Intelligent processing system for wheel of port machinery, processing controller and processing control method

Abstract

The application provides a port machine wheel intelligent processing system, a processing controller and a processing control method, and relates to the field of machining manufacturing. The processing system comprises a feeding device, a laser marking device, a truss carrying device, a processing device, a cleaning device, a size detection device, an ultrasonic flaw detection device and a discharging device. The truss carrying device is used for automatically grabbing, transferring and positioning and placing the workpiece between the devices. The laser marking device is used for marking the identity of the workpiece before the workpiece enters the processing procedure. The cleaning device is arranged after the processing device and before the size detection device, and is used for removing the residues on the surface of the workpiece. The ultrasonic flaw detection device is arranged after the size detection device and before the discharging device, and is used for detecting whether there is a defect in the workpiece. The processing system further comprises a controller, and the controller is in communication connection with each device.

Description

Technical Field

[0001] This invention relates to the field of mechanical processing and manufacturing, specifically to an intelligent machining system, machining controller, and machining control method for port machinery wheels. Background Technology

[0002] As a core load-bearing and moving component of port loading and unloading machinery, port machinery wheels bear the dual function of transmitting the equipment's own weight and load. Their quality and performance directly determine the operational safety, stability, and service life of the entire machine. Advanced manufacturing processes, dimensional accuracy control, and production efficiency are three core indicators for measuring the manufacturing capability of port machinery wheels. Specifically, manufacturing processes determine the performance foundation and quality consistency of the wheel products; dimensional accuracy affects the assembly compatibility and operational smoothness of the wheel with the overall machine system; and production efficiency reflects the resource allocation and responsiveness of the manufacturing system.

[0003] However, current port machinery wheel processing technology has not yet achieved systematic synergistic optimization across the three dimensions mentioned above. Existing port machinery wheel processing technology generally employs a decentralized process layout, with each processing step located in different processing areas or independent workstations. Workpiece transfer between processes relies on manual handling and auxiliary transport tools such as forklifts. During processing, key features such as the wheel's tread, end face, inner hole, and mounting holes are typically completed step-by-step by multiple independently operated CNC machine tools. Each process requires re-clamping and repositioning of the workpiece, introducing clamping and positioning errors with each clamping. Furthermore, differences in clamping force and repositioning methods among different operators result in inconsistent processing benchmarks for wheels from the same batch, leading to significant fluctuations in processing quality and difficulty in ensuring process consistency. Summary of the Invention

[0004] The purpose of this invention is at least to provide a port machinery wheel intelligent processing system, processing controller and processing control method, thereby enabling the integrated production of port machinery wheels with fully automated and intelligent processing from blank to finished product.

[0005] The following provides a brief overview of one or more aspects to offer a basic understanding of them. This overview is not an exhaustive summary of all conceived aspects, nor is it intended to identify key or decisive elements of all aspects, nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form to prepare for the more detailed descriptions that follow.

[0006] One embodiment of the present invention provides a port machinery wheel intelligent processing system, the processing system including a feeding device, a laser marking device, a truss handling device, a processing device, a cleaning device, a dimensional detection device, an ultrasonic flaw detection device, and a unloading device.

[0007] The loading and unloading devices are located at the beginning and end of the processing system along the flow direction of the process.

[0008] The truss handling device is arranged across each device to realize the automatic gripping, transfer and positioning of workpieces between the devices.

[0009] The laser marking device is located after the feeding device and before the processing device, and is used to mark the identification of the workpiece before it enters the processing step.

[0010] The cleaning device is located after the processing device and before the dimensional inspection device to remove residues from the workpiece surface.

[0011] The ultrasonic flaw detector is positioned after the dimensional inspection device and before the unloading device to detect whether there are defects inside the workpiece.

[0012] The processing system also includes a controller, which is connected to the feeding device, laser marking device, gantry handling device, processing device, cleaning device, dimensional detection device, ultrasonic flaw detection device, and unloading device.

[0013] The dimension detection device is configured to send the detection data to the controller, the controller is configured to analyze the dimension deviation trend based on the detection data and issue a compensation command to the processing device, and the processing device is configured to adjust the processing parameters according to the compensation command.

[0014] In some embodiments, the truss handling device includes at least two sets of truss handling robots, which are respectively configured at different workstations, and the travel range of the at least two sets of truss handling robots covers all workstations of the processing system.

[0015] In some embodiments, the gantry handling robot includes a rack and pinion mechanism, a servo motor, and a planetary reducer. The servo motor drives the rack and pinion mechanism via the planetary reducer to enable the operation of the gantry handling robot.

[0016] In some embodiments, the end effector of the gantry handling robot is provided with an adaptive gripping mechanism, which is configured to adapt to the gripping of workpieces of different sizes.

[0017] In some embodiments, the dimensional detection device is a coordinate measuring machine (CMM), which integrates a contact probe and a non-contact optical sensor, and is configured to perform multi-point, multi-dimensional measurements of the wheel's tread diameter, inner diameter, width, flatness, mounting hole position, and coaxiality.

[0018] In some embodiments, the ultrasonic flaw detection device includes an ultrasonic flaw detector and an automatic coupling unit. The automatic coupling unit is configured to apply a coupling agent to the surface of the workpiece to be inspected. The ultrasonic flaw detector is configured to emit ultrasonic waves into the interior of the workpiece through a probe and receive reflected signals to identify cracks, pores and inclusions inside the workpiece.

[0019] In some embodiments, the cleaning device employs a high-pressure spraying method and a weathering drying method to remove residual cutting fluid, iron filings, and oil stains from the surface and inner holes of the workpiece.

[0020] In some embodiments, the truss handling device is also configured to perform automatic workpiece flipping so that the processing device can complete multi-face processing with the workpiece in a single clamping reference.

[0021] In some embodiments, the controller is further configured to compare the detection data with a preset size range and, in response to a mismatch between the detection data and the preset size range, control the truss conveying device to sort out the corresponding workpiece.

[0022] One embodiment of the present invention provides a port machinery wheel processing controller, including a scheduling module, a monitoring module, a quality traceability module and a data storage module.

[0023] The scheduling module is configured to generate production plans and adjust production takt time based on production needs, equipment status, and workpiece flow information.

[0024] The monitoring module is configured to monitor the operating status of the loading device, laser marking device, truss handling device, CNC machining device, cleaning device, dimensional detection device, ultrasonic flaw detection device, and unloading device in the port machinery wheel processing system.

[0025] The quality traceability module is configured to associate and store the processing parameters, inspection data, and operation records of each process with the identification of the workpiece.

[0026] The data storage module is configured to store data generated by the storage scheduling module, monitoring module, and quality traceability module.

[0027] The controller is configured to communicate with the feeding device, laser marking device, truss handling device, processing device, cleaning device, dimensional detection device, ultrasonic flaw detection device, and unloading device respectively.

[0028] The controller is also configured to receive detection data sent by the dimensional detection device, analyze the dimensional deviation trend based on the detection data, and issue compensation commands to the processing device so that the processing device can adjust the processing parameters according to the compensation commands.

[0029] One embodiment of the present invention provides a port machinery wheel processing control method, applied to the intelligent port machinery wheel processing system of the above embodiment. The processing control method includes: The blank workpiece is automatically fed by the feeding device.

[0030] Identification marks are engraved on the blank workpiece using a laser marking device.

[0031] The blank workpiece is picked up and transferred to the processing device by the truss handling device.

[0032] The blank workpiece is machined using a processing device.

[0033] The workpiece is flipped over by a truss handling device, and then processed again by a processing device.

[0034] The processed workpiece is cleaned by a cleaning device to remove residues from the workpiece surface.

[0035] The workpiece is dimensionally inspected by a dimensional inspection device, and the inspection data is sent to the controller.

[0036] The controller analyzes the dimensional deviation trend based on the detection data and sends a compensation command to the processing device, which then adjusts the processing parameters according to the compensation command.

[0037] The workpiece is subjected to ultrasonic flaw detection using an ultrasonic flaw detection device.

[0038] Finished products are automatically fed through a feeding device.

[0039] In some embodiments, it also includes: The controller compares the detection data with the preset size range. If the detection data does not match the preset size range, the controller controls the truss handling device to sort out the corresponding workpiece. If the detection data matches the preset size range, the corresponding workpiece is allowed to enter the ultrasonic flaw detection device. Attached Figure Description

[0040] The above-described features and advantages of the present invention will be better understood after reading the following detailed description of embodiments of the present disclosure in conjunction with the accompanying drawings. In the drawings, components are not necessarily drawn to scale, and components having similar related properties or features may have the same or similar reference numerals. Wherein: Figure 1 This is a schematic diagram of the layout of an intelligent machining system for locomotive wheels, based on some embodiments.

[0041] Figure 2 This is a schematic diagram of the feeding device structure according to some embodiments.

[0042] Figure 3 This is a schematic diagram of the feeding device structure according to some embodiments.

[0043] Figure 4 This is a schematic diagram of the structure of a laser marking device according to some embodiments.

[0044] Figure 5 This is a schematic diagram of a truss handling device structure according to some embodiments.

[0045] Figure 6 This is a schematic diagram of the processing apparatus structure according to some embodiments.

[0046] Figure 7 This is a schematic diagram of the cleaning device structure according to some embodiments.

[0047] Figure 8 This is a schematic diagram of the size detection device structure according to some embodiments.

[0048] Figure 9 This is a schematic diagram of an ultrasonic flaw detection device according to some embodiments.

[0049] Figure 10 This is a block diagram of the controller according to some embodiments. Detailed Implementation

[0050] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. It should be noted that the aspects described below with reference to the accompanying drawings and specific embodiments are merely exemplary and should not be construed as limiting the scope of protection of the present invention in any way.

[0051] It should be understood that the terms “system,” “device,” “unit,” and / or “module” used herein are one method of distinguishing different components, elements, parts, sections, or assemblies at different levels. However, if other words can achieve the same purpose, they may be replaced by other expressions.

[0052] It is understood that the technical terms that may be used in the description of this specification, such as “center,” “longitudinal,” “lateral,” “front,” “rear,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” and “outer,” indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the implementation method and do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the scope of protection of the invention.

[0053] It should be noted that the use of terms such as "first" and "second" to define features in this document is merely for the purpose of distinguishing the corresponding features. Unless otherwise stated, these terms have no special meaning and should not be construed as limiting the scope of protection of this invention. As shown in this specification and claims, the terms "a," "an," "an," and / or "the" do not specifically refer to the singular and may also include the plural, unless the context clearly indicates otherwise. Generally, the terms "comprising" and "including" only indicate the inclusion of explicitly identified steps and elements, and these steps and elements do not constitute an exclusive list; the method or apparatus may also include other steps or elements.

[0054] In the description of this specification, it should also be noted that, unless otherwise expressly specified or limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, an integral connection, or a detachable connection; a mechanical connection or an electrical connection; a direct connection or an indirect connection through an intermediate medium, or a connection within two components, etc. Those skilled in the art can understand the specific meaning of the above terms in this specification according to the specific circumstances.

[0055] This specification provides an intelligent machining system for port machinery wheels, as illustrated in the embodiments. Figure 1 As shown, the processing system is arranged sequentially along the process flow direction, including a loading device 1, a laser marking device 2, a gantry handling device 3, a processing device 4, a cleaning device 5, a dimensional inspection device 6, and an ultrasonic flaw detection device 7, with a unloading device 8 at the end. The processing system also integrates a controller, which is communicatively connected to each of the above devices to achieve seamless connection and closed-loop control of multiple processes such as intelligent workpiece scheduling, marking, machining, cleaning, and inspection.

[0056] The processing system process flow in this embodiment is as follows: feeding device 1 feeds the workpiece → truss transport device 3 picks up and transfers the workpiece to laser marking device 2 for marking → processing device 4 performs first-order processing → truss transport device 3 picks up and flips the workpiece → processing device 4 performs second-order processing → cleaning device 5 cleans → dimensional detection device 6 detects the workpiece → ultrasonic flaw detection device 7 detects the flaws → unloading device 8 unloads the finished product.

[0057] The following provides a detailed description of each component and its working process.

[0058] A loading device is a device used to automatically transport blank workpieces (such as wheel blanks) to the beginning of the processing system, including but not limited to automated guided vehicles, conveyor belts, and robotic loading mechanisms.

[0059] like Figure 2As shown, the loading device 1 is located at the beginning of the processing system and is used to automatically load the blank workpiece. The loading device 1 is linked with the gantry transport device 3, and automatically grabs the workpiece and sends it into the processing system according to the scheduling instructions of the controller. In this embodiment, the loading device 1 can use an automated guided vehicle (AGV) to automatically transport the blank workpiece to the beginning of the processing system. The AGV accurately transports the blank workpiece to the loading station through a preset navigation path and positioning system, and then the gantry transport device 3 grabs the workpiece to enter the next process. However, this is not limiting; the loading device 1 can also use other automatic loading methods such as a conveyor belt or a robotic arm loading mechanism.

[0060] The unloading device is a device used to automatically remove finished workpieces from the end of the processing system. Its structure may be the same as or different from that of the loading device.

[0061] like Figure 3 As shown, the unloading device 8 is located at the end of the processing system and is used to automatically unload finished workpieces (such as finished wheels) after processing. The structure of the unloading device 8 may be the same as or different from that of the loading device 1. Its working process is as follows: the gantry conveying device 3 transfers the qualified wheel workpieces to the unloading station, and the unloading device 8 automatically grabs the finished workpieces. Through the automated operation of the loading and unloading devices, the manual handling link is eliminated, reducing labor intensity and safety risks.

[0062] Laser marking equipment refers to a device used to etch identification marks on the surface of a workpiece using a laser beam. Identification marks include, but are not limited to, QR codes, character codes, or combinations thereof.

[0063] like Figure 4 As shown, the laser marking device 2 is positioned after the feeding device 1 and before the processing device 4, used to engrave a unique identification mark on the workpiece before it enters the processing stage. The identification mark refers to the unique identifiable identifier engraved on the workpiece surface by the laser marking device 2, serving as a data carrier for associating the workpiece with processing parameters, inspection data, and operation records throughout the entire process. In this embodiment, the laser marking device 2 uses a laser beam to etch a QR code or character code onto the surface of the wheel workpiece as the identification mark. This identification mark accompanies the workpiece throughout the entire process, serving as an index for all subsequent processing parameters, inspection data, and operation records. The controller associates the workpiece's identification mark with its process parameters, inspection data, and processing records throughout the entire process, providing a data foundation for subsequent quality traceability. However, this is not limiting; other identifiable encoding forms can also be used for the identification mark.

[0064] A gantry handling device refers to a handling device that spans across the equipment of each process and is used to automatically grab, transfer and position workpieces between processes, including at least two sets of gantry handling robots.

[0065] like Figure 5 As shown, the gantry handling device 3 is spanned above each processing and testing equipment to achieve automatic gripping and transfer of workpieces between processes. The gantry handling device 3 is arranged horizontally above each device and is equipped with multi-axis servo drive and adaptive clamping mechanism to accommodate stable clamping of wheels of different specifications.

[0066] In this embodiment, the gantry handling device 3 uses gantry handling robots for loading and unloading. Two sets of robots are installed, one for the first stage and one for the second stage. Each set of robots has an independent working area, and their travel range can cover all workstations on the entire production line, enabling seamless transfer of workpieces between different processes. However, this is not limiting; the number of robots can be adjusted according to the scale and cycle time requirements of the production line.

[0067] Specifically, the gantry handling robot uses a high-rigidity welded frame as its support structure to ensure structural stability under high-speed operation and heavy-load conditions. The gantry handling robot employs a rack and pinion drive system for its walking mechanism, coupled with a servo motor and a high-precision planetary reducer to achieve high positioning accuracy and smooth operation. The robot's end effector is equipped with an adaptive gripping mechanism 31, which is configured according to the structural characteristics of the wheel workpiece 9 to adapt to the gripping requirements of wheels of different specifications.

[0068] The gantry handling device 3 is also configured to perform an automatic workpiece flipping function. In the machining process, the workpiece first enters the first-stage machining, and after machining is completed, the gantry handling robot grabs and flips the workpiece, which then enters the second-stage machining. Through the automatic flipping function of the gantry handling robot, multi-face machining of the workpiece is realized under a single clamping reference, effectively ensuring the relative positional accuracy between various machining features and fundamentally eliminating the positioning error introduced by repeated clamping.

[0069] Machining equipment refers to equipment used for mechanical processing of wheel workpieces, including but not limited to CNC vertical lathes and CNC grinding machines.

[0070] like Figure 6 As shown, the processing device 4 is positioned after the laser marking device 2 and is used for vertical turning machining of the wheel workpiece. In this embodiment, the processing device 4 includes multiple CNC vertical lathes for turning the wheel tread, end face, inner hole, and mounting hole. However, this is not limiting; the number and type of processing devices can be adjusted according to processing requirements and workpiece characteristics. The processing device 4 is interconnected with the controller and can automatically call the corresponding workpiece's machining program and tool parameters, realizing flexible processing based on identification, avoiding errors and waiting caused by manual intervention.

[0071] Specifically, multiple CNC vertical lathes are divided into a first group and a second group. According to the process flow, the workpiece first enters the first group of CNC vertical lathes for the first-stage machining. After machining, the workpiece is picked up and flipped by a gantry handling robot, and then enters the second group of CNC vertical lathes for the second-stage machining. Through the two-stage machining, the key features such as the wheel tread, end face, inner hole, and mounting hole are machined.

[0072] Cleaning equipment refers to devices used to remove residual cutting fluid, iron filings, and oil stains from the surface and inner holes of workpieces.

[0073] like Figure 7 As shown, the cleaning device 5 is positioned after the machining device 4 and before the dimensional inspection device 6, and is used to clean the wheel workpiece after machining. In this embodiment, the cleaning device 5 uses a high-pressure spray cleaning method combined with a special cleaning medium to remove residual cutting fluid, iron filings, and oil stains from the surface and inner holes of the workpiece. The cleaning device 5 also uses a weathering drying method to physically dry the cleaned workpiece, ensuring the cleanliness of the workpiece surface and providing an interference-free inspection surface for subsequent high-precision dimensional inspection and ultrasonic flaw detection.

[0074] Residual cutting fluid and metal shavings on the workpiece surface can interfere with the contact of the probe and the measurement accuracy of the optical sensor in dimensional inspection devices. These residues can also affect the coupling effect of ultrasonic testing, leading to false positives. By installing a cleaning device after the machining process and before the inspection process, and employing a cleaning scheme combining high-pressure spraying and weathering drying, these interfering factors can be effectively eliminated, ensuring the reliability of the inspection results. However, this is not a limitation; other cleaning methods can also be used, such as ultrasonic cleaning or vacuum drying, which is readily understood by those skilled in the art.

[0075] A dimensional inspection device is a piece of equipment used to perform fully automated, high-precision three-dimensional dimensional inspection on finished wheels, including but not limited to a coordinate measuring machine. Other types of measuring equipment can also be used, such as optical projectors and laser scanners.

[0076] like Figure 8 As shown, the dimension detection device 6 is installed after the cleaning device 5 and is used for online automatic detection of key dimensions of the wheel workpiece. In this embodiment, the dimension detection device 6 is a coordinate measuring machine that integrates a high-precision contact probe and a non-contact optical sensor. It can automatically perform multi-point, multi-dimensional measurements of multiple key features such as wheel tread diameter, rim thickness, inner hole diameter, width, flatness, mounting hole position accuracy, and coaxiality.

[0077] The dimensional inspection device 6 is connected to the controller. After inspection, it automatically uploads the measurement data to the controller and compares it with the preset tolerance range. For workpieces that pass the inspection, they are allowed to proceed to the next process; for workpieces that fail the inspection, the controller issues an alarm and controls the gantry conveying device 3 to automatically sort them to the non-conforming product area. At the same time, the controller can generate process control (SPC) charts based on the inspection data for real-time monitoring of the stability of processing quality.

[0078] Ultrasonic flaw detection equipment refers to devices used for ultrasonic non-destructive testing of finished wheels to identify internal defects. Ultrasonic flaw detection equipment can also employ other non-destructive testing methods, such as eddy current testing and radiographic testing.

[0079] like Figure 9 As shown, the ultrasonic flaw detection device 7 is positioned after the dimensional detection device 6 and before the unloading device 8, and is used to perform ultrasonic non-destructive testing on the wheel workpiece. In this embodiment, the ultrasonic flaw detection device 7 includes an ultrasonic flaw detector and an automatic coupling unit. The automatic coupling unit is configured to apply a coupling agent to the workpiece inspection surface. The ultrasonic flaw detector emits ultrasonic waves into the workpiece through its probe and receives the reflected signals. By analyzing the reflected signals, it determines whether there are defects such as cracks, pores, or inclusions inside the workpiece and in the near-surface area.

[0080] During the inspection process, the automatic coupling unit uniformly applies coupling agent to the workpiece inspection surface to ensure effective transmission of ultrasonic signals. The ultrasonic flaw detector probe emits ultrasonic waves into the workpiece and receives the reflected signals. By analyzing the amplitude, phase, and other characteristics of the reflected signals, the type and location of defects inside the workpiece are automatically identified. The inspection results are uploaded to the controller in real time, linked to the workpiece identification label, and stored to form a complete quality inspection file.

[0081] A controller is a production management and control system used for unified scheduling, data acquisition, analysis and processing, and closed-loop control of various devices, including but not limited to programmable logic controllers, industrial control computers, and embedded control systems.

[0082] The controller, as the core of the entire processing system, is communicatively connected to the feeding device 1, laser marking device 2, gantry handling device 3, processing device 4, cleaning device 5, dimensional detection device 6, ultrasonic flaw detection device 7, and unloading device 8. For example... Figure 10 As shown, the controller 10 includes a scheduling module, a monitoring module, a quality traceability module, and a data storage module.

[0083] The scheduling module is configured to generate production plans and adjust production takt times based on production demand, equipment status, and workpiece flow information. Based on order requirements, equipment availability, and workpiece flow progress, the module automatically generates the optimal production plan and adjusts the production takt times of each workstation in real time, eliminating waiting and congestion between processes and maximizing equipment utilization and output per unit time.

[0084] The monitoring module is configured to monitor the operating status of each device in the processing system, including equipment start / stop status, operating parameters, fault alarms, and other information, to ensure that each device operates under normal conditions.

[0085] The quality traceability module is configured to associate and store all information, including processing parameters (such as cutting speed and feed rate), inspection data (dimensional inspection results and flaw detection results), operation records, and equipment status, with a unique identifier for each workpiece, forming a complete quality traceability file. The quality traceability module supports quick querying of full lifecycle data by workpiece identifier, providing precise evidence for quality problem localization and process improvement.

[0086] Specifically, each wheel is given a unique identification using laser marking device 2. This unique identification serves as the primary key for data association throughout the entire process. The quality traceability module associates and stores information such as processing parameters, inspection results, and equipment status of all processes with this identification, constructing a complete digital quality archive. This enables data flow throughout the entire lifecycle from raw material to finished product, allowing quality issues to be traced back to specific processes, equipment, and parameters within seconds. This allows for precise identification of the root cause of the problem and provides data support for continuous process optimization, something that traditional isolated workstation terminals cannot achieve.

[0087] The data storage module is configured to store all data generated by the storage scheduling module, monitoring module, and quality traceability module, ensuring data integrity and queryability.

[0088] The controller 10 is also configured to receive online detection data from the dimension detection device 6. The controller 10 automatically analyzes the dimensional deviation trend based on the detection data—that is, by comparing the detection results of multiple consecutive workpieces, it identifies whether there is a systematic offset or drift trend in the machining dimensions. When the controller 10 determines that there is a deviation trend, it sends a compensation command to the machining device 4 to dynamically adjust the machining parameters of subsequent workpieces (such as tool compensation value, feed rate correction, etc.), forming a closed-loop precision control loop.

[0089] By feeding back real-time detection data from the dimensional inspection device to the controller, which then analyzes the deviation trend and proactively issues compensation commands to the machining device, feedforward dynamic compensation of the machining dimensions is achieved. This closed-loop control mechanism effectively improves the dimensional accuracy and consistency of key features such as wheel treads and inner holes.

[0090] The controller 10 is also configured to compare the detection data from the dimensional detection device 6 with a preset dimensional range. When the detection data falls within the preset dimensional range, the controller 10 determines that the workpiece is qualified and allows the workpiece to enter the ultrasonic flaw detection device 7 for subsequent inspection; when the detection data exceeds the preset dimensional range, the controller 10 determines that the workpiece is unqualified, issues an alarm signal, and controls the gantry conveying device 3 to automatically sort the unqualified workpiece to the unqualified product area to prevent unqualified products from flowing into subsequent processes.

[0091] Through the coordinated operation of the aforementioned devices and the unified scheduling of the controller, this embodiment of the specification realizes fully automated processing, online inspection, and quality traceability of port machinery wheels from blank loading to finished product unloading, effectively improving the consistency of manufacturing processes, the controllability of dimensional accuracy, and the operating efficiency of the production line.

[0092] Although this invention has been described in detail using the processing of port machinery wheels as an example, the processing system and control method of this invention are not limited to the processing of port machinery wheels, but can also be applied to the processing and manufacturing of other types of wheels, such as rail transit wheels, construction machinery wheels, and mining equipment wheels. Furthermore, the closed-loop precision control circuit and full-process quality traceability technologies described in this invention can also be applied to other mechanical parts manufacturing fields that require continuous processing and online inspection, which is readily understood by those skilled in the art.

[0093] The basic concepts have been described above. It is clear that the detailed disclosure above is merely illustrative and does not constitute a limitation of this specification, especially for those skilled in the art. Furthermore, unless expressly stated in the claims, the order of elements and sequences, the use of numbers and letters, or other names in this specification are not intended to limit the order of the processes and methods described herein. Although various examples of currently considered useful embodiments of the invention have been discussed in the foregoing disclosure, it should be understood that such details are for illustrative purposes only, and the appended claims are not limited to the disclosed embodiments. Rather, the claims are intended to cover all modifications and equivalent combinations that conform to the substance and scope of the embodiments described herein.

Claims

1. A port machinery wheel intelligent processing system, characterized in that, The processing system includes a feeding device, a laser marking device, a truss handling device, a processing device, a cleaning device, a dimensional detection device, an ultrasonic flaw detection device, and a unloading device. The feeding device and the unloading device are arranged at the beginning and end of the processing system along the process flow direction; The truss handling device is arranged across each device to realize the automatic gripping, transfer and positioning of workpieces between the devices. The laser marking device is arranged after the feeding device and before the processing device, and is used to mark the identification mark on the workpiece before the workpiece enters the processing process. The cleaning device is arranged after the processing device and before the size detection device, and is used to remove residues from the surface of the workpiece. The ultrasonic flaw detection device is arranged after the size detection device and before the unloading device, and is used to detect whether there are defects inside the workpiece. The processing system also includes a controller, which is communicatively connected to the loading device, the laser marking device, the truss handling device, the processing device, the cleaning device, the dimensional detection device, the ultrasonic flaw detection device, and the unloading device. The dimension detection device is configured to send detection data to the controller, the controller is configured to analyze the dimension deviation trend based on the detection data and issue a compensation command to the processing device, and the processing device is configured to adjust the processing parameters according to the compensation command.

2. The intelligent machining system for port machinery wheels as described in claim 1, characterized in that, The truss handling device includes at least two sets of truss handling robots, which are respectively configured at different workstations, and the travel range of the at least two sets of truss handling robots covers all workstations of the processing system.

3. The intelligent machining system for port machinery wheels as described in claim 2, characterized in that, The gantry handling robot includes a rack and pinion transmission mechanism, a servo motor, and a planetary reducer. The servo motor drives the rack and pinion transmission mechanism via the planetary reducer to realize the operation of the gantry handling robot.

4. The intelligent machining system for port machinery wheels as described in claim 2 or 3, characterized in that, The end of the gantry handling robot is equipped with an adaptive gripping mechanism, which is configured to grip workpieces of different specifications.

5. The intelligent machining system for port machinery wheels as described in claim 1, characterized in that, The dimension detection device is a coordinate measuring machine, which integrates a contact probe and a non-contact optical sensor. It is configured to perform multi-point, multi-dimensional measurements of the wheel's tread diameter, inner diameter, width, flatness, mounting hole position, and coaxiality.

6. The intelligent machining system for port machinery wheels as described in claim 1, characterized in that, The ultrasonic flaw detection device includes an ultrasonic flaw detector and an automatic coupling unit. The automatic coupling unit is configured to apply a coupling agent to the surface of the workpiece to be inspected. The ultrasonic flaw detector is configured to emit ultrasonic waves into the interior of the workpiece through a probe and receive reflected signals to identify cracks, pores and inclusions inside the workpiece.

7. The intelligent machining system for port machinery wheels as described in claim 1, characterized in that, The cleaning device employs high-pressure spraying and weathering drying methods to remove residual cutting fluid, iron filings, and oil stains from the surface and inner holes of the workpiece.

8. The intelligent machining system for port machinery wheels as described in claim 1, characterized in that, The truss handling device is also configured to automatically flip the workpiece so that the processing device can complete multi-face processing under a single workpiece clamping reference.

9. The intelligent machining system for port machinery wheels as described in claim 1, characterized in that, The controller is further configured to compare the detection data with a preset size range and, in response to a mismatch between the detection data and the preset size range, control the truss conveying device to sort out the corresponding workpiece.

10. A port machinery wheel processing controller, characterized in that, It includes a scheduling module, a monitoring module, a quality traceability module, and a data storage module; The scheduling module is configured to generate a production schedule and adjust the production cycle based on production demand, equipment status and workpiece flow information. The monitoring module is configured to monitor the operating status of the loading device, laser marking device, truss handling device, CNC machining device, cleaning device, dimensional detection device, ultrasonic flaw detection device, and unloading device in the port machinery wheel processing system. The quality traceability module is configured to associate and store the processing parameters, inspection data, and operation records of each process with the identification of the workpiece. The data storage module is configured to store data generated by the scheduling module, the monitoring module, and the quality traceability module. The controller is configured to communicate with the feeding device, the laser marking device, the truss handling device, the processing device, the cleaning device, the size detection device, the ultrasonic flaw detection device, and the unloading device, respectively. The controller is also configured to receive detection data sent by the size detection device, analyze the size deviation trend based on the detection data, and issue a compensation command to the processing device so that the processing device adjusts the processing parameters according to the compensation command.

11. A method for controlling the machining of port machinery wheels, characterized in that, The machining control method applied to the intelligent machining system for port machinery wheels according to claim 1 includes: The loading device automatically loads the blank workpiece; The laser marking device is used to engrave identification marks on the blank workpiece; The truss handling device picks up and transfers the blank workpiece to the processing device; The blank workpiece is mechanically processed using the processing device; The workpiece is flipped over by the truss handling device, and then the flipped workpiece is processed again by the processing device. The cleaning device is used to clean the processed workpiece to remove residues from the workpiece surface. The workpiece is dimensionally inspected using the dimension inspection device, and the inspection data is sent to the controller. The controller analyzes the dimensional deviation trend based on the detection data and sends a compensation command to the processing device, which then adjusts the processing parameters according to the compensation command. The workpiece is subjected to ultrasonic flaw detection using the ultrasonic flaw detection device. Finished products are automatically fed through the feeding device.

12. The port machinery wheel processing control method as described in claim 11, characterized in that, Also includes: The controller compares the detection data with a preset size range. If the detection data does not match the preset size range, the controller controls the truss handling device to sort out the corresponding workpiece. If the detection data matches the preset size range, the corresponding workpiece is allowed to enter the ultrasonic flaw detection device.

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