts the effective conveying length of the conveyor roller according to the main shaft length parameter. The gear transmission component of the synchronous linkage unit has a module of 2.5 and a transmission ratio of 1:1. It meshes with the output shaft of the roller drive unit and the input end of the stroke adjustment unit respectively to ensure that the roller drive and stroke adjustment actions operate in synergy. The mechanism operates according to the cycle time parameter of 2-8 seconds / piece set by the intelligent adaptation control module, gradually moving the main shaft to the lifting, positioning and clamping mechanism. The distance between the output end and the lifting, positioning and clamping mechanism is maintained at 220 mm. This mechanism achieves precise cycle feeding through the cooperation of servo motor and sensor. The stroke adjustment unit is adapted to main shafts of different lengths. The synchronous linkage design ensures coordinated action. The polyurethane coated roller enhances friction and avoids slippage during the main shaft conveying process, improving feeding accuracy and stability.

[0022] The lifting, positioning, and clamping mechanism, serving as the main shaft fixing unit, consists of a vertical lifting unit, a horizontal limiting unit, a pressure detection unit, and a reset and buffer unit. The vertical lifting unit uses a hydraulic push rod (model HSG-80 / 45) vertically mounted on a cast iron base weighing 500 kg to ensure stability. The hydraulic push rod has a stroke of 220 mm, a maximum lifting force of 9000 N, a lifting speed of 60 mm / s, and a working pressure of 2.5-4 MPa. The lifting platform is constructed from 16 mm thick steel plates welded together. The machine measures 500×800 mm and features a 3 mm thick anti-slip rubber pad on its surface. The lateral limit unit uses an SC80×100 cylinder with a working pressure of 0.5-0.7 MPa and a thrust of 2500 N. The drive clamps are symmetrically arranged on both sides of the lifting platform. These clamps are made of 20 mm thick aluminum alloy with V-grooves machined on the inner side at 90-degree angles to accommodate spindles of different cross-sectional sizes. The clamping stroke is 60-160 mm. The strain gauge pressure sensor of the pressure detection unit is embedded inside the clamp. With a measuring range of 0-10 MPa and an accuracy of ±0.1 MPa, the clamping force signal is monitored in real time and transmitted to the intelligent adaptation control module. The cylindrical helical spring of the reset buffer unit is Φ20×Φ10×100 with an elastic coefficient of 50 N / mm, and is elastically connected to the bottom of the lifting platform. When the spindle is moved to the top of the lifting platform by the cycle-type feeding conveyor mechanism, the intelligent adaptation control module sends a command. The vertical lifting unit pushes the lifting platform upward to lift the spindle, so that the spindle is 10 mm away from the conveyor roller. Then, the horizontal limiting unit drives the clamping plates to move in opposite directions to clamp the spindle. The clamping force is controlled at 3-6 MPa. After the pressure sensor feedback signal reaches the standard, the system enters the punching preparation state. After punching is completed, the horizontal limiting unit first releases the clamp, the vertical lifting unit drives the platform to fall back, and the reset buffer unit assists in a smooth fall to avoid impact. This mechanism achieves double fixation through hydraulic lifting and cylinder clamping. The pressure detection and buffer design ensure accurate and undamaged spindle positioning and adapt to the clamping requirements of spindles of different specifications.

[0023] The double-ended punching actuator, as the core processing unit, is symmetrically arranged on both sides of the lifting, positioning, and clamping mechanism. The spacing between them can be adjusted within the range of 1200-6500 mm. The mechanism includes a moving support unit, a mold mounting unit, a punching drive unit, and a position calibration unit. The linear guide rail of the moving support unit is model HGW45CC, with a length of 3000 mm and a guide rail accuracy grade of H. The slider and the moving seat are rigidly connected. The moving seat is driven by a servo motor with a power of 5.5 kW, a positioning accuracy of ±0.05 mm, and a stepless adjustment speed of 0-100 mm / s. The quick-change chuck of the mold mounting unit adopts a wedge-type structure with a positioning accuracy of ±0.03 mm, which can quickly assemble molds with different hole shapes. The mold hole diameter range is 10-22 mm, and the material is Cr12MoV with a hardness of HRC60-62. The punching drive unit uses an electric hydraulic cylinder of model YE2-160M-4 with a rated thrust of... With a 350 kN range, 80 mm stroke, and a punching speed of 15-35 mm / s, the laser rangefinder of the position calibration unit is installed at the end of the moving support unit. The measurement range is 0-1000 mm with an accuracy of ±0.02 mm. It detects the relative position of the die and the spindle end in real time and provides a calibration signal. The intelligent adaptation control module sends movement commands to the mechanism according to the hole design parameters. The moving support unit moves the die to the set position along the linear guide. After the position calibration unit confirms that the deviation is within the allowable range, the punching drive unit outputs axial force to drive the die to move towards both ends of the spindle, completing the punching action. After punching, the drive unit drives the die to reset, and the moving support unit returns to its initial position. This mechanism achieves precise positioning through servo motor drive, quick-change chuck improves die replacement efficiency, laser calibration ensures punching position accuracy, and the dual-end synchronous punching design improves processing efficiency, adapting to processing needs of different hole types and diameters.

[0024] The intelligent adaptive control module, as the core control unit of the system, adopts an industrial-grade PLC controller, model S7-1500, with a CPU processing speed of 0.1 microseconds / instruction. It is equipped with 16DI / 16DO digital input modules and 8AI / 8AO analog input modules, supports Profinet bus communication, and has a data transmission rate of 100 megabits / second. It features a 12-inch color touchscreen with a resolution of 1920×1080 and an operation response time of ≤0.3 seconds. The module has a built-in 8GB storage unit, capable of storing 1000 sets of machining parameters for different spindle specifications. It establishes a closed-loop control link with the drive units of the continuous material conveyor rollers, feeding diversion guide mechanism, cycle-type feeding conveyor mechanism, lifting, positioning, and clamping mechanism, and double-end punching actuator. The sensors, motors, cylinders, and other actuators of each mechanism are connected via cables using shielded polyurethane cables. The cable, with an IP67 protection rating, is suitable for industrial environments. The module collects position, pressure, and speed signals from each mechanism in real time. After processing by the CPU, it outputs control commands to control each mechanism to operate collaboratively according to preset logic. It can automatically adjust the position and operating parameters of each mechanism based on the spindle length and hole position parameters. For example, after receiving the spindle dimension signal of the continuous material conveying roller, it automatically calculates and sends commands to the stroke adjustment unit to adjust the roller length and sends hole position positioning commands to the double-end punching actuator. It also has a fault diagnosis function. When abnormal sensor signals or mechanism action timeouts are detected, an alarm signal is immediately issued and the system stops. This module achieves fully automated operation through centralized control, and closed-loop control ensures control accuracy. Large-capacity storage and fault diagnosis functions enhance the practicality and stability of the system, providing accurate and reliable control support for the collaborative work of each mechanism.

[0025] Preferably, the cycle-type feeding and conveying mechanism includes: a roller conveyor drive unit, a cycle detection unit, a stroke adjustment unit, and a synchronous linkage unit. The roller conveyor drive unit is connected to the conveyor roller shaft via a coupling. The sensor assembly of the cycle detection unit is mounted on the supports on both sides of the conveyor roller conveyor. The screw and nut mechanism of the stroke adjustment unit is slidably connected to the conveyor roller conveyor frame. The gear transmission assembly of the synchronous linkage unit is respectively engaged with the output shaft of the roller conveyor drive unit and the input end of the stroke adjustment unit. The roller conveyor drive unit receives the speed signal from the intelligent adaptation control module to drive the conveyor roller shaft to rotate. The cycle detection unit collects the main shaft conveying position signal in real time and feeds it back to the intelligent adaptation control module. The stroke adjustment unit adjusts the effective conveying length of the conveyor roller conveyor according to the main shaft length parameter. The synchronous linkage unit ensures that the roller conveyor drive and stroke adjustment actions operate in tandem.

[0026] Specifically, the cycle-type feeding conveyor mechanism, as the core unit connecting the feeding and positioning processes, uses a servo motor (model 130STM-07520) as its roller drive unit. This motor has a rated power of 4.5 kW and a rated speed of 3000 rpm. It is rigidly connected to a 65 mm diameter conveyor roller shaft via a flexible coupling, achieving a transmission efficiency of no less than 98%. It can achieve stepless speed regulation from 0.5 to 3 m / s, ensuring precise matching between the main shaft conveying speed and subsequent processes. The cycle-type detection unit uses laser displacement sensors, installed on supports on both sides of the conveyor rollers at a spacing of 800 mm. The detection accuracy is ±0.02 mm, and the sampling frequency is 1000 Hz. It collects the main shaft conveying position signal in real time and outputs it at a 12 MHz frequency. The speed feedback per second is sent to the intelligent adaptive control module to provide data support for cycle time adjustment; the ball screw nut mechanism of the stroke adjustment unit has a lead of 10 mm and a screw length of 3000 mm. It is driven by a stepper motor and has an adjustment speed of 5 mm / s. It can accurately adjust the effective conveying length of the conveyor roller within the range of 3000-6000 mm according to the spindle length parameter, with an adjustment accuracy of ±0.1 mm; the gear transmission component of the synchronous linkage unit has a module of 2.5, 40 teeth, and a transmission ratio of 1:1. It meshes with the output shaft of the roller drive unit and the input end of the stroke adjustment unit, respectively. The rigid transmission through gear meshing ensures that the roller drive and stroke adjustment actions operate in tandem, with an action synchronization error of no more than 0.2 seconds. Through the organic coordination of its four main units, this mechanism enables the spindle to be precisely moved according to a set cycle time. The cycle time range of 2-8 seconds per piece can be flexibly adjusted to adapt to different production efficiency requirements. Its servo drive and precision detection design ensure the positional accuracy of the spindle conveying, the stroke adjustment function adapts to the processing of multiple spindle specifications, and the synchronous linkage design avoids action conflicts, laying the foundation for the precise implementation of subsequent lifting, positioning, and punching operations.

[0027] Preferably, the lifting, positioning, and clamping mechanism includes: a vertical lifting unit, a horizontal limiting unit, a pressure detection unit, and a reset buffer unit. The hydraulic push rod of the vertical lifting unit is vertically installed on the base. The cylinder-driven clamping plates of the horizontal limiting unit are symmetrically arranged on both sides of the lifting platform. The pressure sensor of the pressure detection unit is embedded inside the clamping plate. The spring assembly of the reset buffer unit is elastically connected to the bottom of the lifting platform. After receiving the command, the vertical lifting unit pushes the lifting platform upward to lift the main shaft. After the main shaft is in place, the horizontal limiting unit drives the clamping plates to move in opposite directions to clamp the main shaft. The pressure detection unit monitors the clamping force signal in real time and transmits it to the intelligent adaptation control module. After punching is completed, the reset buffer unit assists the lifting platform to fall back smoothly.

[0028] Specifically, the vertical lifting unit of the lifting and positioning clamping mechanism uses a hydraulic push rod of model HSG-80 / 45, vertically mounted on a 500 kg cast iron base. The hydraulic push rod has a stroke of 220 mm, a maximum lifting force of 9000 N, a lifting speed of 60 mm / s, and a working pressure of 2.5-4 MPa. The hydraulic system's pressure stabilization control ensures a smooth lifting process, with the main shaft lifting height error not exceeding ±0.5 mm. The lateral limiting unit uses a cylinder of model SC80×100, with a working pressure of 0.5-0.7 MPa and a thrust of 2500 N. It drives 20 mm thick aluminum alloy clamping plates symmetrically arranged on both sides of the lifting platform. The inner side of the clamping plates is machined with a 90-degree V-groove, and the clamping stroke is 60-160 mm, adaptable to different cross-sectional sizes. The spindle has a 3mm thick anti-slip rubber pad pasted on the inside of the clamping plate to increase the friction coefficient and prevent scratches on the spindle surface. The strain gauge pressure sensor of the pressure detection unit is embedded in the inside of the clamping plate, with a range of 0-10 MPa, an accuracy of ±0.1 MPa, and a sampling frequency of 500 Hz. It monitors the clamping force signal in real time and transmits it to the intelligent adaptation control module. When the clamping force reaches the preset range of 3-6 MPa, the feedback signal triggers the next process. The cylindrical helical springs of the reset buffer unit are Φ20×Φ10×100 with an elastic coefficient of 50 N / mm. There are 4 springs, which are evenly distributed at the bottom of the lifting platform and elastically connected to the platform. After punching, they help the lifting platform to fall back smoothly at a speed of 30 mm / s, and the impact force of the fall is controlled within 50 N. This mechanism achieves dual fixation of vertical lifting and horizontal limiting of the spindle through the coordinated operation of four major units. Vertical lifting removes the spindle from the conveyor rollers to avoid conveying interference, while horizontal clamping ensures no displacement of the spindle during processing. Pressure detection ensures that the clamping force is moderate, and reset buffering reduces wear on the mechanism. The design with a positioning accuracy of ±0.05 mm meets the requirements of high-precision punching and effectively solves the problem of manual positioning deviation.

[0029] Preferably, the double-ended punching actuator includes: a movable bearing unit, a mold mounting unit, a punching drive unit, and a position calibration unit. The linear guide rail of the movable bearing unit is fixedly connected to the frame. The quick-change bracket of the mold mounting unit is rigidly connected to the slider of the movable bearing unit. The electric hydraulic cylinder of the punching drive unit is connected to the mold mounting unit for transmission. The laser rangefinder of the position calibration unit is installed at the end of the movable bearing unit. The movable bearing unit moves along the linear guide rail under the drive of a servo motor. The mold mounting unit performs rapid assembly of molds with different hole shapes through the quick-change bracket. The punching drive unit outputs axial force to drive the mold to complete the punching action. The position calibration unit detects the relative position between the mold and the end of the spindle in real time and feeds back a calibration signal.

[0030] Specifically, the moving support unit of the double-ended punching actuator uses a linear guide rail of model HGW45CC, with a length of 3000 mm, accuracy class H, and a parallelism error not exceeding 0.015 mm / m. The slider is rigidly connected to the moving seat, which is driven by a 5.5 kW servo motor via ball screw transmission. The moving speed is infinitely adjustable from 0-100 mm / s, with a positioning accuracy of ±0.05 mm. It can flexibly move the punching parts within a range of 1200-6500 mm, adapting to the punching needs of spindles of different lengths. The quick-change chuck of the die mounting unit adopts a wedge-type structure with a positioning accuracy of ±0.03 mm. The die is fastened with four M16 bolts. The die material is Cr12MoV, with a hardness of HRC60-62 and a hole diameter range of 10-22 mm, allowing for quick assembly. It is equipped with different hole-shaped dies, and the die replacement time is no more than 5 minutes; the punching drive unit adopts an electric hydraulic cylinder of model YE2-160M-4, with a rated thrust of 350 kN, a stroke of 80 mm, and a punching speed of 15-35 mm / s. The punching force is precisely adjusted through the flow control of the hydraulic system to meet the punching requirements of spindles of different thicknesses. The pressure fluctuation during the punching process does not exceed ±5%; the laser range sensor of the position calibration unit is installed at the end of the moving support unit, with a measurement range of 0-1000 mm, an accuracy of ±0.02 mm, and a sampling frequency of 800 Hz. It detects the relative position of the die and the end of the spindle in real time and feeds back the calibration signal. When the detected position deviation exceeds ±0.03 mm, the intelligent adaptation control module immediately sends an adjustment command to drive the moving support unit to fine-tune and ensure accurate punching position. This mechanism achieves synchronous punching at both ends through the coordinated operation of four major units. The high-precision positioning of the moving load-bearing unit ensures uniform hole spacing, the quick-change mold design enhances the flexibility of multi-specification production, the high thrust output of the punching drive unit ensures punching quality, and the position calibration unit corrects deviations in real time, keeping the hole position accuracy within ±0.05 mm, which greatly improves the accuracy and efficiency of punching processing.

[0031] Preferably, the intelligent adaptation control module has a built-in spindle length adaptation model, the model expression of which is: ,in, Adjust the length of the mechanism. Main spindle detection length The length occupied by the clamping mechanism, This is the transmission efficiency coefficient. This is the temperature compensation amount. To calibrate the angle, The wear coefficient of the component. The standard installation length is used.

[0032] Specifically, the intelligent adaptation control module incorporates a spindle length adaptation model to dynamically adjust the installation and operating positions of various mechanisms based on actual spindle detection data, ensuring the system adapts to machining different spindle specifications. During implementation, the spindle detection length is first collected by infrared sensors on the continuous material conveyor rollers. The accuracy of this data is controlled within ±1 mm. Simultaneously, the length occupied by the clamping mechanism is acquired; this length is a preset fixed value, set to 50 to 80 mm based on the clamping mechanism's structural parameters. The transmission efficiency coefficient is determined based on the operating losses of transmission components such as rollers and guide rails, ranging from 0.95 to 0.99. The temperature compensation is calculated based on the difference between the ambient temperature and the standard temperature, with a compensation of 0.1 to 0.3 mm per degree Celsius deviation. The calibration angle is obtained by the position calibration unit, ranging from 0 to 5 degrees. The component wear coefficient is dynamically updated based on the equipment's operating time, with an initial value of 0.01, increasing by 0.002 every 1000 hours of operation. The reference installation length is the system's preset initial spacing between mechanisms, set to 1000 mm. After receiving the above parameters, the module calculates the adjustment length of the mechanism through the model, and then sends adjustment commands to the stroke adjustment unit, double-end punching actuator, etc., to drive the relevant components to move to the corresponding positions, ensuring that the mechanism and the spindle length are accurately matched. The application of this model enables the system to achieve adaptive machining of multi-specification spindles without manual intervention, improving the system's versatility and adjustment accuracy.

[0033] Preferably, the double-ended punching actuator is equipped with a punching position calculation model, the model expression of which is: ,in, This refers to the actual punching location. For reference base position, Design parameters for the i-th hole position. This is the position correction factor. The cumulative deviation for the i-th hole position, For feeding speed, For acceleration, This is the signal delay time.

[0034] Specifically, the punching position calculation model of the double-ended punching actuator is used to accurately determine the actual machining coordinates of each hole on the spindle, ensuring the hole spacing and positional accuracy. During implementation, the reference datum position is the system-preset initial punching datum point, set 50 mm from one end of the spindle. The design parameters for the i-th hole are determined according to the product drawings, representing the theoretical distance of the hole relative to the datum point. The position correction coefficient is determined based on factors such as mold installation errors and mechanism operation deviations, ranging from 0.998 to 1.002. The cumulative deviation of the i-th hole is the sum of the machining deviations of previous holes, updated in real time through the position calibration unit. The feeding speed is the actual operating speed of the cycle-type feeding conveyor, ranging from 0.5 to 3 m / s. The acceleration is the rate of change of speed during mechanism startup and operation, set to 0.2 to 1 m / s. 2 The signal delay time is the total duration of sensor signal transmission and control command response, which has been tested and stabilized between 0.01 and 0.03 seconds. After receiving the above parameters from the intelligent adaptive control module, the actuator calculates the actual punching position of each hole using the model, and then drives the moving support unit to move along the linear guide to the corresponding coordinates. The position calibration unit detects the deviation in real time and provides feedback for correction, ensuring that the hole processing accuracy is controlled within ±0.05 mm. This model effectively compensates for position deviations caused by various factors, improving the accuracy and consistency of punching processing.

[0035] Preferably, the lifting, positioning, and clamping mechanism is equipped with a clamping force control model, the model expression of which is: ,in, To output clamping force, To minimize the required clamping force, The coefficient of friction, The angle of inclination of the clamping plate. The elastic coefficient, For contact area, For preload, The attenuation coefficient is... The clamping and holding time.

[0036] Specifically, the clamping force control model of the lifting and positioning clamping mechanism is used to dynamically adjust the clamping force according to the spindle machining requirements, so as to ensure the spindle positioning is stable and avoid damage to the spindle due to excessive clamping. During implementation, the minimum required clamping force is calculated based on the spindle weight and punching force, ranging from 1500 to 3000 N. The coefficient of friction is the coefficient of friction between the anti-slip rubber pad on the inner side of the clamping plate and the surface of the spindle, which is tested to be 0.3 to 0.5. The clamping plate tilt angle is the angle between the clamping plate and the horizontal direction, set to 3 to 8 degrees. The elastic coefficient is the comprehensive elastic parameter of the clamping plate and the buffer assembly, ranging from 500 to 800 N / mm. The contact area is the actual contact area between the clamping plate and the spindle, calculated based on the spindle cross-sectional dimensions, ranging from 1000 to 3000 square millimeters. The preload force is the initial output force of the clamping mechanism, set to 500 to 1000 N. The attenuation coefficient is determined based on the wear of the mechanism during operation, ranging from 0.001 to 0.003. The clamping holding time is the duration from clamping to punching completion, ranging from 2 to 10 seconds. The pressure detection unit collects clamping force signals in real time and transmits them to the intelligent adaptation control module. The module calculates the target clamping force through the model and then sends an adjustment command to the lateral limit unit to control the cylinder output pressure, so that the clamping force is stabilized within ±5% of the target value. This model realizes precise control of clamping force, adapts to the clamping requirements of different spindle specifications, and ensures positioning stability and spindle integrity.

[0037] Preferably, the continuous material conveying roller conveyor is equipped with a conveying speed adaptation model, the model expression of which is: ,in, For roller conveyor speed, Main axis length, To produce the cycle frequency, For synchronization correction coefficients, For the delivery time constant, The waiting time constant, The number of spindles to be transported simultaneously.

[0038] Specifically, the conveying speed adaptation model of the continuous material conveying roller conveyor is used to dynamically adjust the conveying speed according to the production cycle and spindle parameters to ensure smooth connection between each process. During implementation, the spindle length is the actual length data collected by sensors on the continuous material conveying roller conveyor, ranging from 1000 to 6000 mm; the production cycle frequency is the number of products processed per unit time set by the system, ranging from 6 to 30 pieces / hour; the synchronization correction coefficient is determined based on the cooperative operation deviation between the roller conveyor and subsequent mechanisms, with a value between 1.01 and 1.05; the conveying time constant is the theoretical time for the roller conveyor to transport the spindle from the input end to the output end, calculated based on the roller conveyor length and the reference speed, ranging from 1 to 5 seconds; the waiting time constant is the waiting processing time of the spindle in the subsequent mechanism, set to 0.5 to 2 seconds; and the number of simultaneously conveyed spindles is the number of spindles simultaneously carried on the roller conveyor, ranging from 1 to 3. After receiving the above parameters, the intelligent adaptation control module calculates the roller conveyor speed through the model, and then sends a speed adjustment command to the roller drive unit to dynamically adjust the conveyor speed within the range of 0.5 to 4 m / s. This ensures that the time for the main shaft to reach the feeding diversion guide mechanism is precisely matched with the preparation time of subsequent processes. This model effectively improves the coordination efficiency of each process, avoids waiting or congestion, and ensures the continuity and stability of production.

[0039] Preferably, the feed diversion guide mechanism is equipped with a diversion angle control model, the model expression of which is: ,in, The rotation angle of the reversing mechanism, As the initial angle, To guide travel deviation, As the guiding coefficient, For conveying speed deviation, For response time, For rotational inertia, For driving torque.

[0040] Specifically, the reversing angle control model of the feeding diversion guide mechanism is used to precisely adjust the rotation angle of the guide plate, ensuring that the main shaft smoothly and accurately guides the cycle-type feeding conveyor mechanism. During implementation, the initial angle is the angle between the guide plate and the roller conveyor axis when the guide plate is not moving, set to 0 degrees. The guide stroke deviation is the difference between the actual guide stroke and the theoretical stroke of the guide plate, obtained through position sensor detection, ranging from -5 to 5 mm. The guide coefficient is determined based on the guide plate structure and material, ranging from 0.8 to 1.2. The conveying speed deviation is the difference between the actual conveying speed and the set speed of the roller conveyor, ranging from -0.3 to 0.3 m / s. The response time is the time from when the sensor detects the main shaft to when the guide plate begins to move, set to 0.05 to 0.2 seconds. The moment of inertia is the combined moment of inertia of the guide plate and transmission components, calculated to be 0.5 to 2 kg·m². The driving torque is the output torque of the pneumatic push rod driving the guide plate to rotate, ranging from 50 to 200 N·m. After receiving parameters collected by various sensors, the intelligent adaptation control module calculates the target reversing angle of the guide plate through a model. Then, it sends a control command to the pneumatic push rod to drive the guide plate to rotate around the shaft to the corresponding angle. The angle adjustment accuracy is controlled within ±1 degree. This model ensures that the reversing angle is accurately matched with the main shaft conveying state and the position of the subsequent mechanism, avoiding collisions or deviations when the main shaft turns, and ensuring the smoothness and accuracy of the flow.

[0041] like Figure 2As shown, an online automatic punching system for photovoltaic bracket spindles includes the following steps: First, the sensor components of the material continuous conveying roller conveyor collect the external dimensions and position information of the spindle to be punched, and transmit the collected information to the intelligent adaptation control module for data analysis and processing; Second, the intelligent adaptation control module calls the preset parameter library according to the analysis results, sends a reversing angle command to the feeding and diverting guide mechanism, and simultaneously adjusts the conveying speed of the material continuous conveying roller conveyor to match the process rhythm; Third, the spindle is guided by the feeding and diverting guide mechanism into the cycle-type feeding conveyor mechanism, which gradually moves the spindle to the working area of ​​the lifting, positioning, and clamping mechanism according to the cycle parameters set by the intelligent adaptation control module; Fourth, the lifting and positioning mechanism... After receiving the positioning signal, the clamping mechanism initiates a vertical lifting action. Once the spindle is disengaged from the conveyor rollers, the lateral limiting unit performs precise positioning and clamping of the spindle, and the pressure detection unit provides real-time feedback on the clamping status data. In the fifth step, the intelligent adaptation control module sends a movement command to the double-end punching actuator according to the hole design parameters. The double-end punching actuator moves along the guide rail to the set position, and the punching drive unit drives the mold to complete the double-end synchronous punching. The position calibration unit calibrates the punching position deviation in real time. In the sixth step, after the punching action is completed, the double-end punching actuator first resets, the lifting positioning clamping mechanism releases and falls back, and the cycle-type feeding conveyor moves the punched spindle to the discharge end. It is then transferred to the next workstation via the conveying unit, while the system prepares to receive the next spindle to be punched.

[0042] Figure 3The diagram shown is a three-dimensional schematic of the overall structure of the photovoltaic bracket main shaft online automatic flow punching system. It fully presents the integrated layout of the entire process from feeding, reversing, feeding, positioning and clamping, double-end punching to discharge. The overall equipment adopts a frame-type integrated design, with each functional unit connected in sequence along the production line. The left side is the feeding end, the right side is the discharge end, and the middle is the core processing area. The layout is compact and the process is smooth. The leftmost part of the equipment is a continuous material conveying roller conveyor, serving as the initial feeding unit to receive the main shaft to be punched from the main shaft forming process, ensuring continuous and stable conveying of the main shaft. Adjacent to the conveying roller conveyor is the feeding diversion guide mechanism, composed of a guide plate and pneumatic drive components, responsible for precisely guiding the main shaft to the cycle-type feeding conveyor mechanism, completing the conveying direction switch. The central core area is the cycle-type feeding conveyor mechanism, equipped with a length adaptation mechanism, which can adjust the conveying stroke according to the main shaft specifications, enabling precise movement of the main shaft according to a set cycle. Below and on both sides of the feeding mechanism are lifting, positioning, and clamping mechanisms, and double-ended symmetrical punching execution mechanisms, respectively. The lifting and clamping mechanism fixes the main shaft through vertical lifting and horizontal clamping, while the double-ended punching mechanism is equipped with quick-change molds and linear guides, allowing for synchronous... The machine completes the punching operation at both ends of the spindle, with a position calibration unit ensuring hole accuracy. On the right side of the equipment, a discharge reversing mechanism, discharge roller conveyor, and receiving roller conveyor are sequentially installed to smoothly transfer the punched spindle to the next workstation. The front of the equipment features a 12-inch color touchscreen and an industrial control cabinet. The control cabinet has a built-in intelligent adaptive control module that establishes closed-loop control with various mechanism drive units and sensors via a bus. This allows for real-time adjustment of parameters such as conveyor speed, reversing angle, clamping force, and punching position, adapting to different spindle specifications. The entire machine eliminates manual handling, achieving online automatic spindle rotation and high-precision punching. It combines automation, intelligence, and multi-specification adaptability, intuitively demonstrating the core design features of modular integration, full-process automation, and high-precision collaborative operation.

[0043] An online automatic punching system for photovoltaic bracket spindles systematically overcomes key defects in the prior art through the close cooperation of six modules and sub-units. The system directly connects the spindle forming process with a continuous material conveyor roller, and achieves automated spindle rotation through a feeding diversion guide mechanism and a cycle-type feeding conveyor mechanism. This eliminates the manual stacking and hoisting processes of traditional methods, reducing contact damage to the spindle during transport and fundamentally avoiding the risk of product scratches and deformation, while significantly shortening the production cycle. Relying on the vertical lifting and lateral limiting functions of the lifting, positioning, and clamping mechanism, coupled with the position calibration function of the double-end punching actuator, precise mechanical positioning replaces manual pushing operations. Closed-loop control through an intelligent adaptive control module ensures consistent action of each mechanism, effectively solving the problems of unstable hole spacing and diameter accuracy caused by manual operation.

[0044] Furthermore, the system's modular design and quick-change mold structure allow for flexible adaptation to spindle machining requirements of different lengths and hole shapes. Production specifications can be switched without significant equipment adjustments, enhancing production flexibility and versatility. The entire process eliminates the need for manual intervention in core processes such as loading, positioning, and unloading, reducing labor costs and avoiding the impact of subjectivity and uncertainty in manual operation on production efficiency. Each mechanism operates efficiently according to a preset rhythm, significantly increasing the processing volume per unit time. Through intelligent adaptive control modules that dynamically regulate the operating parameters of each mechanism, combined with feedback mechanisms such as pressure detection and position detection, the stability and consistency of the machining process are ensured. This successfully overcomes the limitations of traditional segmented manual operations, which suffer from low efficiency, high cost, and large fluctuations in product quality, providing reliable technical support for the large-scale, high-precision production of photovoltaic bracket spindles.

[0045] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," "link," and "fix" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0046] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various equivalent changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A photovoltaic bracket spindle online automatic rotary punching system, characterized in that, include: Continuous material conveying roller conveyor, feeding diversion guide mechanism, intermittent feeding conveyor mechanism, lifting positioning and clamping mechanism, double-end punching actuator, intelligent adapter control module; The input end of the continuous material conveying roller conveyor connects to the output end of the main shaft forming process. The output end corresponds to the input end of the feeding diversion and guiding mechanism. The output end of the feeding diversion and guiding mechanism is rigidly connected to the input end of the cycle-type feeding conveyor. A lifting, positioning, and clamping mechanism is installed below the output end of the cycle-type feeding conveyor. Double-end punching actuators are symmetrically arranged on both sides of the lifting, positioning, and clamping mechanism. These double-end punching actuators are signal-connected to an intelligent adaptation control module. The intelligent adaptation control module is connected to the continuous material conveying roller conveyor, the feeding diversion and guiding mechanism, the cycle-type feeding conveyor, and the lifting, positioning, and clamping mechanism, respectively. The drive unit of the double-end punching actuator establishes a closed-loop control link. The material continuous conveying roller conveyor carries the main shaft to be punched and conveys it along the preset trajectory. After receiving the trigger signal, the feeding diversion guide mechanism guides the main shaft to the cycle feeding conveyor mechanism. The cycle feeding conveyor mechanism moves the main shaft to the lifting, positioning and clamping mechanism according to the set cycle. The lifting, positioning and clamping mechanism lifts the main shaft vertically and limits it laterally. Under the control of the intelligent adaptation control module, the double-end punching actuator moves to the set position and completes the punching action. After punching, each mechanism is reset in sequence, and the main shaft is transferred to the next workstation via the conveying unit.

2. The photovoltaic bracket spindle online automatic rotary punching system according to claim 1, characterized in that, The cycle-type feeding and conveying mechanism includes a roller conveyor drive unit, a cycle detection unit, a stroke adjustment unit, and a synchronous linkage unit. The roller conveyor drive unit is connected to the conveyor roller shaft via a coupling. The sensor assembly of the cycle detection unit is mounted on the supports on both sides of the conveyor roller. The screw and nut mechanism of the stroke adjustment unit is slidably connected to the conveyor roller frame. The gear transmission assembly of the synchronous linkage unit meshes with the output shaft of the roller conveyor drive unit and the input end of the stroke adjustment unit, respectively. The roller conveyor drive unit receives the speed signal from the intelligent adaptation control module to drive the conveyor roller shaft to rotate. The cycle detection unit collects the main shaft conveying position signal in real time and feeds it back to the intelligent adaptation control module. The stroke adjustment unit adjusts the effective conveying length of the conveyor roller according to the main shaft length parameter. The synchronous linkage unit ensures that the roller drive and stroke adjustment actions operate in tandem.

3. The photovoltaic bracket spindle online automatic rotary punching system according to claim 1, characterized in that, The lifting, positioning, and clamping mechanism includes: a vertical lifting unit, a horizontal limiting unit, a pressure detection unit, and a reset buffer unit. The hydraulic push rod of the vertical lifting unit is vertically installed on the base. The cylinder-driven clamping plates of the horizontal limiting unit are symmetrically arranged on both sides of the lifting platform. The pressure sensor of the pressure detection unit is embedded inside the clamping plate. The spring assembly of the reset buffer unit is elastically connected to the bottom of the lifting platform. After receiving the command, the vertical lifting unit pushes the lifting platform upward to lift the main shaft. After the main shaft is in place, the horizontal limiting unit drives the clamping plates to move in opposite directions to clamp the main shaft. The pressure detection unit monitors the clamping force signal in real time and transmits it to the intelligent adaptation control module. After punching is completed, the reset buffer unit assists the lifting platform to fall back smoothly.

4. The photovoltaic support spindle online automatic rotary punching system according to claim 1, characterized in that, The dual-end punching actuator includes: a moving support unit, a mold mounting unit, a punching drive unit, and a position calibration unit. The linear guide rail of the moving support unit is fixedly connected to the frame. The quick-change bracket of the mold mounting unit is rigidly connected to the slider of the moving support unit. The electric hydraulic cylinder of the punching drive unit is connected to the mold mounting unit for transmission. The laser rangefinder of the position calibration unit is installed at the end of the moving support unit. The moving support unit moves along the linear guide rail under the drive of a servo motor. The mold mounting unit quickly assembles molds of different hole types through the quick-change bracket. The punching drive unit outputs axial force to drive the mold to complete the punching action. The position calibration unit detects the relative position of the mold and the end of the spindle in real time and feeds back a calibration signal.

5. The photovoltaic bracket spindle online automatic rotary punching system according to claim 1, characterized in that, The intelligent adaptation control module has a built-in spindle length adaptation model, the model expression of which is: ,in, Adjust the length of the mechanism. Main spindle detection length The length occupied by the clamping mechanism, This is the transmission efficiency coefficient. This is the temperature compensation amount. To calibrate the angle, The wear coefficient of the component. The standard installation length is used.

6. The photovoltaic bracket spindle online automatic rotary punching system according to claim 1, characterized in that, The double-ended punching actuator has a punching position calculation model, and the model expression is: ,in, This refers to the actual punching location. For reference base position, Design parameters for the i-th hole position. This is the position correction factor. The cumulative deviation for the i-th hole position, For feeding speed, For acceleration, This is the signal delay time.

7. The photovoltaic bracket spindle online automatic rotary punching system according to claim 1, characterized in that, The lifting, positioning, and clamping mechanism is equipped with a clamping force control model, the model expression of which is: ,in, To output clamping force, To minimize the required clamping force, The coefficient of friction, The angle of inclination of the clamping plate. The elastic coefficient, For contact area, For preload, The attenuation coefficient is... The clamping and holding time.

8. The photovoltaic bracket spindle online automatic rotary punching system according to claim 1, characterized in that, The continuous material conveying roller conveyor is equipped with a conveying speed adaptation model, the model expression of which is: ,in, For roller conveyor speed, Main axis length, To produce the cycle frequency, For synchronization correction coefficients, For the delivery time constant, The waiting time constant, The number of spindles to be transported simultaneously.

9. The photovoltaic bracket spindle online automatic rotary punching system according to claim 1, characterized in that, The feeding diversion guide mechanism is equipped with a diversion angle control model, the model expression of which is: ,in, The rotation angle of the reversing mechanism, As the initial angle, To guide travel deviation, As the guiding coefficient, For conveying speed deviation, For response time, For rotational inertia, For driving torque.

10. A photovoltaic bracket spindle online automatic rotary punching system according to any one of claims 1-9, the system operation includes the following steps: The first step involves collecting the external dimensions and position information of the main shaft to be punched through the sensor components of the continuous material conveying roller conveyor, and transmitting the collected information to the intelligent adaptation control module for data analysis and processing. The second step involves the intelligent adaptation control module calling the preset parameter library according to the analysis results, sending the reversing angle command to the feeding reversing guide mechanism, and simultaneously adjusting the conveying speed of the continuous material conveying roller conveyor to match the process rhythm. The third step involves the spindle being guided into the cycle-feed conveyor mechanism via the feeding diversion guide mechanism. The cycle-feed conveyor mechanism, according to the cycle parameters set by the intelligent adaptation control module, gradually moves the spindle to the working area of ​​the lifting, positioning, and clamping mechanism. The fourth step involves the lifting, positioning, and clamping mechanism receiving a positioning signal and initiating a vertical lifting action. After the spindle disengages from the conveyor rollers, the lateral limit unit performs precise positioning and clamping of the spindle, while the pressure detection unit provides real-time feedback on the clamping status data. The fifth step involves the intelligent adaptation control module sending a movement command to the double-end punching actuator according to the hole design parameters. The double-end punching actuator moves along the guide rail to the set position, and the punching drive unit drives the die to complete synchronous double-end punching. The position calibration unit calibrates the punching position deviation in real-time. The sixth step involves the double-end punching actuator resetting first, the lifting, positioning, and clamping mechanism releasing and falling back, and the cycle-feed conveyor mechanism transferring the punched spindle to the discharge end. The spindle is then transported to the next workstation via the conveying unit, while the system prepares to receive the next spindle to be punched.

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