A multi-directional top die forging press automatic spraying system and spraying method

Abstract

The application discloses a kind of multi-direction top die forging pressure automatic spraying system and spraying method, belong to the field of automatic technology of forging die.It is compact to the structure of multi-direction top die forging pressure equipment, and traditional device cannot cover the problem of side die ejector rod spraying blind area, the application proposes a kind of modular partition spraying scheme, including upper and lower die cavity swing spraying assembly, double-sided independent side die ejector rod rotary spraying assembly, constant pressure feed unit and PLC control unit.By using "station time staggered dislocation parallel spraying process", the full coverage atomization spraying of die cavity and double-sided die ejector rod is completed step by step in the gap of forging operation.The application realizes the full-automatic dead angle-free spraying of side die ejector rod, the coating uniformity is high, and the spraying process and forging process are parallel, without additional production cycle.

Description

Technical Field

[0001] This invention belongs to the field of automated spraying technology for forging dies, specifically relating to an automated spraying system and method for multi-directional top die forging. Background Technology

[0002] Multi-directional die forging is widely used in the mass production of complex forgings due to its high forming accuracy. During hot forging, in order to reduce the frictional resistance between the forging and the die cavity, improve the surface quality of the forging, and prevent adhesion, a release agent / lubricant such as graphite emulsion needs to be sprayed onto the die cavity and the surface of the side die ejector pins before forging.

[0003] In the existing technology, the spraying of mold release agents has the following technical defects: (1) The equipment has a compact structure and the side mold ejector pin holes at the working position are small. Traditional methods cannot achieve synchronous spraying of the mold cavity and the double side mold ejector pins, resulting in a spraying blind area; (2) Existing automatic spraying devices (such as CN210160333U) can only cover the upper and lower molds and cannot spray the side mold ejector pins; (3) The quality of manual spraying is unstable and greatly affected by the operator's skill level; (4) It cannot be adapted to unmanned production lines, resulting in long production cycles; (5) Uneven coating leads to rapid mold wear and short lifespan.

[0004] Therefore, there is an urgent need for a fully automatic, blind-angle-free spraying system that can adapt to narrow workstations and simultaneously cover the mold cavity and side mold ejector pins. Summary of the Invention

[0005] The purpose of this invention is to solve the problems of blind spots in the spraying (especially the inability to cover the side mold ejector pins), unstable quality, and low efficiency in the existing technology, and to provide a multi-directional top die forging automatic spraying system and method to achieve fully automatic coverage spraying of the side mold ejector pins.

[0006] System components: Upper and lower mold swing spraying unit: includes servo telescopic arm and swing nozzle, used for spraying the inner walls of the upper and lower mold cavities; Side mold ejector rotary spraying unit: Two sets of independent rotary nozzles, each equipped with a servo driver and a fluid rotary distributor, for uniform circumferential spraying of the double side mold ejectors; Constant pressure feeding unit: storage tank + constant pressure cabinet, ensuring stable spraying pressure; PLC timing control unit: coordinates the timing of spraying and forging actions.

[0007] A servo telescopic arm is used to send the oscillating nozzle into the center of the mold cavity for oscillating spraying, achieving full coverage of the inner wall of the mold cavity; two sets of independent rotating nozzles are used to perform rotating spraying on the ejector pins on both sides outside the mold cavity according to the switching of the side top mold position. Rotating spraying makes the paint evenly adhere to the circumferential surface of the ejector pin, solving the lubrication problem of narrow hole walls.

[0008] Method flow: S1 Initial spraying of the non-working ejector pin; S2 Spraying the mold cavity; S3 Material feeding; S4 Simultaneous spraying of the other ejector pin during forging; S5 Switching stations to perform supplementary spraying of the ejector pin on the previous side of the mold; S6 Material removal; S7 Cycle. The following results are obtained: (1) Eliminating blind spots in spraying: The combination of "swinging + rotation" process achieves fully automatic coverage spraying of the side mold ejector pins for the first time; (2) Fully automated and unmanned: PLC closed-loop control, no manual intervention required; (3) High efficiency and parallel operation: The top rod spraying is embedded in the forging process, which does not take up extra time; (4) High quality: Constant pressure feeding + rotary spraying ensures uniform and dense coating, extending mold life; (5) High versatility: core process parameters can be preset and finely adjusted to adapt to different mold specifications.

[0009] In the field of multi-directional top die forging, due to the compact equipment structure and the extremely small distance between the side die ejector pins and the die cavity, those skilled in the art generally believe that this narrow space cannot accommodate an automatic spraying device, thus manual spraying has been the long-standing practice. Existing automatic spraying devices (such as CN210160333U) can only cover the upper and lower dies, without providing technical guidance on setting up a spraying device at the side die ejector pins. This invention overcomes the aforementioned technical bias by innovatively utilizing a fluid rotary distributor (which maintains stable fluid transmission during the transport process of a rotating mechanical carrier) to remove the ejector pins, which are set on the outside of the die via servo-driven rotating nozzles, from their exit position. Spraying is completed using the gap between the side die ejector pins entering and exiting the die, thereby achieving fully automatic coverage spraying of the side die ejector pins without increasing equipment complexity. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of the system structure of the present invention; Figure 2 This is a schematic diagram of the mobile spray painting machine. Figure 3 This is a schematic diagram of the swing mechanism unit; Figure 4 This is a schematic diagram of the side mold ejector rotating spraying mechanism unit.

[0011] 1-Mobile spray painting machine; 1.1-Swing mechanism; 1.2-Telescopic arm; 1.3-Telescopic arm base; 1.4-Telescopic arm connecting plate; 1.5-Side slide rail; 1.6-Telescopic arm bottom rail slide rail; 1.7-Telescopic arm bottom rail slider; 1.8-Spray painting machine outer cover; 1.9-Side slide rail slider; 1.1.1-Servo drive; 1.1.2-Eccentric wheel; 1.1.3-Rocker arm frame-1; 1.1.4-Rocker arm frame-2; 1.1.5-Swing shaft frame; 1.1.6-Spraying pipe; 1.1.7-Upper nozzle; 1.1.8-Lower nozzle; 1.1.9-Swing head housing; 2-Side mold ejector pin rotary spraying mechanism-1; 2.1-Servo driver; 2.2-Left side fluid rotary distributor; 2.3-Left side spraying nozzle; 2.4-Mold ejector pin rotary spraying bracket; 2.5-Right side fluid rotary distributor; 2.6-Right side spraying nozzle; 3-Side mold ejector rotary spraying mechanism-2 (same structure as side mold ejector rotary spraying mechanism-1); 4-Moving side top mold; 5-Lower mold; 6-upper mold; 7-Control cabinet; 8-Constant pressure switchgear; 9-Storage tank. Detailed Implementation

[0012] The invention will now be further described with reference to the accompanying drawings. like Figure 1 As shown, this system includes a mobile spraying machine (1), a side mold top rod rotating spraying mechanism (2, 3), a mobile side top mold (4), a lower mold (5), an upper mold (6), a control cabinet (7), a constant pressure cabinet (8), and a storage tank (9). The storage tank (9) stores the paint, which is then pressure-stabilized by the constant pressure cabinet (8) and transported to the mobile spraying machine (1) and the rotating spraying mechanism (2, 3).

[0013] like Figure 2-3 As shown, the mobile spraying machine is equipped with a servo-driven telescopic arm (1.2) and a swing mechanism (1.1). The telescopic arm can adjust its extension stroke according to the depth of the mold cavity, sending the upper nozzle (1.1.7) and lower nozzle (1.1.8) at the end into the predetermined position inside the mold cavity. The swing mechanism is driven by a servo drive (1.1.1) to drive the eccentric wheel (1.1.2) to make the rocker arm frame (1.1.3, 1.1.4) swing back and forth around the swing axis frame (1.1.5), driving the nozzle to perform uniform atomized spraying on the inner wall of the mold cavity.

[0014] like Figure 4As shown, the side mold ejector rotary spraying mechanism is equipped with a servo driver (2.1) and a fluid rotary distributor (2.2, 2.5). The fluid rotary distributor (2.2, 2.5) is one of the key components of this invention, which can maintain a continuous supply of paint while the spray nozzle (2.3, 2.6) rotates around the ejector axis, thereby achieving circumferential uniform spraying on the ejector surface.

[0015] S1 Initial spraying: The equipment is started, the side top mold is located at the side mold top rod-2 station, the side mold rotating nozzle-1 (2) is started, and the side mold top rod-1 is initially sprayed.

[0016] S2 Mold Cavity Spraying: The mold is reset to the initial position, the telescopic arm (1.2) extends to the center of the mold cavity, the swing nozzle is started, and the inner walls of the upper mold (6) and lower mold (5) are sprayed with full-area swing atomization.

[0017] S3 Feeding: The telescopic arm retracts, and hot blanks are fed into the mold cavity.

[0018] S4 Synchronous Spraying: The upper mold (6) moves down to close the mold, and the side mold ejector pin-1 is positioned to press and perform forging operations. At this time, the side mold rotating nozzle-2 (3) is activated to perform low-speed constant rotation spraying on the side mold ejector pin-2. This step is parallel to the forging process and does not take up extra production time.

[0019] S5 Re-spraying: After the die forging is completed, the side top die is moved forward to the side die ejector rod-2 position to perform side top operation. The side die rotating nozzle-1 (2) simultaneously sprays the side die ejector rod-1 to ensure full coverage.

[0020] S6 Material Retrieval and Cycle: Forging is completed, and the die is lifted to retrieve the material. After the die is reset, the system automatically enters the next cycle (starting from S2 die cavity spraying).

[0021] This invention achieves seamless integration of spraying and forging by precisely controlling the timing of each mechanism using a PLC. Compared with the closest prior art (CN210160333U), the side mold ejector rotating spraying assembly and the timing-staggered parallel process of this invention realize fully automated coverage spraying of both side mold ejectors for the first time, significantly improving production efficiency and coating quality.

[0022] In this embodiment, core process parameters such as the rotational speed of the rotary nozzle, the nozzle swing amplitude, the spraying time, and the constant pressure can all be preset and precisely fine-tuned by the PLC, making it adaptable to different specifications of molds and different forging processes, with extremely strong versatility and equipment compatibility.

[0023] This invention innovatively employs a modular, zoned spraying and time-sharing, staggered parallel operation process, overcoming the technical bottleneck of not being able to automatically and synchronously spray multiple parts in a narrow workstation of a multi-directional top mold. In particular, it solves the long-standing industry problem of not being able to automatically spray the side mold ejector pins. The equipment has a simple structure, low modification costs, and can be directly adapted to upgrade existing equipment. Through PLC fully automatic closed-loop control, it achieves unmanned spraying operations, standardized quality, and collaborative processes, effectively improving the forming quality of forgings and reducing mold maintenance costs, possessing extremely high industrialization and promotion value.

Claims

1. A multi-directional top die forging automatic spraying system, characterized in that, Includes forging die components, zoned spraying components, material feeding components, and electrical control components; The forging die assembly includes an upper die, a lower die, a side die ejector pin-1, a side die ejector pin-2, and a movable side die. The partitioned spraying assembly includes an upper and lower mold cavity swing spraying unit and a double-sided mold ejector rotating spraying unit. The upper and lower mold cavity swing spraying unit includes a servo-driven telescopic arm and upper and lower symmetrical swing nozzles installed at the ends of the telescopic arm for full-area atomization spraying of the inner walls of the upper and lower mold cavities. The double-sided mold ejector rotating spraying unit includes a first rotating nozzle corresponding to the side mold ejector-1 and a second rotating nozzle corresponding to the side mold ejector-2. Both sets of rotating nozzles can perform circumferential rotating spraying corresponding to the ejector axis. The feeding assembly includes a storage tank, a constant pressure cabinet, and a mobile spraying machine. The storage tank is connected to the mobile spraying machine and the double-sided mold ejector rotary spraying unit via the constant pressure cabinet, and is used to supply paint with constant pressure and constant flow. The electrical control component includes a control cabinet with a built-in PLC control module. The control cabinet is connected to the electrical control system of the forging equipment, the zone spraying component, and the material feeding component to realize the time-linked closed-loop control of the spraying process and the forging process.

2. The multi-directional top die forging automatic spraying system according to claim 1, characterized in that, The telescopic arm is a servo-electric driven structure that can precisely adjust the telescopic stroke according to the depth of the mold cavity, driving the end swing nozzle to extend into the preset spraying position of the mold cavity, and completing the full coverage spraying of the inner wall of the mold cavity in conjunction with the reciprocating swing action.

3. The multi-directional top die forging automatic spraying system according to claim 1, characterized in that, The dual-sided mold ejector rotary spraying unit is equipped with a servo driver and a fluid rotary distributor. The fluid rotary distributor can maintain continuous and stable coating delivery during nozzle rotation, without material interruption or pressure fluctuation.

4. The multi-directional top die forging automatic spraying system according to claim 1, characterized in that, The constant pressure cabinet has a built-in pressure sensing and adjustment module that stabilizes the coating pressure inside the pipeline in real time, ensuring a constant spray output flow and uniform coating thickness.

5. An automatic spraying method for multi-directional top die forging, characterized in that, The automatic spraying system according to any one of claims 1-4 comprises the following steps: S1. Initial spraying of single-sided ejector pin: After the equipment is reset, the movable side ejector pin is moved to the working position of the side ejector pin-2, so that the side ejector pin-1 is completely separated from the mold cavity. The first rotating nozzle is started to perform 360° all-round atomized spraying on the side ejector pin-1. S2, Mold Cavity Full Area Spraying: All molds are reset to the initial standby position, the servo telescopic arm extends and enters the preset position inside the upper and lower mold cavities, and the swing nozzle is started to swing back and forth to complete the full area atomization spraying of the inner wall of the upper and lower mold cavities. S3. Precise billet delivery: After the mold cavity spraying operation is completed, the telescopic arm drives the swing nozzle to automatically reset and retract, delivering the hot forging billet into the mold cavity; S4. Forging and ejector pin synchronous spraying: Drive the upper mold to move down and close the mold, and cooperate with the side mold ejector pin-1 to complete the forging and clamping operation. Simultaneously start the second rotating nozzle to perform all-round atomized spraying on the side mold ejector pin-2 that has detached from the mold cavity. The spraying process and the forging process are carried out in parallel. S5, Station Switching and Re-spraying: After the single-wheel forging process is completed, the side top die can be moved to the side die ejector pin-2 working position to perform side top operation. At the same time, the first rotating nozzle is started to spray the coating on the side die ejector pin-1 to ensure that the ejector pin coating is uniform, dense and without omissions. S6. Forming and material removal: After the multi-directional top die forging process is completed, the side dies and the upper die are reset and the formed forging blank is removed. S7. Automated Cyclic Operation: All molds and spraying mechanisms are reset to their initial state, and the system automatically restarts the spraying program, cyclically executing processes S2 to S6 to achieve continuous automated production.

6. The automatic spraying method for multi-directional top die forging according to claim 5, characterized in that, In steps S1, S4, and S5, the rotating nozzle maintains a constant low speed rotation, which, combined with the constant pressure cabinet, ensures real-time pressure stabilization and material supply, so that the coating adheres evenly to the circumferential surface of the top rod, forming a dense protective coating with uniform thickness and strong adhesion.

7. The automatic spraying method for multi-directional top die forging according to claim 5, characterized in that, The entire spraying process is controlled by a PLC program with a pre-set closed-loop timing. All top rod spraying operations are embedded in the forging operation intervals, without requiring additional equipment production cycle time and man-hours.

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