A two-dimensional laser scanning and automatic positioning shaft workpiece straightening machine and automatic straightening method

Abstract

The application discloses a two-dimensional laser scanning and automatic positioning shaft workpiece straightening machine, which comprises a hydraulic machine, an upper pressing head arranged on the hydraulic machine and vertically moving, a machine body walking mechanism which can move along the longitudinal direction of a workbench and whose position is fed back in real time by a displacement sensor, and workpiece rotating devices arranged on both ends of the workbench and capable of lifting the workpiece and driving the workpiece to rotate, wherein an active end is provided with an angular displacement sensor. The application has the beneficial effects that the straightening is fully automatic and closed-loop, from measurement, peak searching, alignment, support adjustment, pressing to re-inspection, no manual intervention is needed in the whole process, and the production efficiency is greatly improved. The straightening precision is high, and the consistency is good: the two-dimensional laser scanning obtains a complete cross-section profile, which is more accurate than traditional single-point measurement; the closed-loop force-position control avoids over-straightening or under-straightening; and the straightening results of batch products are highly consistent.

Description

Technical Field

[0001] This invention relates to the field of workpiece straightening technology, specifically a two-dimensional laser scanning and automatic positioning shaft workpiece straightening machine and automatic straightening method. Background Technology

[0002] Currently, for bending and straightening long and narrow workpieces such as shafts and bars, semi-automatic equipment with manual assistance is commonly used. A typical process is as follows: The operator uses a lifting device to place the workpiece on fixed rotating devices at both ends of the worktable. Then, a handheld or mobile measuring device (such as a dial indicator) is manually moved along the length of the workpiece to manually locate and mark the highest point of bending. Next, the operator manually inputs parameters such as the support spacing of the straightening anvil and the preset pressing amount on the touchscreen, and manually controls the machine body to align the upper pressing head with the highest point. Afterward, the main hydraulic cylinder is manually lowered to press down using a button. After pressing, the operator manually moves the measuring device again for re-inspection; if it fails, the above process is repeated until the requirements are met. Although some equipment is equipped with simple displacement sensors, the entire process of "measurement-calculation-positioning-pressing-re-inspection" still heavily relies on manual intervention and operator experience.

[0003] 1. Numerous manual intervention steps lead to low efficiency: The determination of the highest bending point, the alignment of the machine body, the setting of the straightening anvil spacing, and the input of the pressing amount all need to be done manually, resulting in long straightening time for a single piece and making it unsuitable for mass production.

[0004] 2. Straightening accuracy depends on operator experience and has poor consistency: the judgment of the highest point position and the setting of the overbending amount are all based on the operator's feeling. Different operators will have different results, which can easily lead to insufficient straightening or reverse over-straightening.

[0005] 3. Outdated measurement methods and incomplete data: Traditional dial indicators or single-point lasers can only measure the runout of a single point on the workpiece surface and cannot obtain complete cross-sectional contour information, resulting in the inability to accurately identify complex bends (such as ellipticity and local depressions).

[0006] 4. Process parameters cannot be self-learned and optimized: The straightening parameters (bending amount, support distance) of each batch of workpieces rely on manual experience input. The equipment cannot accumulate data and automatically generate optimal parameters, which is not conducive to process standardization.

[0007] 5. Safety hazards exist: When manual measurement and parameter setting are performed near the workpiece, if the equipment malfunctions or the workpiece slips, it can easily cause personal injury. Summary of the Invention

[0008] The purpose of this invention is to solve the existing problems by providing a two-dimensional laser scanning and automatic positioning shaft workpiece straightening machine and automatic straightening method.

[0009] The technical solution of the present invention is as follows:

[0010] A two-dimensional laser scanning and automatic positioning shaft workpiece straightening machine includes a hydraulic press and an upper pressure head disposed on the vertically moving hydraulic press;

[0011] The machine body traveling mechanism can move longitudinally along the worktable, and its position is fed back in real time by displacement sensors;

[0012] A workpiece rotation device mounted at both ends of a worktable, capable of lifting and driving the workpiece to rotate, wherein the active end is equipped with an angular displacement sensor;

[0013] Two straightening anvil mechanisms are symmetrically arranged on both sides of the upper pressure head, can move independently, and their positions are controlled by a closed-loop displacement sensor.

[0014] A workpiece measuring device that moves along the workpiece axis and uses a two-dimensional laser displacement sensor is used to acquire the full-length cross-sectional contour data of the workpiece.

[0015] It also includes a PLC control system that receives measurement data, automatically calculates the position of the highest bending point and straightening parameters, and coordinates the actions of all mechanisms.

[0016] Preferably, the hydraulic press consists of an upper crossbeam, a main cylinder, a worktable, a lower crossbeam, a column, and nuts. The upper pressure head is installed on the main cylinder and has a built-in pressure sensor and displacement sensor.

[0017] Preferably, the workpiece measuring device automatically scans once before and once after straightening. The control system determines whether secondary correction is needed based on the re-inspection data and automatically calculates the correction amount before execution.

[0018] Preferably, the workpiece measuring device uses a non-contact two-dimensional laser displacement sensor, which is driven to move linearly along the longitudinal direction of the worktable by a motor reducer, and its position is fed back by the displacement sensor.

[0019] Preferably, the straightening anvil mechanism has a movement interlock function: it can only move longitudinally when the U-shaped anvil descends to the lower limit position, and can only rise to support the workpiece after it has moved into position; its movement is driven by a motor reducer and has self-locking properties.

[0020] Preferably, the active end of the workpiece rotation device is driven by a motor reducer and a chain sprocket, and in conjunction with an angular displacement sensor, the highest point of the workpiece bending is precisely rotated to a vertically upward position; each end is provided with an adjustable pressure lifting cylinder, which continuously holds the workpiece in place during the straightening process to buffer impact vibration.

[0021] Preferably, the PLC control system has a built-in straightening algorithm based on the workpiece material, diameter, heat treatment state, and fulcrum distance, which can automatically generate the bending amount, pressing amount, pressing speed, and holding time; and it has a self-learning function, which can automatically generate straightening parameters according to product attributes after accumulating experience data, without the need for manual input.

[0022] Preferably, the machine body walking mechanism is driven by a drive gear and a fixed rack, and the center position of the machine body is fed back in real time by a displacement sensor so as to automatically align with the highest point of the workpiece bending identified by the measuring device.

[0023] Preferably, the hydraulic system of the main cylinder is independent of the hydraulic systems of the workpiece rotation device and the straightening anvil mechanism, and is respectively arranged in the auxiliary hydraulic stations on the top of the crossbeam of the machine body and in the machine pit.

[0024] An automatic straightening method includes the following steps:

[0025] Step 1: The measuring device moves along the workpiece axis, and the two-dimensional laser sensor scans to obtain the full-length cross-sectional contour data of the workpiece. The control system calculates the position of the highest bending point and the amount of bending.

[0026] Step 2: The machine body traveling mechanism drives the upper pressure head to move directly above the highest point;

[0027] Step 3: The workpiece rotation device rotates the workpiece so that the highest point of the bend is vertically upward;

[0028] Step 4: Move the straightening anvil to the set fulcrum distance position and raise it to support the workpiece;

[0029] Step 5: The main hydraulic cylinder presses down to straighten the cylinder according to the algorithm, providing real-time feedback on pressure and displacement;

[0030] Step 6: The upper pressure head returns, and the measuring device scans and re-inspects again;

[0031] Step 7: If the re-inspection fails, the control system will automatically calculate the amount of correction required and repeat steps 3 to 6 until it passes.

[0032] The beneficial effects of this invention are as follows:

[0033] 1. Fully automated closed-loop straightening: From measurement, peak finding, alignment, support adjustment, pressing to re-inspection, no manual intervention is required throughout the process, greatly improving production efficiency.

[0034] 2. High straightening accuracy and good consistency: Two-dimensional laser scanning obtains the complete cross-sectional profile, which is more accurate than traditional single-point measurement; closed-loop force and position control avoids over-correction or under-correction; the straightening results of batch products are highly consistent.

[0035] 3. High adaptability: The workpiece length is automatically adapted by the passive rotation device at the right end; the spacing between the straightening anvils is automatically adjustable; the U-shaped anvil can be quickly replaced to accommodate different diameters.

[0036] 4. Protect the workpiece surface: Non-contact laser measurement avoids scratches; lifting cylinder buffer reduces impact; precise force control avoids indentation.

[0037] 5. Data traceability and self-learning: The PLC records the original data, straightening parameters and final results of each workpiece, and can automatically optimize the straightening parameters of subsequent workpieces of the same type through a self-learning algorithm.

[0038] 6. Safe and reliable: Multiple safety devices (two-stage support for the main cylinder, two-hand buttons, hydraulic safety valve, electrical overload protection, etc.) ensure safe operation. Attached Figure Description

[0039] Figure 1 This is a front view schematic diagram of the present invention;

[0040] Figure 2 This is a top view of the present invention;

[0041] Figure 3 This is a schematic diagram of the left side of the present invention;

[0042] In the attached diagram: 1. Upper pressure head; 2. Machine body traveling mechanism; 3. Workpiece rotation device; 4. Straightening anvil mechanism; 5. Workpiece measuring device; 6. Upper crossbeam; 7. Main hydraulic cylinder; 8. Worktable; 9. Lower crossbeam; 10. Column; 11. Nut; 12. Two-dimensional laser displacement sensor; 13. Lifting hydraulic cylinder; 14. Drive gear; 15. Fixed rack. Detailed Implementation

[0043] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0044] It should be noted that when a component is described as "fixed to" another component, it can be directly on the other component or may have a component in between. When a component is considered "connected to" another component, it can be directly connected to the other component or may have a component in between. When a component is considered "set on" another component, it can be directly set on the other component or may have a component in between. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0045] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the specification of this invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "or / and" as used herein includes any and all combinations of one or more of the associated listed items.

[0046] like Figure 1-3 As shown, a two-dimensional laser scanning and automatic positioning shaft workpiece straightening machine includes a hydraulic press and an upper pressure head 1 that is vertically moving on the hydraulic press;

[0047] The machine body traveling mechanism 2 can move longitudinally along the worktable 8, and its position is fed back in real time by a displacement sensor;

[0048] A workpiece rotation device 3, mounted at both ends of the worktable 8, can lift the workpiece and drive it to rotate, wherein the active end is equipped with an angular displacement sensor.

[0049] Two straightening anvil mechanisms 4 are symmetrically arranged on both sides of the upper pressure head 1, can move independently and whose positions are controlled by a closed-loop displacement sensor;

[0050] A workpiece measuring device 5, which moves along the workpiece axis and uses a two-dimensional laser displacement sensor 12, is used to acquire the full-length cross-sectional contour data of the workpiece.

[0051] It also includes a PLC control system that receives measurement data, automatically calculates the position of the highest bending point and straightening parameters, and coordinates the actions of all mechanisms.

[0052] Specifically, the hydraulic press consists of an upper crossbeam 6, a main oil cylinder 7, a worktable 8, a lower crossbeam 9, a column 10, and a nut 11. The upper pressure head 1 is installed on the main oil cylinder 7 and has a built-in pressure sensor and displacement sensor.

[0053] Specifically, the workpiece measuring device 5 automatically scans once before and once after straightening. The control system determines whether secondary correction is needed based on the re-inspection data and automatically calculates the correction amount before execution.

[0054] Specifically, the workpiece measuring device 5 uses a non-contact two-dimensional laser displacement sensor 12. The two-dimensional laser displacement sensor 12 is driven to move linearly along the longitudinal direction of the worktable 8 by a motor reducer, and its position is fed back by the displacement sensor.

[0055] Specifically, the straightening anvil mechanism 4 has a movement interlock function: it can only move longitudinally when the U-shaped anvil descends to the lower limit position, and can only rise to support the workpiece after it has moved into position; its movement is driven by a motor reducer and has self-locking properties.

[0056] Specifically, the active end of the workpiece rotation device 3 is driven by a motor reducer and a chain sprocket, and in conjunction with an angular displacement sensor, it precisely rotates the highest point of the workpiece bending to a vertically upward position; each end is provided with an adjustable pressure lifting cylinder 13, which continuously holds the workpiece in place during the straightening process to buffer impact vibration.

[0057] Specifically, the PLC control system has a built-in straightening algorithm based on the workpiece material, diameter, heat treatment status, and fulcrum distance, which can automatically generate the bending amount, pressing amount, pressing speed, and holding time; and it has a self-learning function, which can automatically generate straightening parameters based on product attributes after accumulating experience data, without the need for manual input.

[0058] Specifically, the machine body walking mechanism 2 is driven by the cooperation of the drive gear 14 and the fixed rack 15, and the displacement sensor provides real-time feedback on the center position of the machine body so as to automatically align with the highest point of the workpiece bending identified by the measuring device.

[0059] Specifically, the hydraulic system of the main cylinder 7 is independent of the hydraulic systems of the workpiece rotation device 3 and the straightening anvil mechanism 4, and is respectively arranged on the top of the crossbeam 6 on the machine body and in the machine pit as auxiliary hydraulic stations.

[0060] An automatic straightening method includes the following steps:

[0061] Step 1: The measuring device moves along the workpiece axis, and the two-dimensional laser sensor scans to obtain the full-length cross-sectional contour data of the workpiece. The control system calculates the position of the highest bending point and the amount of bending.

[0062] Step 2: The machine body traveling mechanism 2 drives the upper pressure head 1 to move directly above the highest point;

[0063] Step 3: The workpiece rotation device 3 rotates the highest point of the workpiece bending so that it faces vertically upwards;

[0064] Step 4: Move the straightening anvil to the set fulcrum distance position and raise it to support the workpiece;

[0065] Step 5: The main hydraulic cylinder 7 presses down to straighten the cylinder according to the algorithm, and provides real-time feedback on pressure and displacement;

[0066] Step 6: The upper pressure head returns to its original position, and the measuring device scans and re-inspects the device again;

[0067] Step 7: If the re-inspection fails, the control system will automatically calculate the amount of correction required and repeat steps 3 to 6 until it passes.

[0068] The above description is only for understanding the method and core idea of ​​the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made to the present invention without departing from the principle of the present invention, and these improvements and modifications also fall within the protection scope of the present invention.

Claims

1. A two-dimensional laser scanning and automatic positioning shaft workpiece straightening machine, comprising a hydraulic press, characterized in that: The upper pressure head is installed in the vertical movement of the hydraulic press; The machine body traveling mechanism can move longitudinally along the worktable, and its position is fed back in real time by displacement sensors; A workpiece rotation device mounted at both ends of a worktable, capable of lifting and driving the workpiece to rotate, wherein the active end is equipped with an angular displacement sensor; Two straightening anvil mechanisms are symmetrically arranged on both sides of the upper pressure head, can move independently, and their positions are controlled by a closed-loop displacement sensor. A workpiece measuring device that moves along the workpiece axis and uses a two-dimensional laser displacement sensor is used to acquire the full-length cross-sectional contour data of the workpiece. It also includes a PLC control system that receives measurement data, automatically calculates the position of the highest bending point and straightening parameters, and coordinates the actions of all mechanisms.

2. The shaft workpiece straightening machine with two-dimensional laser scanning and automatic positioning according to claim 1, characterized in that: The hydraulic press consists of an upper crossbeam, a main oil cylinder, a worktable, a lower crossbeam, a column, and nuts. The upper pressure head is installed on the main oil cylinder and has a built-in pressure sensor and displacement sensor.

3. The shaft workpiece straightening machine with two-dimensional laser scanning and automatic positioning according to claim 1, characterized in that: The workpiece measuring device automatically scans once before and once after straightening. The control system determines whether secondary correction is needed based on the re-inspection data and automatically calculates the correction amount before execution.

4. The shaft workpiece straightening machine with two-dimensional laser scanning and automatic positioning according to claim 3, characterized in that: The workpiece measuring device uses a non-contact two-dimensional laser displacement sensor. The two-dimensional laser displacement sensor is driven to move linearly along the longitudinal direction of the worktable by a motor reducer, and the position is fed back by the displacement sensor.

5. The shaft workpiece straightening machine with two-dimensional laser scanning and automatic positioning according to claim 1, characterized in that: The straightening anvil mechanism has a movement interlock function: it can only move longitudinally when the U-shaped anvil descends to the lower limit position, and can only rise to support the workpiece after it has moved into position. Its movement is driven by a motor reducer and has self-locking properties.

6. The shaft workpiece straightening machine with two-dimensional laser scanning and automatic positioning according to claim 1, characterized in that: The active end of the workpiece rotation device is driven by a motor reducer and chain sprockets, and with the help of an angular displacement sensor, it precisely rotates the highest point of the workpiece bending to a vertically upward position; each end is equipped with an adjustable pressure lifting cylinder, which continuously holds the workpiece in place during the straightening process to buffer impact vibration.

7. The shaft workpiece straightening machine with two-dimensional laser scanning and automatic positioning according to claim 1, characterized in that: The PLC control system has a built-in straightening algorithm based on workpiece material, diameter, heat treatment status, and fulcrum distance. It can automatically generate bending amount, pressing amount, pressing speed, and holding time. It also has a self-learning function. After accumulating experience data, the machine can automatically generate straightening parameters according to product attributes without manual input.

8. The shaft workpiece straightening machine with two-dimensional laser scanning and automatic positioning according to claim 1, characterized in that: The machine body walking mechanism is driven by a drive gear and a fixed rack, and the displacement sensor provides real-time feedback on the center position of the machine body so as to automatically align with the highest point of the workpiece bending identified by the measuring device.

9. The shaft workpiece straightening machine with two-dimensional laser scanning and automatic positioning according to claim 2, characterized in that: The hydraulic system of the main cylinder is independent of the hydraulic systems of the workpiece rotation device and the straightening anvil mechanism, and is respectively arranged on the top of the crossbeam of the machine body and in the auxiliary hydraulic station in the machine pit.

10. An automatic straightening method based on the straightening machine according to any one of claims 1-9, characterized in that... Includes the following steps: Step 1: The measuring device moves along the workpiece axis, and the two-dimensional laser sensor scans to obtain the full-length cross-sectional contour data of the workpiece. The control system calculates the position of the highest bending point and the amount of bending. Step 2: The machine body traveling mechanism drives the upper pressure head to move directly above the highest point; Step 3: The workpiece rotation device rotates the workpiece so that the highest point of the bend is vertically upward; Step 4: Move the straightening anvil to the set fulcrum distance position and raise it to support the workpiece; Step 5: The main hydraulic cylinder presses down to straighten the cylinder according to the algorithm, providing real-time feedback on pressure and displacement; Step 6: The upper pressure head returns, and the measuring device scans and re-inspects again; Step 7: If the re-inspection fails, the control system will automatically calculate the amount of correction required and repeat steps 3 to 6 until it passes.

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