An automatic control method and system for oil reservoir seat production mold

Abstract

The application discloses an automatic control method and system for a production mold of an oil storage cylinder seat. The control method is applied to a mold integrated with a composite machining station and a stamping station, and a shearing cutter and a punch are coaxially driven. The method is cyclically executed: in a shearing stage, the downward speed and pressure are dynamically adjusted according to stress feedback, and stamping forming is synchronously completed; in a re-cutting stage, a re-cutting cutter with a back structure with barbs hooks and cuts off a waste connection point and discharges the waste when an upper die goes up; in a pushing stage, a blank pushing track is corrected in real time through position feedback, and a finished product is synchronously pushed out; in a quality monitoring stage, automatic diversion of the finished product is performed based on visual detection, and mold partition constant temperature control is realized according to multi-point temperature acquisition and a preset algorithm. The control system comprises a core logic controller, a state sensing module, an execution driving module and a data interaction module. The application realizes full-process automatic production, and effectively improves production efficiency and product precision.

Description

Technical Field

[0001] This invention belongs to the field of industrial automation control technology, and more specifically, it relates to an automated control method and system for producing molds for oil storage tank seats. Background Technology

[0002] As a key component in automotive shock absorbers and various hydraulic equipment, the production quality of the oil reservoir seat directly affects the sealing performance and durability of the entire machine. In the existing production process of oil reservoir seats, multiple sets of molds are usually used to complete the shearing, blanking and stamping in steps, or the continuous action is achieved in the same mold through simple mechanical transmission.

[0003] Currently, an existing technical solution (the applicant's prior patent application, application number: 202610413776.9) discloses a mold structure for the production of oil reservoir seats. This structure integrates the shearing and stamping stations into the same mold, achieving integrated production at the physical level and effectively improving production efficiency.

[0004] However, this mold structure still has the following shortcomings in actual operation: the actions of its various actuators (such as pushers and waste removal mechanisms) are mostly based on preset fixed programs, lacking real-time perception and intelligent control of the production process. For example, when shearing different batches of plates or plates with thickness tolerances, fixed shearing parameters can easily lead to tool wear or unstable shearing quality; the temperature changes of the mold under high-frequency stamping also lack precise control, affecting product accuracy. Therefore, an intelligent control method is urgently needed to fully realize the performance potential of this integrated mold. Summary of the Invention

[0005] The present invention aims to overcome the deficiencies in the prior art and provide an automated control method and control system for the production mold of oil storage tank seat.

[0006] To achieve the above objectives, the present invention provides the following technical solution: An automated control method for producing oil reservoir base molds, applied to the production of oil reservoir base molds, includes the following steps: Flow and shearing stage: Control the upper die to descend and perform shearing action on the sheet metal located at the composite processing station to obtain a circular blank; during the descent of the upper die, the shearing cutter completes the cutting, and the stress data of the sheet metal during the shearing process is collected by the stress sensor and the shearing parameters are dynamically adjusted; during the period when the upper die descends to the bottom and holds pressure, the punch is used to simultaneously perform stamping action on the previous blank located at the stamping station to obtain the finished oil reservoir seat; Double cutting stage: Control the upper die to move upward and reset. During the upward movement of the upper die, the double cutting tool uses the barbed structure blade located on the back of the shearing tool to hook and trim the waste material connection point. After the upper die is fully reset, the waste discharge mechanism is triggered to discharge the trimmed waste material. Pushing phase: During or after the upper die is resetting, the first pushing mechanism is controlled to push the circular blank from the composite processing station to the stamping station to prepare for the next stamping, and the pushing trajectory is corrected in real time during the pushing process; at the same time, the second pushing mechanism is controlled to push the finished product out of the mold. Quality monitoring stage: The visual inspection unit identifies surface defects and dimensional accuracy of the finished product, and controls the operation of the finished product diversion mechanism to adjust the flow direction of the finished product based on the identification results; at the same time, the temperature sensor collects temperature data at multiple points of the mold, and controls the operation of the cooling system and auxiliary heating unit to maintain the constant temperature of the mold.

[0007] Furthermore, the logic for dynamically adjusting the shearing parameters during the flow and shearing stages is as follows: the collected stress data is compared with a preset stress threshold; when the stress data is greater than the preset upper limit threshold, the downward speed of the upper die is reduced, and the shearing pressure is maintained or increased; when the stress data is less than the preset lower limit threshold, the downward speed of the upper die is increased and the shearing pressure is reduced.

[0008] Furthermore, in the pushing phase, the specific steps for correcting the pushing trajectory include: collecting real-time displacement and velocity data of the first pushing mechanism through a position sensor, comparing the real-time data with preset pushing trajectory parameters, and correcting the pushing trajectory in real time based on the comparison deviation.

[0009] Furthermore, the double-cutting tool is fixedly installed on the back of the shearing tool, and its blade has an outwardly protruding barb structure; the protrusion height of the barb structure is adapted to the thickness of the waste connection point, so that the waste can be separated by relative motion when the upper die moves upward.

[0010] Furthermore, the specific logic of mold temperature control in the quality monitoring stage is as follows: the multi-point temperature data is compared with the preset zone temperature threshold range, and the cooling power is calculated by a preset algorithm in combination with the stamping frequency and billet material parameters; if the temperature data exceeds the upper limit of the threshold range, the cooling system is controlled to increase the output power; if the temperature data is lower than the lower limit, the cooling system is controlled to reduce the power and start the auxiliary heating unit.

[0011] Furthermore, the preset algorithm is: Cooling power = Adjustment coefficient × (Current temperature - Midpoint of threshold range) × Stamping frequency coefficient × Material thermal conductivity.

[0012] The present invention also provides a control system for an oil reservoir base production mold, for implementing the above-mentioned control method, comprising: Core logic controller: includes a PLC programmable logic controller and an industrial microcontroller, wherein the PLC and the industrial microcontroller communicate bidirectionally and work together. Status perception module: includes stress sensor, position sensor, temperature sensor and vision inspection unit, used to collect mold operation status data; The execution drive module includes a punch press driver, a push mechanism driver, a cooling driver, a flow divider driver, and a waste discharge driver. Data interaction module: Used to store production data and display equipment operating status and alarm information.

[0013] Compared with the prior art, the present invention has the following beneficial effects: 1. By mounting the shearing cutter and the stamping punch on the same drive shaft, the shearing and stamping actions are performed synchronously, eliminating the waiting time between processes. Combined with the coordinated actions of the first pushing mechanism, the second pushing mechanism, the waste discharge mechanism, and the finished product diversion mechanism, the entire process from sheet metal shearing, waste re-cutting, blank pushing, stamping, finished product inspection to waste discharge and finished product diversion is fully automated, which greatly improves production efficiency, reduces labor costs, and avoids the safety hazards caused by manual operation.

[0014] 2. During the shearing process, stress sensors collect data in real time and dynamically adjust shearing parameters to avoid stress overload fracture of the sheet or incomplete shearing; during the pushing process, the pushing trajectory is corrected in real time to ensure accurate positioning of the billet; the mold is temperature controlled in zones to avoid thermal deformation of the mold, effectively improving the dimensional accuracy of the billet and the forming quality of the finished product, and reducing the product defect rate. Attached Figure Description

[0015] Figure 1 This is a flowchart illustrating the method. Figure 2 This is a schematic diagram of the system structure; Figure 3 This is a schematic diagram of the shearing blade structure. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of this invention clearer, the automated control method and control system for the production mold of the oil storage tank seat of this invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of protection of this invention.

[0017] Example 1 like Figure 1As shown, an automated control method for an oil reservoir seat production mold is disclosed. This control method is applied to the oil reservoir seat production mold, which includes a frame, a composite processing station, a stamping station, a first pushing mechanism located between the composite processing station and the stamping station, a second pushing mechanism located on the discharge side of the composite processing station, a vision inspection unit, a waste removal mechanism, a finished product diversion mechanism, and a temperature control component, all mounted on the frame. The composite processing station is equipped with an upper mold integrating a shearing tool and a double-cutting tool, and a lower mold adapted to the upper mold. The shearing tool of the upper mold and the punch of the stamping station are mounted on the same drive shaft, achieving synchronous coordination of shearing and stamping actions. This drive shaft is driven by a punch press driver, allowing precise control of the downward speed and pressure.

[0018] The control method includes the following steps that are executed cyclically: The flow and shearing stage control system issues commands to control the drive shaft to move the upper die downwards along the guide assembly, performing a shearing action on the strip sheet located on the lower die of the composite processing station. Through the cooperation of the shearing cutter and the lower die, a circular blank that meets the size requirements is obtained. After the circular blank is cut, the first pushing mechanism pushes the circular blank to the stamping station.

[0019] During the downward movement of the upper die, stress sensors installed on the lower die of the composite processing station collect stress data of the sheet metal in real time and transmit it to the core logic controller. The core logic controller analyzes and processes the received stress data in real time, dynamically adjusts the shearing parameters, ensures the stability of the shearing process, and avoids damage to the sheet metal. When the upper die reaches the bottom and enters the pressure holding stage, since the shearing cutter and the punch of the stamping station are installed on the same drive shaft, the punch moves downward synchronously, performing a stamping forming action on the pre-push circular blank to the stamping station to produce a finished oil reservoir seat that meets the specifications; the pressure holding time can be preset according to the blank material and stamping accuracy requirements.

[0020] The logic for dynamically adjusting shearing parameters is as follows: The core logic controller pre-stores preset stress thresholds corresponding to the billet material and thickness, including an upper limit threshold and a lower limit threshold. Real-time stress data is compared with the preset stress thresholds: when the real-time stress data is greater than the preset upper limit threshold, the core logic controller controls the punch press driver to reduce the upper die's downward speed and maintain or appropriately increase the shearing pressure to ensure smooth shearing; when the real-time stress data is less than the preset lower limit threshold, the core logic controller controls the punch press driver to increase the upper die's downward speed and reduce the shearing pressure, balancing shearing efficiency and quality.

[0021] Secondary cutting stage: After stamping, the core logic controller controls the drive shaft to move the upper die upwards and reset. During the upward movement of the upper die, the secondary cutting tool integrated into the upper die moves upwards synchronously. This secondary cutting tool is fixedly installed on the back of the shearing tool, and its cutting edge has an outwardly protruding barb structure. The protrusion height of the barb structure is adapted to the thickness of the waste material connection point. When the upper die moves upwards, the barb structure cutting edge and the sheared waste material end generate relative movement, hooking and trimming the remaining waste material connection point to ensure complete separation of the waste material from the sheet metal.

[0022] After the upper mold has fully moved upward and reset, the core logic controller triggers the waste discharge mechanism to discharge the recut and trimmed waste material from the discharge channel of the composite processing station by blowing air or pushing. The waste material is collected by the guide plate to ensure that the discharge channel is unobstructed.

[0023] Pushing Phase: During or after the upper die's upward reset, the core logic controller controls the first pushing mechanism to push the sheared circular blank from the feeding channel of the composite processing station to the stamping cavity of the stamping station, preparing for the next stamping process. During the pushing process, the real-time displacement and speed data of the first pushing mechanism are collected by position sensors. The core logic controller analyzes and processes the data, corrects the pushing trajectory in real time, and ensures that the blank is accurately pushed to the preset position.

[0024] At the same time, the core logic controller controls the second pushing mechanism to push the stamped oil reservoir seat out of the mold from the stamping cavity and transport it to the detection area of ​​the vision inspection unit, so as to realize the synchronous operation of blank pushing and finished product ejection.

[0025] The specific steps for correcting the push trajectory include: the core logic controller pre-stores the preset push trajectory parameters of the first push mechanism; the displacement and velocity data collected in real time by the position sensor are compared with the preset parameters to calculate the deviation value; the core logic controller controls the push mechanism driver to adjust the push speed and displacement of the first push mechanism according to the deviation value, thereby correcting the push trajectory in real time.

[0026] Quality monitoring stage: After the finished product is conveyed to the inspection area of ​​the vision inspection unit, the vision inspection unit identifies the surface defects and dimensional accuracy of the finished product in real time and transmits the identification results to the core logic controller. The core logic controller controls the operation of the finished product diversion mechanism: if the finished product is qualified, it is conveyed to the qualified finished product collection area; if it is unqualified, it is conveyed to the defective product collection area, realizing automatic diversion.

[0027] Simultaneously, temperature sensors collect temperature data from multiple points on the mold and transmit it to the core logic controller in real time. The core logic controller, based on the zoned temperature threshold ranges and current operating conditions, controls the cooling system and auxiliary heating unit to maintain a constant mold temperature. Specifically, the control logic is as follows: when the temperature of a certain part exceeds the upper limit of the corresponding threshold range, the core logic controller controls the cooling driver to increase the cooling power; when the temperature is below the lower limit of the threshold range, the cooling power is reduced and the auxiliary heating unit is activated until the temperature recovers. The cooling power is calculated using a preset algorithm: Cooling power = Adjustment coefficient × (Current temperature - Midpoint of threshold range) × Stamping frequency coefficient × Material thermal conductivity. This algorithm enables precise zoned control of the mold temperature.

[0028] This embodiment specifically applies the above-mentioned control method. The blank uses 3mm thick steel, with a preset stress threshold upper limit of 50MPa and a lower limit of 30MPa; the mold zone temperature threshold range is 50-80℃, with an adjustment coefficient of 1.0; the stamping frequency is 10 times / minute, the stamping frequency coefficient is 1.2, and the thermal conductivity of the steel is 48W / (m·K); the preset pushing displacement is 150mm, and the pushing speed is 50mm / s.

[0029] Its working process is as follows: In the flow and shearing stage: the core logic controller controls the upper die to descend, shearing to obtain a circular blank with a diameter of 80mm. When the stress sensor detects a stress of 55MPa (greater than the upper limit of 50MPa), the controller reduces the descending speed of the upper die from 100mm / s to 80mm / s; when the stress is 28MPa (less than the lower limit of 30MPa), the descending speed is increased to 110mm / s, and the shearing pressure is reduced from 100kN to 90kN. After the upper die reaches the bottom, it holds pressure for 2 seconds, and the punch simultaneously completes the stamping of the previous blank.

[0030] Secondary cutting stage: The upper die moves upward, and the secondary cutting tool (with a barb protrusion height of 0.5mm) completes the hook cutting and trimming. After resetting, the waste discharge mechanism discharges the waste material by blowing air.

[0031] Pushing phase: When the upper die moves to half position, the first pushing mechanism pushes the blank. When the pushing displacement deviation is detected to be 2mm, the controller corrects the pushing trajectory in real time; at the same time, the second pushing mechanism pushes out the finished product.

[0032] During the quality monitoring phase: Visual inspection identifies defective products with 0.1mm scratches on the surface, and the controller directs the diversion mechanism to guide them to the defective product area. Simultaneously, if the temperature of the first die at the stamping station is detected to be 85℃ (exceeding the upper limit of 80℃), the controller calculates the cooling power as 1.0×(85-65)×1.2×48=1152W using a preset algorithm and adjusts the cooling system output power to 1152W for cooling. If the temperature of the lower die at the composite processing station is detected to be 48℃ (below the lower limit of 50℃), the auxiliary heating unit is activated to raise the temperature.

[0033] The above steps are repeated cyclically, enabling continuous, high-precision automated production of the oil storage tank seat.

[0034] Example 2 like Figure 2 As shown, a control system for an oil reservoir base production mold is used to implement the above-mentioned automated control method. It includes a core logic controller, a state sensing module, an execution drive module, and a data interaction module. The modules are connected to each other via wired or wireless communication.

[0035] The core logic controller comprises a PLC (Programmable Logic Controller) and an industrial microcontroller, which communicate bidirectionally and work collaboratively. The PLC is responsible for the logic control and process scheduling of each mechanism's actions, while the industrial microcontroller is responsible for real-time acquisition of sensor data, parameter calculation, and instruction amplification. The core logic controller has built-in preset programs that store control parameters such as shearing parameters, push trajectory parameters, temperature threshold ranges, stamping and holding times, and preset algorithms. It can also automatically adjust the control strategy based on data collected by the status sensing module.

[0036] The state perception module includes a stress sensor installed on the lower die of the composite processing station to collect shear stress data; position sensors installed on the first and second pushing mechanisms and the upper die to collect real-time displacement, velocity, and position data; temperature sensors evenly distributed on key parts such as the first die, the second die of the stamping station, and the lower die of the composite processing station to collect multi-point temperature data; and a vision inspection unit installed on one side of the finished product discharge channel to identify surface defects and dimensional accuracy of the finished product.

[0037] The execution drive module includes: a punch press driver connected to the drive shaft to control the upper die movement; a push mechanism driver connected to the first and second push mechanisms respectively to control the push movement; a cooling driver connected to the cooling system of the temperature control component to control the cooling power; a diversion driver connected to the finished product diversion mechanism to control the finished product flow direction; and a waste discharge driver connected to the waste discharge mechanism to control the waste discharge movement.

[0038] The data interaction module includes a data storage unit and a display unit. The data storage unit stores data such as stress, temperature, push notifications, and quality inspection data during the production process and supports historical queries. The display unit uses a touch screen to display the equipment's operating status, various parameters, and alarm information in real time, and supports parameter setting, command issuance, and fault reset operations.

[0039] During operation, the status perception module collects various types of data and transmits them to the core logic controller. After analysis and processing, the controller issues instructions to the execution drive module to drive the actions of each mechanism, achieving fully automated control of the entire process. At the same time, all statuses and data are displayed, stored, and used for human-machine interaction through the data interaction module.

[0040] It should be noted that the preset parameters, tool structure dimensions and types of actuators involved in this invention can be flexibly adjusted and adapted according to the blank material, thickness, stamping accuracy and production cycle requirements in actual production, and are not limited to the specific values ​​and models recorded in the above embodiments. Any non-creative changes made based on the concept of this invention are within the protection scope of this invention.

Claims

1. An automated control method for a production mold of an oil reservoir base, characterized in that, The mold used in the production of oil reservoir seats includes the following steps: Flow and shearing stage: Control the upper die to descend and perform shearing action on the sheet metal located at the composite processing station to obtain a circular blank; during the descent of the upper die, the shearing tool completes the cutting, and the stress data of the sheet metal during the shearing process is collected by the stress sensor and the shearing parameters are dynamically adjusted; during the period when the upper die descends to the bottom and holds pressure, the punch is used to simultaneously perform stamping action on the previous blank located at the stamping station to obtain the finished oil reservoir seat; Double cutting stage: Control the upper die to move upward and reset. During the upward movement of the upper die, the double cutting tool uses the barbed structure on the back of the shearing tool to hook and trim the waste material connection point. After the upper die is fully reset, the waste discharge mechanism is triggered to discharge the trimmed waste material. Pushing phase: During or after the upper die is resetting, the first pushing mechanism is controlled to push the circular blank from the composite processing station to the stamping station to prepare for the next stamping, and the pushing trajectory is corrected in real time during the pushing process; at the same time, the second pushing mechanism is controlled to push the finished product out of the mold. Quality monitoring stage: The visual inspection unit identifies surface defects and dimensional accuracy of the finished product, and controls the operation of the finished product diversion mechanism and adjusts the flow direction of the finished product based on the identification results; at the same time, the temperature sensor collects temperature data at multiple points of the mold, and controls the operation of the cooling system and auxiliary heating unit to maintain the constant temperature of the mold.

2. The automated control method for an oil reservoir base production mold according to claim 1, characterized in that, The logic for dynamically adjusting the shearing parameters during the flow and shearing stages is as follows: compare the collected stress data with the preset stress threshold. When the stress data exceeds the preset upper limit threshold, reduce the downward speed of the upper mold and maintain or increase the shear pressure; When the stress data is less than the preset lower threshold, the downward speed of the upper mold is increased and the shear pressure is reduced.

3. The automated control method for an oil reservoir base production mold according to claim 1, characterized in that, During the pushing phase, the specific steps for correcting the pushing trajectory include: collecting real-time displacement and velocity data of the first pushing mechanism through a position sensor, comparing the real-time data with preset pushing trajectory parameters, and correcting the pushing trajectory in real time based on the comparison deviation.

4. The automated control method for an oil reservoir base production mold according to claim 1, characterized in that, The double-cutting tool is fixedly installed on the back of the shearing tool, and its blade has an outward-protruding barb structure; the protrusion height of the barb structure is adapted to the thickness of the waste material connection point, so that the waste material can be separated by relative motion when the upper die moves upward.

5. The automated control method for an oil reservoir base production mold according to claim 1, characterized in that, The specific logic of mold temperature control in the quality monitoring stage is as follows: the multi-point temperature data is compared with the preset zone temperature threshold range, and the cooling power is calculated by combining the stamping frequency and blank material parameters through a preset algorithm; if the temperature data exceeds the upper limit of the threshold range, the cooling system is controlled to increase the output power; if the temperature data is lower than the lower limit, the cooling system is controlled to reduce the power and start the auxiliary heating unit.

6. The automated control method for an oil reservoir base production mold according to claim 5, characterized in that, The preset algorithm is: Cooling power = Adjustment coefficient × (Current temperature - Midpoint of threshold range) × Stamping frequency coefficient × Material thermal conductivity.

7. A control system for a production mold for an oil reservoir base, characterized in that, For implementing the control method as described in any one of claims 1 to 6, comprising: Core logic controller: includes a PLC programmable logic controller and an industrial microcontroller, wherein the PLC and the industrial microcontroller communicate bidirectionally and work together. Status perception module: includes stress sensor, position sensor, temperature sensor and vision inspection unit, used to collect mold operation status data; The execution drive module includes a punch press driver, a push mechanism driver, a cooling driver, a flow divider driver, and a waste discharge driver. Data interaction module: Used to store production data and display equipment operating status and alarm information.

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