A floating actuator calibration device

Abstract

The present application relates to the technical field of automobile parts preparation, and particularly relates to a floating actuator calibration device, which comprises a floating frame, a transmission device for being connected to an output end of an actuator, a driving device for driving the actuator to rotate, and a calibration device for calibrating a rotation angle of the actuator, wherein the calibration device comprises an encoder connected to an upper end of a transmission shaft, and further comprises a limiting device capable of angularly positioning the transmission shaft, a controller records the rotation angle of the actuator, and the encoder records the rotation angle of the transmission shaft; if a difference between the rotation angle recorded by the controller and the rotation angle recorded by the encoder is within a set range, it is determined that the rotation angle of the actuator is accurate; if the difference between the rotation angle recorded by the controller and the rotation angle recorded by the encoder exceeds the set range, it is determined that the rotation angle of the actuator is inaccurate.

Description

Technical Field

[0001] This invention relates to the field of automotive parts manufacturing technology, and more particularly to a floating actuator calibration device. Background Technology

[0002] Currently, production line actuators commonly employ an angle detection structure that combines a Hall sensor and a magnet. The magnet is fixed to the bottom of the actuator's output gear, and the Hall sensor and magnet maintain a specific relative position. The actuator requires prior calibration and learning before it can achieve precise control of the output angle. To further improve the actuator's angle control accuracy, higher requirements are placed on the stroke angle accuracy during calibration and the perpendicularity of the calibration mechanism to the product.

[0003] The existing production line actuator calibration mechanism has the following obvious shortcomings in practical applications, which seriously affect calibration accuracy, operational stability and service life, as follows: 1. Poor orientation and positioning accuracy, prone to coordination failures. The original calibration mechanism's transmission spline shaft relied on a rigid spring to provide downward aligning force. However, the spring force distribution of this rigid spring was uneven, resulting in poor centering guidance. During the alignment process, the spline shaft was prone to skew and misalignment, preventing it from smoothly inserting into the spline hole of the product's output gear. This not only affected calibration efficiency but could also cause mechanical damage to the spline shaft or the product's output gear, increasing production costs.

[0004] 2. Insufficient stroke accuracy leads to angle control deviation. In existing calibration mechanisms, the installation distance between the limit block and the spline shaft is relatively large, and the intermediate drive shaft adopts a segmented structure, with each segment connected by a coupling. During the calibration process, when the drive shaft rotates, relative sliding and rotational deviations easily occur between the segments, leading to reduced stroke accuracy. Consequently, there are significant differences in the angle control of the actuator, failing to meet the requirements for high-precision calibration.

[0005] 3. High operating resistance, prone to wear and tear, and high energy consumption. In the original calibration mechanism, the drive shaft and spline groove are connected by a rectangular spline block, which engages with the spline groove through sliding friction. The sliding friction provides significant resistance, leading to increased current and energy consumption as the product drives the calibration mechanism. Furthermore, prolonged sliding friction causes wear on the spline block and spline groove, reducing the mechanism's lifespan and increasing maintenance costs and downtime. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a floating actuator calibration device.

[0007] This invention is achieved through the following technical solution: a floating actuator calibration device, comprising a floating frame, wherein the floating frame is equipped with a transmission device for connecting to the output end of the actuator, a drive device for driving the actuator to rotate, and a calibration device for calibrating the rotation angle of the actuator. The transmission device includes a transmission shaft, and the lower end of the transmission shaft is provided with a connecting shaft for connecting to the actuator. The drive device includes a pin plug mounted on a floating frame. The pin plug is electrically connected to a controller. The pin plug is connected to a plug-in drive structure, which drives the pin plug to plug into and disconnect from the electrical interface of the actuator. The calibration device includes an encoder connected to the upper end of the drive shaft, and also includes a limiting device that can position the drive shaft at an angle.

[0008] Furthermore, the floating frame includes an upper mounting plate, which is connected to a lower mounting plate via a connecting column.

[0009] Furthermore, the lower end of the drive shaft extends outside the floating frame, and a connecting shaft for connecting to the actuator is coaxially arranged at the lower end of the drive shaft. The upper end of the connecting shaft is detachably connected to the lower end of the drive shaft through a connecting sleeve. A guide head is also coaxially installed at the lower end of the connecting shaft, and the lower end surface of the guide head is a spherical surface.

[0010] Furthermore, the insertion and removal drive structure includes a drive cylinder three connected to the lower mounting plate. The drive cylinder three is installed laterally, and the drive cylinder three is connected to a lateral connecting frame via a downward push plate three. The free end of the connecting frame is connected to a pin via a pin seat.

[0011] Furthermore, the needle holder is also equipped with a buffer device for providing elastic cushioning for the pin. The buffer device includes a support sleeve on the needle holder, with the pin inserted through the outer end of the support sleeve and an electrical post connected to the inner end of the support sleeve. The pin is electrically connected to the controller through the electrical post. The pin slides with the support sleeve to form an electrical connection. The pin and the electrical post are electrically connected through the support sleeve. A buffer cavity is formed inside the support sleeve, and a buffer spring is installed inside the buffer cavity to provide elastic cushioning for the pin.

[0012] Furthermore, the limiting device includes a guide seat disposed on the upper end of the encoder, a drive cylinder mounted on the lower mounting plate via a support, the drive cylinder being connected to a plate-shaped stop pin via a push plate, a guide port cooperating with the stop pin being provided on the guide seat, the stop pin and the guide port being in sliding engagement, a pressure plate being provided at the guide port to limit the stop pin, and a limiting block cooperating with the stop pin being mounted on the transmission shaft.

[0013] Furthermore, it also includes a marking device for marking the side of the actuator. The marking device includes a second drive cylinder mounted on the lower mounting plate. The second drive cylinder is connected to a horizontal support tube via a downward push plate. The support tube is connected to a marking head pointing towards the actuator.

[0014] Furthermore, the marking head is installed inside the support tube, a plug is provided at the outer end of the support tube, and a compression spring is also provided inside the support tube. The compression spring is limited by the plug, thereby providing elastic force to the marking head. A limit cover is provided at the inner end of the support tube, and the marking head cooperates with the limit cover through a step.

[0015] Furthermore, the floating frame is also equipped with a handle, which is connected to the upper mounting plate.

[0016] The beneficial effects of this invention are as follows: During the calibration process, the actuator is first gripped onto the positioning fixture by a robotic arm, with the output end of the actuator facing upwards. The lifting drive cylinder actuates, driving the connecting shaft downwards to connect with the output end of the actuator. Then, the drive cylinder actuates again, driving the pin to connect electrically with the actuator's electrical interface. The controller then drives the actuator to rotate, causing the drive shaft to rotate until the stop pin contacts the limit block. The controller detects an increase in current, confirming that the stop pin is in contact with the limit block. The encoder is zeroed, and calibration begins. The controller then controls the actuator to rotate in the opposite direction until the stop pin... Upon re-contact with the limit block, the controller records the actuator's rotation angle, and the encoder records the drive shaft's rotation angle. If the difference between the rotation angle recorded by the controller and the rotation angle recorded by the encoder is within the set range, the actuator's rotation angle is determined to be accurate. If the difference between the rotation angle recorded by the controller and the rotation angle recorded by the encoder exceeds the set range, the actuator's rotation angle is determined to be inaccurate. The second drive cylinder is activated, and a mark is made on the side of the actuator using a marking head. Then, the second and third drive cylinders are reset, and the actuator is removed from the self-positioning fixture by a robotic arm. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the main view of Example 1; Figure 2 This is a schematic diagram of the floating frame structure; Figure 3 This is a schematic diagram of the limiting device structure; Figure 4 This is a schematic diagram of a pin connector structure; Figure 5 This is a cross-sectional view of a pin connector; Figure 6 This is a schematic diagram of the retaining pin structure; Figure 7 This is a schematic diagram of the drive shaft structure; Figure 8 This is a schematic diagram of the connecting shaft structure; Figure 9 This is a schematic diagram of the cross-section of the marker head; Figure 10 This is a schematic diagram of the retaining pin structure in Example 2; Figure 11 This is a schematic diagram of the guide seat structure in Example 2.

[0018] in: 101. Upper mounting plate; 102. Connecting column; 103. Lower mounting plate; 104. Guide sleeve; 105. Connecting block; 106. Opening; 2. Drive shaft; 201. Retaining ring; 202. Rotating seat; 203. Limiting block; 204. Keyway; 3. Encoder; 4. Guide seat; 401. Guide port; 402. Adjustment port; 5. Drive cylinder one; 502. Pressure plate; 503. Push plate one; 504. Stop pin; 6. Aviation connector; 7. Actuator; 801. Drive cylinder two; 802. Push plate two; 803. Support tube; 804. Plug; 805. Marking head; 806. Limit cover; 901. Connecting sleeve; 902. Connecting shaft; 903. Guide head; 1001. Drive cylinder three; 1002. Push plate three; 1003. Connecting frame; 1004. Pin seat; 1005. Pin; 1006. Support sleeve; 1007. Electric stake; 1008. Buffer chamber. Detailed Implementation

[0019] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" 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 connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0020] 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.

[0021] Example 1 like Figure 1-9As shown, a floating actuator calibration device is used to calibrate the actuator 7 of an automotive thermal management module, mainly a control valve. The device includes a floating frame, which comprises an upper mounting plate 101 connected to a lower mounting plate 103 via a connecting column 102. The upper and lower mounting plates 101 and 103 provide a foundation for the calibration device and form a frame structure for easy installation and maintenance. Either the upper or lower mounting plate 101 is connected to a lifting drive source. In this embodiment, a lifting drive source is selected. The cylinder of the lifting drive cylinder (not shown in the figure) is fixed on the frame. The piston rod of the lifting drive cylinder passes downward through the opening 106 on the upper mounting plate 101 and then connects with the connecting block 105 on the lower mounting plate 103. A guide sleeve 104 is also installed on the upper mounting plate 101. The lifting of the floating frame is guided by the guide rod installed in the guide sleeve 104. The lifting drive cylinder drives the floating frame to float as a whole. The structures installed on the floating frame are relatively stationary, thus preventing the components from becoming loose.

[0022] A transmission device for connecting to the output end of actuator 7 is installed on the floating frame. Specifically, the transmission device includes a transmission shaft 2. The upper end of the transmission shaft 2 extends upward outside the floating frame, thereby connecting to a torque load. The lower end of the transmission shaft 2 extends outside the floating frame. A connecting shaft 902 for connecting to actuator 7 is coaxially connected to the lower end of the transmission shaft 2. The connecting shaft 902 matches the output end of actuator 7, thereby enabling precise transmission. The upper end of the connecting shaft 902 is detachably connected to the lower end of the transmission shaft 2 through a connecting sleeve 901 and is radially positioned by a key. A guide head 903 is also coaxially installed on the lower end of the connecting shaft 902. The lower end surface of the guide head 903 is a spherical surface and is made of nylon material, thereby avoiding rigid contact between the connecting shaft 902 and the output end of actuator 7.

[0023] The floating frame is equipped with a radial positioning structure for radial positioning of the drive shaft 2. In this embodiment, the radial positioning structure includes a bearing fitted on the lower end of the drive shaft 2. The lower end of the drive shaft 2 is connected to the floating frame through the bearing, thereby protecting the lower end of the drive shaft 2. When the connecting shaft 902 is damaged, it can be quickly replaced. A retaining ring 201 is also installed on the upper end of the drive shaft 2 to prevent the drive shaft 2 from sliding downward. A keyway 204 is machined along the length direction on the drive shaft 2 to radially position the rotating seat 202 and other structures.

[0024] The floating frame is also equipped with a drive device for driving the actuator 7 to rotate. In this embodiment, the drive device includes a pin plug 6, which is electrically connected to the controller. The pin plug 6 is connected to a plug-in drive structure, which drives the pin plug 6 to plug in and disconnect from the electrical interface of the actuator 7. Specifically, the plug-in drive structure includes a drive cylinder 1001 connected to the lower mounting plate 103. The drive cylinder 1001 is mounted horizontally and is connected to a horizontal connecting frame 1003 via a downward push plate 1002. The free end of the connecting frame 1003 is connected to a pin 1005 via a pin seat 1004. When the drive cylinder 1001 moves, it drives the pin 1005 to connect or disconnect from the electrical interface of the actuator 7. To improve the efficiency of the pin 1005... To ensure the connection stability between the electrical interface of 05 and actuator 7, a buffer device is also installed on the needle holder 1004 to provide elastic cushioning for the pin 1005. The buffer device includes a support sleeve 1006 that is mounted on the needle holder 1004. The support sleeve 1006 is a copper sleeve with good conductivity. The pin 1005 is mounted on the outer end of the support sleeve 1006, and an electrical post 1007 is connected to the inner end of the support sleeve 1006. The controller is electrically connected through the electrical post 1007. The pin 1005 and the support sleeve 1006 slide to form an electrical connection. The pin 1005 and the electrical post 1007 are electrically connected through the support sleeve 1006. A buffer cavity 1008 is formed inside the support sleeve 1006. A buffer spring is installed in the buffer cavity 1008 to provide elastic cushioning for the pin 1005.

[0025] The floating frame is also equipped with a calibration device for calibrating the rotation angle of the actuator 7. The calibration device includes an encoder 3 connected to the upper end of the drive shaft 2. Specifically, the encoder 3 is mounted on the lower mounting plate 103. The encoder 3 detects the rotation angle of the drive shaft 2 to calibrate the actuator 7. The calibration device also includes a limiting device that can position the drive shaft 2 at an angle. In this embodiment, the limiting device includes a guide seat 4 connected to the upper end of the encoder 3. A drive cylinder 501 is mounted on the lower mounting plate 103 via a support. The drive cylinder 501 is connected to a plate-shaped stop pin 504 via a push plate 503. A guide is machined on the guide seat 4 to cooperate with the stop pin 504. The guide port 401 and the stop pin 504 slide together. A pressure plate 502 is also installed at the guide port 401 to limit the stop pin 504. A limiting block 203 that cooperates with the stop pin 504 is installed on the drive shaft 2. Specifically, a rotating seat 202 is mounted on the drive shaft 2 and can rotate with the drive shaft 2. The limiting block 203 is integrally formed on the rotating seat 202. When the limiting block 203 contacts the stop pin 504, the angle of the encoder 3 is zeroed and calibration begins. To facilitate the adjustment of the angle of the guide seat 4, an arc-shaped adjustment port 402 is machined on the guide seat 4. The guide seat 4 is connected to the encoder 3 by bolts installed in the adjustment port 402.

[0026] The floating frame is also equipped with a marking device for marking the side of the actuator 7. In this embodiment, the marking device includes a second drive cylinder 801 connected to the lower mounting plate 103. The second drive cylinder 801 is connected to a horizontal support tube 803 via a downward push plate 802. The support tube 803 is connected to a marking head 805 pointing towards the actuator 7. Specifically, the marking head 805 is a smearing head, which can be a marker pen. The marking head 805 is inserted into the support tube 803. A plug 804 is installed at the outer end of the support tube 803. A compression spring is also installed inside the support tube 803. The compression spring is limited by the plug 804, thereby providing elastic force to the marking head 805. A limit cover 806 is installed at the inner end of the support tube 803. The marking head 805 cooperates with the limit cover 806 through a step, thereby preventing it from detaching from the support tube 803.

[0027] In this embodiment, a handle is also installed on the floating frame, which is connected to the upper mounting plate 101 to facilitate overall handling. After the floating frame and its transmission device, drive device, calibration device, marking device and other structures are pre-assembled, they are moved as a whole through the handle and then installed on the lifting drive cylinder. The floating frame is also connected to an aviation plug 6 to facilitate connection to the controller via a cable.

[0028] The floating actuator calibration device provided in this embodiment, in conjunction with the positioning fixture on the platform, first uses a robotic arm to grip the actuator 7 onto the positioning fixture during the calibration process. With the output end of the actuator 7 pointing upwards, the lifting drive cylinder actuates, driving the connecting shaft 902 downwards to connect with the output end of the actuator 7. Then, the drive cylinder 1001 actuates, driving the pin 1005 to electrically connect with the electrical interface of the actuator 7. The controller then drives the actuator 7 to rotate, causing the drive shaft 2 to rotate until the stop pin 504 contacts the limit block 203. The controller detects an increase in current, determining that the stop pin 504 is in contact with the limit block 203. The encoder 3 is zeroed, and calibration begins. The controller controls... Actuator 7 rotates in the reverse direction until stop pin 504 contacts limit block 203 again. Controller records the rotation angle of actuator 7, and encoder 3 records the rotation angle of drive shaft 2. If the difference between the rotation angle recorded by controller and encoder 3 is within the set range, the rotation angle of actuator 7 is judged to be accurate. If the difference between the rotation angle recorded by controller and encoder 3 exceeds the set range, the rotation angle of actuator 7 is judged to be inaccurate. Drive cylinder 2 801 is activated, and a mark is made on the side of actuator 7 by marking head 805. Then drive cylinder 2 801 and drive cylinder 3 1001 are reset, and actuator 7 is taken out of the self-positioning fixture by robotic arm.

[0029] It is worth noting that when the calibration angle exceeds one revolution, the stop pin 504 is moved outward by the drive cylinder 501 to avoid interference with the limit block 203. When the calibration is about to end, the stop pin 504 is reset by the drive cylinder 501 to stop the limit block 203.

[0030] Example 2 like Figure 10-11 As shown, a floating actuator calibration device differs from Embodiment 1 in that it has two sets of limiting devices. There is an angle between the two limiting blocks 203 of the two sets of limiting devices and an angle between the two stop pins 504. With two limiting blocks 203 and two stop pins 504, by controlling the extension and retraction of the stop pins 504, it is possible to calibrate the actuator 7 at multiple angles within the same circumference.

[0031] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A floating actuator calibration device, characterized in that, The system includes a floating frame, on which are mounted a transmission device for connecting to the output end of the actuator, a drive device for driving the actuator to rotate, and a calibration device for calibrating the rotation angle of the actuator. The transmission device includes a transmission shaft, and the lower end of the transmission shaft is provided with a connecting shaft for connecting to the actuator. The drive device includes a pin plug mounted on a floating frame. The pin plug is electrically connected to the controller. The pin plug is connected to a plug-in drive structure, which drives the pin plug to plug in and disconnect from the electrical interface of the actuator. The calibration device includes an encoder connected to the upper end of the drive shaft, and also includes a limiting device that can position the drive shaft at an angle.

2. The floating actuator calibration device according to claim 1, characterized in that, The floating frame includes an upper mounting plate, which is connected to a lower mounting plate via a connecting column.

3. The floating actuator calibration device according to claim 2, characterized in that, The lower end of the drive shaft extends outside the floating frame. A connecting shaft for connecting to the actuator is coaxially arranged at the lower end of the drive shaft. The upper end of the connecting shaft is detachably connected to the lower end of the drive shaft through a connecting sleeve. A guide head is also coaxially installed at the lower end of the connecting shaft. The lower end surface of the guide head is a spherical surface.

4. The floating actuator calibration device according to claim 2, characterized in that, The insertion and removal drive structure includes a drive cylinder three connected to the lower mounting plate. The drive cylinder three is installed horizontally. The drive cylinder three is connected to a horizontal connecting frame through a downward push plate three. The free end of the connecting frame is connected to a pin through a pin seat.

5. The floating actuator calibration device according to claim 4, characterized in that, The needle holder is also provided with a buffer device for providing elastic cushioning for the pin. The buffer device includes a support sleeve on the needle holder, the outer end of the support sleeve is fitted with the pin, and the inner end of the support sleeve is connected to an electrical stake, which is electrically connected to the controller. The pin slides with the support sleeve to form an electrical connection. The pin and the electrical stake are electrically connected through the support sleeve. A buffer cavity is formed inside the support sleeve, and a buffer spring is installed in the buffer cavity to provide elastic cushioning for the pin.

6. The floating actuator calibration device according to claim 2, characterized in that, The limiting device includes a guide seat set on the upper end of the encoder, a drive cylinder mounted on the lower mounting plate via a support, the drive cylinder being connected to a plate-shaped stop pin via a push plate, a guide port on the guide seat that cooperates with the stop pin, the stop pin slidingly engaging with the guide port, a pressure plate at the guide port for limiting the stop pin, and a limiting block on the drive shaft that cooperates with the stop pin.

7. The floating actuator calibration device according to claim 2, characterized in that, It also includes a marking device for marking the side of the actuator, the marking device including a second drive cylinder mounted on the lower mounting plate, the second drive cylinder being connected to a horizontal support tube via a downward push plate, and the support tube being connected to a marking head pointing towards the actuator.

8. The floating actuator calibration device according to claim 7, characterized in that, The marking head is installed inside the support tube, and a plug is provided at the outer end of the support tube. A compression spring is also provided inside the support tube. The compression spring is limited by the plug, thereby providing elastic force to the marking head. A limit cover is provided at the inner end of the support tube, and the marking head cooperates with the limit cover through a step.

9. The floating actuator calibration device according to claim 2, characterized in that, The floating frame is also equipped with a handle, which is connected to the upper mounting plate.

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