Spring grinding system with automatic feeding and processing method thereof

Abstract

The application relates to the technical field of spring processing, and discloses a spring grinding and flattening processing system with automatic feeding and a processing method thereof, which aims to solve the technical problems of clamping position deviation, poor precision consistency, low production efficiency and untimely scrap cleaning caused by manual feeding in spring grinding and flattening processing. The method comprises the following steps: S1, automatically feeding and posture correcting the spring through a vibration feeding mechanism and a sorting and arranging mechanism; S2, fixing the spring on a grinding and flattening station through a clamping mechanism; S3, synchronously starting the upper and lower end grinding and flattening devices to polish the two ends of the spring; S4, removing metal scraps through a scrap removing structure; and S5, centrally recycling and processing the scraps through a scrap recycling mechanism. The system comprises a vibration feeding device, a sorting and arranging device, a clamping device, a grinding and flattening device, a scrap removing device and a scrap recycling device, which are sequentially arranged and coordinately controlled through a control system. Through automatic feeding instead of manual operation, the consistency and stability of the spring grinding and flattening processing precision are realized, the production efficiency is improved, and the working environment is kept clean.

Description

Technical Field

[0001] This invention relates to the field of spring processing technology, specifically to an automatic feeding spring grinding system and its processing method. Background Technology

[0002] Springs, as a key basic component in automotive parts, are widely used in critical parts such as suspension systems, engine valve mechanisms, and clutch pressure plates. In actual use, some spring components require the bottom of both ends to be ground flat to form a smooth support surface, ensuring reliable contact with other components and stable mechanical transmission performance.

[0003] One of the precision surface treatment processes is the grinding of the bottom ends of the spring. Specifically, the spring to be processed is first accurately conveyed to the grinding station, then clamped in a specific position by a clamping mechanism. The bottom of the spring is then ground by grinding devices located at both ends to create a flat end face that meets design requirements. After grinding, a specialized chip removal structure and chip recovery mechanism are required to remove metal chips generated during processing, maintain a clean working environment, and prevent chips from adversely affecting product quality.

[0004] However, in existing technologies, the grinding of both ends of springs mainly relies on manual loading. Springs are placed one by one into the clamping mechanism of the grinding machine. Due to the poor consistency of manual operation, deviations in the clamping position and posture of the springs are easily caused, thus affecting the consistency of grinding accuracy. At the same time, the speed of manual loading is limited, making it difficult to meet the stringent efficiency requirements of large-scale industrial production. Furthermore, if metal shavings generated during the grinding process are not removed promptly and effectively, they may scratch the spring surface or affect the normal operation of the equipment in subsequent processes. Although some technologies have attempted to automate the loading of similar parts, the inherent elastic deformation characteristics of springs and the range of differences in their shape and size present challenges. Maintaining the stability of the spring's posture during vibration loading and sorting, and ensuring its accurate and reliable delivery to the grinding station for clamping and grinding, remains a significant technical challenge in this field. Summary of the Invention

[0005] The purpose of this invention is to provide an automatic feeding spring grinding system and its processing method, which can effectively solve the technical problems in the prior art caused by manual feeding of spring ends, such as clamping position and posture deviation, poor grinding accuracy consistency, low production efficiency, and untimely cleaning of metal debris.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: an automatic feeding spring grinding system and its processing method, including an automatic feeding step, a sorting and organizing step, a clamping and fixing step, a grinding process step, a chip removal process, and a chip recycling step.

[0007] S1: Automatic feeding step: The spring to be processed is fed from the storage device by a vibrating feeding mechanism. Under the action of vibration, the spring is conveyed forward along the vibrating track and enters the sorting and sorting station. S2: Sorting and sorting step: The sorting and sorting mechanism detects the posture and corrects the direction of the conveyed spring to ensure that the spring enters the subsequent clamping station in the correct direction and posture. S3: Clamping and fixing step: The clamping mechanism positions and clamps the spring to be processed, fixing the spring in the designated position of the grinding station. S4: Grinding step: The grinding devices set at the top and bottom ends of the spring are started simultaneously to grind the bottom of the spring ends to form a flat end surface that meets the design requirements. S5: Chip removal step: The chip removal structure removes the metal chips generated during the grinding process to prevent chips from remaining on the spring surface or working area. S6: Chip recycling step: The chip recycling mechanism collects the metal chips collected by the chip removal structure and recycles them in a centralized manner to maintain a clean working environment.

[0008] Preferably, the vibratory feeding mechanism includes a vibratory motor and a vibratory track. The vibration frequency of the vibratory motor can be adjusted by the control system. The tilt angle and vibration amplitude of the vibratory track work together to keep the spring in a stable conveying posture during vibration, thus preventing the spring from flipping or falling off during the vibratory feeding process.

[0009] Preferably, the sorting and organizing mechanism includes a spring posture detection sensor and a direction correction device. The spring posture detection sensor is a photoelectric sensor or a vision sensor used to detect the spring's entry direction and posture angle. The direction correction device pushes or rotates the spring according to the detection results to ensure that the spring enters the clamping station in a preset direction.

[0010] Preferably, the clamping mechanism includes an upper clamping block and a lower clamping block, which are respectively disposed at the upper and lower ends of the spring. The inner side of the clamping block is provided with an arc-shaped clamping surface adapted to the shape of the spring. The clamping block is driven by a cylinder or a hydraulic cylinder to realize the rapid clamping and release of the spring. The clamping force can be adjusted according to the specifications of the spring.

[0011] Preferably, the grinding device includes a grinding motor and a grinding wheel. The grinding wheel is made of silicon carbide or aluminum oxide. The speed of the grinding motor can be precisely controlled by a frequency converter. The grinding device is set at the upper and lower ends of the spring and works synchronously to ensure that the grinding amount at both ends of the spring is consistent. The grinding depth can be preset and adjusted by the control system.

[0012] Preferably, the chip removal structure includes a high-pressure airflow nozzle and a brushing mechanism. The high-pressure airflow nozzle is arranged around the grinding station and continuously sprays high-pressure airflow during the grinding process to blow the splashed metal chips away from the spring surface. The brushing mechanism uses flexible bristles to brush the surface after the spring is ground to further remove residual chips.

[0013] Preferably, the debris recycling mechanism includes a debris collection trough, a filter device, and a debris collection container. The debris collection trough is located below the grinding station and is used to collect fallen metal debris. The filter device separates the debris by particle size. The debris collection container is used to store the recycled metal debris. The debris recycling mechanism is equipped with an automatic unblocking device to prevent debris accumulation from causing blockage.

[0014] The present invention also provides an automatic feeding spring grinding system, including a vibratory feeding device, a sorting and arranging device, a clamping device, a grinding device, a chip removal device, and a chip recycling device. The vibratory feeding device, sorting and arranging device, clamping device, grinding device, chip removal device, and chip recycling device are arranged in sequence and coordinated and controlled by a control system.

[0015] The vibrating feeding device includes a vibrating motor, a vibrating track, and a storage bin. The vibrating motor drives the vibrating track to generate directional vibration. The storage bin is located at the starting end of the vibrating track and is used to store the springs to be processed. Under the action of vibration, the springs are conveyed along the vibrating track towards the sorting and organizing device.

[0016] The sorting and tidying device includes a spring attitude detection sensor, a direction correction device, and a sorting track. The spring attitude detection sensor is located at the entrance of the sorting track to detect the spring's entry attitude in real time. The direction correction device is located in the middle of the sorting track to adjust the spring's direction according to the detection signal. The exit of the sorting track is connected to the entrance of the clamping device.

[0017] The clamping device includes a clamping base, an upper clamping block, a lower clamping block, and a clamping drive mechanism. The upper and lower clamping blocks are arranged opposite each other on both sides of the clamping base. The clamping drive mechanism drives the clamping blocks to open and close, fixing the spring between the upper and lower clamping blocks. A position sensor is provided on the clamping base to detect the clamping position of the spring.

[0018] The grinding device includes an upper grinding mechanism and a lower grinding mechanism. The upper grinding mechanism is located above the spring, and the lower grinding mechanism is located below the spring. The upper grinding mechanism and the lower grinding mechanism each include a grinding motor and a grinding wheel. The grinding motor drives the grinding wheel to rotate at high speed to perform synchronous grinding on the bottom of both ends of the spring.

[0019] The chip removal device includes a high-pressure airflow system, a brushing mechanism, and a chip guide plate. The high-pressure airflow system is located around the grinding station, the brushing mechanism is located on the outlet side of the grinding station, and the chip guide plate is inclinedly located below the grinding station to guide the chips to the chip recycling device.

[0020] The debris recycling device includes a debris collection hopper, a filtration and separation mechanism, and a debris collection box. The debris collection hopper is located below the debris removal device to receive the falling debris. The filtration and separation mechanism performs particle grading on the debris. The debris collection box is located at the bottom of the debris recycling device to store the recycled metal debris.

[0021] Compared with the prior art, the beneficial effects achieved by the present invention are: 1. The automatic feeding spring grinding system and its processing method described in this invention achieve automatic feeding and posture correction of springs by adopting a vibration feeding mechanism and a sorting mechanism, effectively replacing manual feeding operations, eliminating the clamping position and posture deviation problems caused by manual operation, and ensuring the consistency and stability of spring grinding accuracy.

[0022] 2. The automatic feeding spring grinding system and its processing method of the present invention, by setting grinding devices at both ends and working synchronously, realizes synchronous grinding of the bottom of both ends of the spring. Compared with the prior art of processing one end at a time, it significantly improves the grinding efficiency and meets the efficiency requirements of large-scale industrial production.

[0023] 3. The automatic feeding spring grinding system and its processing method described in this invention, by configuring a chip removal structure and a chip recycling mechanism, realizes the timely removal and centralized recycling of metal chips generated during the grinding process, effectively preventing chips from scratching the spring surface or affecting the normal operation of the equipment in subsequent processes, and maintaining a clean working environment.

[0024] 4. The automatic feeding spring grinding system and its processing method described in this invention, by setting up a spring posture detection sensor and a direction correction device, can detect and adjust the posture of the spring in real time during the spring conveying process, which solves the problem of conveying stability caused by the elastic deformation characteristics of the spring itself and the difference in shape and size, and ensures that the spring can be accurately and reliably conveyed to the grinding station for clamping and grinding. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the overall technical process of the automatic feeding spring grinding system proposed in this invention; Figure 2 This is a schematic diagram of the process of simultaneously grinding the upper and lower ends in this invention; Figure 3This is a flowchart illustrating the automatic feeding and sorting stages in this invention. Figure 4 This is a schematic diagram of the multi-level interaction relationship and data flow between debris removal and debris recycling in this invention. Detailed Implementation

[0026] 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.

[0027] Example 1 This embodiment is applied to the automated grinding process of automotive component springs, specifically involving the industrial production application of grinding the bottom of both ends of the spring to form a flat support surface.

[0028] First, the scenario deploys a complete processing system including an automatic feeding system, a sorting and arranging system, a clamping and positioning system, a double-end grinding system, a chip removal system, and a chip recycling system. The automatic feeding system is located at the beginning of the entire processing line, with its discharge end fixedly connected to the feed end of the sorting and arranging system via a rigid connecting frame, forming a continuous material conveying channel. The discharge end of the sorting and arranging system is positioned opposite the input station of the clamping and positioning system, ensuring that the spring can enter the clamping station in a preset posture. The clamping and positioning system is located within the processing area of ​​the double-end grinding system, with an upper grinding mechanism and a lower grinding mechanism on each side, symmetrically distributed and capable of synchronous operation. Below the double-end grinding system is a chip removal system, which is connected to the chip recycling system via pipelines, forming a closed-loop chip collection and processing circuit.

[0029] The vibratory feeding unit in the automatic feeding system adopts a groove-type vibration structure with an internal spiral feeding track. The cross-sectional shape of this track is adapted to the geometry of the spring, forming a concave channel that matches the outer contour of the spring. An electromagnetic vibration actuator is installed at the bottom of the vibratory feeding unit. This actuator is electrically connected to an external power supply, and its vibration frequency and amplitude can be adjusted via a control module. A discharge guide chute is provided at the discharge port of the vibratory feeding unit. The extension direction of this chute is consistent with the input direction of the sorting and arranging system, ensuring a smooth transition of the spring to the sorting and arranging system.

[0030] The sorting and organizing system includes a material channel organizing mechanism and a posture correction mechanism. The material channel organizing mechanism comprises a first guide rail group and a second guide rail group, with a gap channel formed between the two groups for the spring to pass through. The width of this gap channel is designed to be slightly larger than the maximum outer diameter of the spring, but smaller than the maximum diameter of the spring in its free state, ensuring that the spring maintains a straight-line travel posture when passing through the gap channel. The posture correction mechanism is located at the exit position of the material channel organizing mechanism and includes a correction wheel group and a limiting baffle. The correction wheel group consists of at least two oppositely arranged rollers, and the center distance between the two rollers can be adjusted according to the spring specifications. When the spring passes through the correction wheel group, its axial direction is forcibly corrected to be consistent with the conveying direction. The limiting baffle is located downstream of the correction wheel group, forming a posture correction zone together with the correction wheel group. When the spring passes through this zone, its two end faces are restricted within a preset planar range, completing the initial posture correction.

[0031] The clamping and positioning system includes a rotary clamping mechanism and a position adjustment mechanism. The rotary clamping mechanism, located within the machining area, comprises a clamping body and a clamping jaw assembly. The clamping body is a hollow structure, housing a drive motor and a transmission mechanism. The output shaft of the drive motor is connected to the transmission mechanism, and the output end of the transmission mechanism is connected to the clamping jaw assembly. The clamping jaw assembly includes at least three clamping jaws, evenly distributed circumferentially. Each jaw has an arc-shaped clamping surface at its end, the radius of curvature of which matches the curvature of the spring's outer surface. When the drive motor is energized, the transmission mechanism drives the three clamping jaws to move simultaneously towards the center, firmly fixing the spring inside the clamping body. The position adjustment mechanism, located at the bottom of the clamping body, includes a vertical adjustment mechanism and a horizontal adjustment mechanism. The vertical adjustment mechanism employs a screw-nut transmission structure. The screw is fixedly connected to the clamping body, and the drive motor is connected to the screw via a reducer. When the reducer outputs power, the screw rotates, driving the nut to move vertically, thereby adjusting the clamping body's position in the vertical direction. The horizontal adjustment mechanism adopts a linear guide structure, with its slider fixedly connected to the clamping body. The piston rod of the drive cylinder is connected to the slider. When the drive cylinder is ventilated, the piston rod pushes the slider to move in the horizontal direction, thereby driving the clamping body to adjust its position in the horizontal direction.

[0032] The double-end grinding system comprises an upper grinding mechanism and a lower grinding mechanism. The upper grinding mechanism, located above the clamping and positioning system, includes an upper grinding bracket, an upper grinding motor, and an upper grinding wheel. The upper grinding bracket is fixedly mounted on the top crossbeam of the frame and has a box-shaped cross-section, providing sufficient rigidity to resist radial forces during the grinding process. The upper grinding motor is fixedly mounted inside the upper grinding bracket, and its output shaft is connected to the spindle of the upper grinding wheel via a coupling. The outer surface of the upper grinding wheel is the grinding working surface, made of corundum-based abrasive. The grit size is selected based on the hardness of the spring material; for common spring steel, a 60-80 mesh grinding wheel is used. The lower grinding mechanism, located below the clamping and positioning system, is symmetrically arranged with the upper grinding mechanism and includes a lower grinding bracket, a lower grinding motor, and a lower grinding wheel. The lower grinding bracket is fixedly mounted on the bottom base of the frame and has the same structural form as the upper grinding bracket. The output shaft of the lower grinding motor is connected to the spindle of the lower grinding wheel via a coupling, with the grinding working surface of the lower grinding wheel facing upwards. The relative vertical position of the upper and lower grinding mechanisms can be detected by a position sensor. The signal from the position sensor is fed back to the control module, which calculates and adjusts the downward distance of the grinding mechanism based on preset grinding parameters.

[0033] The chip removal system is located around the machining area of ​​the double-end grinding system and includes a high-pressure airflow nozzle assembly and a chip suction hood. The high-pressure airflow nozzle assembly is positioned to the sides of the upper and lower grinding wheels, with at least four nozzles evenly arranged circumferentially. Each nozzle's spray direction is directed towards the core of the grinding area. The output pressure of the high-pressure air source is set to 0.4 to 0.8 MPa. Compressed air is delivered to each nozzle through high-pressure air pipes, forming a high-speed airflow curtain during grinding that blows splashed metal chips towards the inlet of the chip suction hood. The chip suction hood is located below the grinding area, with its inlet corresponding to the position of the high-pressure airflow nozzle assembly, forming a coordinated guiding path for airflow and chips. The chip suction hood contains a filter layer with a pore size designed to be 0.1 to 0.3 mm, capable of blocking larger chip particles while allowing fine dust to pass through.

[0034] The debris recovery system is located below the debris removal system and includes a debris collection box, a conveying pipe, and a filtration and separation device. The debris collection box is located at the outlet below the debris suction hood and is used to collect metal debris falling from the hood. One end of the conveying pipe is connected to the debris collection box, and the other end is connected to the filtration and separation device. A screw conveyor mechanism is installed inside the conveying pipe; the blade pitch and rotation speed of the screw conveyor are designed according to the amount of debris being conveyed. The filtration and separation device includes a primary filter and a secondary filter. The primary filter uses a wire mesh structure with a pore size of 1 to 2 mm to intercept larger debris particles; the secondary filter uses a paper filter element structure with a pore size of 0.01 to 0.05 mm to capture fine metal dust. The air outlet of the filtration and separation device is connected to the inlet of an air pump. The air pump continuously operates to generate negative pressure, driving the dust-laden airflow from the debris suction hood through the conveying pipe to the filtration and separation device, forming a continuous debris suction airflow channel.

[0035] The system's workflow is as follows: After the vibratory feeding unit is started, the electromagnetic vibration driver generates periodic vibrations. Under the action of the vibration force, the spring moves upward along the spiral feeding track and slides out from the discharge port. After entering the sorting and organizing system, the spring first passes through the gap channel of the material channel organizing mechanism, maintaining a straight-line traveling posture under the constraint of the first and second guide rail groups. Subsequently, the spring enters the posture correction mechanism, where the correction wheel group forcibly corrects the axial direction of the spring, and the limit baffle restricts the position of the two ends of the spring. After completing the posture correction, the spring continues to move towards the clamping station with its head and tail facing the same direction and its axis horizontal. After the position sensor in the clamping and positioning system detects that the spring has reached its position, the control module issues a clamping command, the drive motor of the rotating clamping mechanism is energized, and the transmission mechanism drives the clamping claw group to move towards the center, firmly fixing the spring inside the clamping body. Subsequently, the position adjustment mechanism fine-tunes the position of the spring in the vertical and horizontal directions according to the preset processing parameters, ensuring that the bottom ends of the spring are exactly aligned with the working positions of the upper and lower grinding wheels.

[0036] The double-end grinding system enters the grinding stage. The upper and lower grinding motors are simultaneously energized, driving their respective grinding wheels to rotate at high speed. The rotation speed is set to 3000 to 8000 revolutions per minute, depending on the hardness of the spring material and the required grinding volume. The upper grinding wheel moves downwards, and the lower grinding wheel moves upwards; their relative motion simultaneously grinds the bottom ends of the spring. During grinding, the high-pressure airflow nozzle group continuously sprays compressed air, blowing metal debris generated in the grinding area towards the dust collection hood. Under negative pressure, the dust collection hood draws in the debris-laden airflow, which is then conveyed through a pipeline to a filtration and separation device. The primary filter intercepts larger debris particles, while fine dust is captured by the secondary filter. The purified air is discharged from the exhaust port of the suction pump. After grinding is complete, the upper and lower grinding wheels return to their initial positions, the rotating clamping mechanism releases its clamping jaws, and the ground spring is pushed from the clamping station to the discharge conveyor line for the next process.

[0037] In the above workflow, the control module coordinates and controls the entire processing. The input terminals of the control module are connected to various sensor signals, including the material level sensor of the vibratory feeding unit, the position sensor of the sorting system, the clamping force sensor of the clamping station, the displacement sensor of the grinding mechanism, and the negative pressure sensor of the chip removal system. The output terminals of the control module are connected to actuators such as the electromagnetic vibration driver of the vibratory feeding unit, the drive motor of the sorting system, the drive motor and cylinder of the clamping and positioning mechanism, the grinding motor of the double-end grinding system, and the solenoid valve of the chip removal system. The control module internally stores a processing parameter database, including parameters such as vibration frequency, clamping force, grinding speed, and grinding amount corresponding to different specifications of springs. When the operator selects the specification of the spring to be processed, the control module automatically calls up the corresponding parameters and issues control commands to each actuator, realizing rapid switching of processing parameters and automated operation of the processing process.

[0038] The double-end grinding mechanism in this embodiment employs a simultaneous upper and lower grinding method, which significantly improves processing efficiency compared to the traditional single-end grinding method. When the upper and lower grinding wheels simultaneously grind the bottom ends of the spring, the grinding time for a single spring is only half that of the single-end grinding method. Furthermore, since the grinding parameters of the upper and lower grinding wheels can be set independently and adjusted synchronously, the consistency of the grinding amount at both ends of the spring can be ensured, improving the dimensional accuracy and surface quality of the product. In addition, the symmetrical arrangement of the upper and lower grinding mechanisms ensures uniform heating of the spring during the grinding process, minimizing thermal deformation and helping to guarantee the spring's dimensional and positional tolerance requirements.

[0039] The automatic feeding system in this embodiment employs a vibration feeding method, which, compared to manual feeding, enables continuous and stable spring feeding. The feeding speed of the vibration feeding unit can be controlled by adjusting the vibration parameters of the electromagnetic vibration driver to adapt to different production rhythms. The posture correction mechanism in the sorting system automatically adjusts the spring's posture, eliminating any possible flipping or offset during vibration feeding and ensuring the spring enters the clamping station in the correct posture. Compared to manual feeding, the automatic feeding system eliminates clamping position and posture deviations caused by human factors, improving the consistency and stability of the grinding process.

[0040] The chip removal system in this embodiment combines high-pressure airflow with negative pressure suction to effectively remove metal chips generated during the grinding process. High-pressure airflow nozzles are positioned around the grinding area to blow chips away from the processing zone the instant they are generated, preventing them from adhering to or embedding on the spring surface. The combined use of a chip suction hood and a negative pressure pump quickly collects the scattered chips, preventing their accumulation in the working area. The chip recovery system treats the dust-laden airflow through multi-stage filtration. The primary filter intercepts large particles of chipping, while the secondary filter captures fine dust, resulting in high separation efficiency, maintaining a clean working environment, and facilitating the recycling and reuse of metal chips.

[0041] Example 2 Based on Example 1, this example makes adaptive improvements to the automatic feeding system and sorting system for the application scenario of mixed production of springs of different specifications, so as to meet the need for rapid switching of springs of different specifications on the same production line.

[0042] The adaptive feeding system deployed in this scenario includes an adjustable vibratory feeding unit and a modular sorting unit. The feeding track of the adjustable vibratory feeding unit adopts a replaceable structure, with different specifications of springs corresponding to different feeding track assemblies. Each feeding track assembly consists of three parts: a base track section, a middle track section, and a discharge track section. These sections are connected and fixed by positioning pins and quick clamps. When it is necessary to change the spring specification, the operator only needs to release the quick clamp, remove the currently used feeding track assembly, install the new assembly of the corresponding specification, and then re-fix it to complete the changeover. The entire changeover process is controlled within five minutes. The internal contour of the feeding track assembly is CNC machined according to the external dimensions of the corresponding spring, ensuring that the spring maintains a uniform gap with the track wall during vibratory conveying, which not only ensures smooth conveying but also prevents the spring from getting stuck in the track.

[0043] The modular sorting and organizing unit's material handling mechanism employs an adjustable-width guide rail structure. The first and second guide rail groups each consist of fixed and movable guide rails. The movable guide rails are mounted on guide rail supports via linear bearings, and a drive motor drives the movable guide rails to move perpendicular to the conveying direction via a screw and nut mechanism. When the material channel width needs adjustment, the control module issues an adjustment command, causing the drive motor to rotate and, through the screw and nut mechanism, move the movable guide rails to match the gap width between the two guide rails with the outer diameter of the currently processed spring. A position sensor detects the position of the movable guide rails in real time and feeds the signal back to the control module, achieving precise control of the gap width. The posture correction mechanism's correction wheel group also adopts an adjustable structure. Each correction wheel is mounted on an independent adjustment seat, which is connected to the main body of the correction mechanism via a dovetail groove. Rotating the adjustment handle moves the correction wheel along the dovetail groove direction, thereby adjusting the center distance between the two correction wheels. This center distance adjustment range covers the range of commonly used spring outer diameters, with an adjustment accuracy of 0.1 mm.

[0044] The adaptive feeding system also includes a spring specification recognition device, located between the discharge port of the vibratory feeding unit and the sorting system. This device comprises a vision sensor and a dimensional measurement sensor. The vision sensor consists of an industrial camera and a light source, with its field of view covering the passageway through which the springs pass. The camera captures image information of the springs and transmits it to the image processing unit. The image processing unit performs edge detection and feature extraction on the captured images to obtain the spring's outline information. The dimensional measurement sensor uses a laser rangefinder, with its measuring beam positioned perpendicular to the spring's conveying direction. The laser rangefinder measures the spring's outer diameter and transmits the measurement result to the control module. The control module compares the measurement results from the vision sensor and the dimensional measurement sensor with the characteristic parameters of springs of various specifications stored in the database, automatically identifying the specification of the currently fed spring and calling the corresponding processing parameters based on the identification result. When the identification result does not match the preset specification, the control module issues an alarm signal and stops feeding, awaiting operator confirmation and handling.

[0045] This system adds specification recognition and adaptive parameter adjustment steps to the workflow of Example 1. After the springs enter the sorting and organizing system from the vibratory feeding unit, they first pass through a specification recognition device. A visual sensor collects image information of the springs, and a laser rangefinder measures their outer diameter. The control module determines the spring specifications based on the recognition results. If the recognition is successful and the specifications match the current processing task, the sorting and subsequent processing continues. If the recognition is successful but the specifications do not match the current processing task, the spring is guided to the waiting hopper and processed after the current processing task is completed. If the recognition fails, the spring is guided to the abnormal hopper for manual inspection and handling. During the sorting and organizing process, the control module automatically adjusts the gap width of the material channel sorting mechanism and the center distance of the correction wheels of the posture correction mechanism according to the identified spring specifications to match the current spring dimensions. The processing parameters of the clamping and positioning system and the double-end grinding system are also automatically retrieved from the parameter database based on the recognition results, without manual intervention.

[0046] The adaptive feeding system in this embodiment, through replaceable feeding track components and adjustable material channel structure, can quickly adapt to the feeding requirements of springs of different specifications, resulting in short changeover time and high production efficiency. The spring specification recognition device enables automatic recall of processing parameters and automatic switching of processing flows, reducing manual intervention, lowering the risk of operational errors, and improving the intelligence level and operating efficiency of the production line.

[0047] Example 3 Based on Embodiment 1 and Embodiment 2, this embodiment addresses the precision control issue during the grinding process by introducing online measurement and closed-loop feedback technology to improve the precision of the double-end grinding system, thereby meeting the processing requirements of high-precision spring products.

[0048] The high-precision grinding system deployed in this scenario includes an upper grinding mechanism, a lower grinding mechanism, an online measurement mechanism, and a closed-loop control module. The online measurement mechanism is positioned between the clamping and positioning system and the double-end grinding system, and includes an upper end-face measuring device and a lower end-face measuring device. The upper end-face measuring device is located above the clamping station and includes a first laser displacement sensor and a first support frame. The first support frame is fixedly mounted on the frame, and the first laser displacement sensor is mounted at the bottom of the first support frame. The measuring beam is vertically downwards towards the upper end face of the spring. The lower end-face measuring device is located below the clamping station and includes a second laser displacement sensor and a second support frame. The second support frame is fixedly mounted on the frame, and the second laser displacement sensor is mounted at the top of the second support frame. The measuring beam is vertically upwards towards the lower end face of the spring. Both the first and second laser displacement sensors have a measurement accuracy of 0.001 mm and a sampling frequency of 10 kHz, enabling real-time acquisition of the position information of both end faces of the spring.

[0049] The input of the closed-loop control module is connected to the measurement signal output of the online measuring mechanism, and the output is connected to the servo drivers of the upper and lower grinding mechanisms, respectively. The closed-loop control module internally includes a machining parameter storage unit and an error compensation algorithm unit. The machining parameter storage unit stores data such as the target grinding amount, tolerance range, and grinding parameters corresponding to springs of different specifications. The error compensation algorithm unit calculates the deviation between the current grinding amount and the target grinding amount based on the end face position data collected in real time by the online measuring mechanism, and dynamically adjusts the feed rate of the grinding mechanism according to the deviation value, thus achieving closed-loop control of the grinding process.

[0050] The high-precision grinding system's workflow, based on Example 1, adds online measurement and real-time compensation. After the spring is clamped and fixed, before the grinding process begins, the initial end face position of the spring is measured by the online measurement mechanism. The control module records the initial position coordinates of the upper end face of the spring measured by the first laser displacement sensor and the initial position coordinates of the lower end face of the spring measured by the second laser displacement sensor, serving as the reference data for the grinding process. After the grinding process begins, the upper and lower grinding wheels approach the spring end face at a set feed rate. During the grinding process, the first and second laser displacement sensors continuously collect the position data of the spring end face and transmit the data to the closed-loop control module in real time. The closed-loop control module compares the real-time measured end face position with the initial position, calculates the current grinding amount, and compares this grinding amount with the target grinding amount. If the current grinding amount is less than the target grinding amount, grinding continues at the current feed rate. If the current grinding amount has reached the target grinding amount but the error exceeds the tolerance range, the closed-loop control module adjusts the output of the servo driver according to the error value, so that the grinding mechanism continues to feed or retreats to compensate for the error. If the current grinding amount has reached the target grinding amount and the error is within the tolerance range, the closed-loop control module issues a grinding completion command, and the grinding mechanism stops feeding and returns to the initial position.

[0051] After the grinding process is completed, the online measuring mechanism measures the positions of both end faces of the spring again to obtain the post-grinding end face position data. The control module compares the post-grinding end face position data with the target position data, calculates the actual grinding amount and the error value, and records and stores this data. If the error value exceeds the allowable tolerance range, the spring is judged as a defective product and automatically enters the defective product channel; if the error value is within the allowable tolerance range, the spring is judged as a qualified product and enters the next process. The control module also continuously optimizes the error compensation algorithm based on the statistical analysis results of a large amount of processing data to improve the accuracy and stability of closed-loop control.

[0052] The high-precision grinding system in this embodiment acquires end-face position data in real time during the grinding process through an online measuring mechanism, and uses a closed-loop control module to perform dynamic error compensation based on the measurement data, achieving precise control of the grinding amount. Compared with the traditional open-loop grinding method, this embodiment can control the grinding amount error within ±0.01 mm, significantly improving the dimensional accuracy and consistency of the product. The online measuring mechanism can also automatically detect and record the processing results of each spring, realizing traceable management of the processing process and providing data support for quality analysis and process improvement. The error compensation algorithm of the closed-loop control module can effectively overcome the influence of interference factors such as equipment precision error, thermal deformation, and abrasive wear, improving the stability and reliability of the processing system.

[0053] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for automatically feeding springs to grind flat, characterized in that, Includes the following steps: S1: The springs to be processed are taken out from the storage device by the vibrating feeding mechanism. Under the action of vibration, the springs are conveyed forward along the vibrating track and enter the sorting and sorting station. S2: The sorting and organizing mechanism performs posture detection and orientation correction on the delivered springs to ensure that the springs enter the subsequent clamping station in the correct direction and posture; S3: The clamping mechanism positions and clamps the spring to be processed, fixing the spring in the designated position of the grinding station; S4: The grinding devices located at the top and bottom ends of the spring are activated simultaneously to grind the bottom of both ends of the spring to form a flat end surface that meets the design requirements. S5: The chip removal structure removes metal chips generated during the grinding process, preventing chips from remaining on the spring surface or working area. S6: The scrap recycling unit will centrally recycle the metal scrap collected by the scrap removal structure to maintain a clean working environment.

2. The automatic feeding spring grinding method according to claim 1, characterized in that: The vibrating feeding mechanism includes a vibrating motor and a vibrating track. The vibration frequency of the vibrating motor can be adjusted by the control system. The tilt angle and vibration amplitude of the vibrating track work together to keep the spring in a stable conveying posture during vibration.

3. The automatic feeding spring grinding method according to claim 1, characterized in that: The sorting and organizing mechanism includes a spring attitude detection sensor and a direction correction device. The spring attitude detection sensor is a photoelectric sensor or a vision sensor used to detect the spring's entry direction and attitude angle. The direction correction device corrects the spring by pushing or rotating it according to the detection results.

4. The automatic feeding spring grinding method according to claim 1, characterized in that: The clamping mechanism includes an upper clamping block and a lower clamping block, which are respectively located at the upper and lower ends of the spring. The inner side of the clamping block is provided with an arc-shaped clamping surface that matches the shape of the spring. The clamping block is driven by a cylinder or a hydraulic cylinder to achieve rapid clamping and release of the spring. The clamping force can be adjusted according to the specifications of the spring.

5. The automatic feeding spring grinding method according to claim 1, characterized in that: The grinding device includes a grinding motor and a grinding wheel. The grinding wheel is made of silicon carbide or aluminum oxide. The speed of the grinding motor is precisely controlled by a frequency converter. The grinding device is set at the upper and lower ends of the spring and works synchronously to ensure that the grinding amount at both ends of the spring is consistent. The grinding depth is preset and adjusted by the control system.

6. The automatic feeding method for spring grinding according to claim 1, characterized in that: The chip removal structure includes a high-pressure airflow nozzle and a brushing mechanism. The high-pressure airflow nozzle is located around the grinding station and continuously sprays high-pressure airflow during the grinding process to blow the splashed metal chips away from the spring surface. The brushing mechanism uses flexible bristles to brush the surface after the spring has been ground to further remove residual chips.

7. The automatic feeding method for spring grinding according to claim 1, characterized in that: The debris recycling mechanism includes a debris collection tank, a filter device, and a debris collection container. The debris collection tank is located below the grinding station and is used to collect fallen metal debris. The filter device separates the debris by particle size. The debris collection container is used to store the recycled metal debris. The debris recycling mechanism is equipped with an automatic unblocking device to prevent debris from accumulating and causing blockages.

8. An automatic feeding spring grinding system, characterized in that: It includes a vibrating feeding device, a sorting and arranging device, a clamping device, a grinding device, a chip removal device, and a chip recycling device. The vibrating feeding device, sorting and arranging device, clamping device, grinding device, chip removal device, and chip recycling device are arranged in sequence and coordinated and controlled by a control system.

9. The automatic feeding spring grinding system according to claim 8, characterized in that: The vibrating feeding device includes a vibrating motor, a vibrating track, and a storage bin. The vibrating motor drives the vibrating track to generate directional vibration. The storage bin is located at the starting end of the vibrating track and is used to store the springs to be processed. Under the action of vibration, the springs are conveyed along the vibrating track towards the sorting and organizing device.

10. The automatic feeding spring grinding system according to claim 8, characterized in that: The grinding device includes an upper grinding mechanism and a lower grinding mechanism. The upper grinding mechanism is located above the spring, and the lower grinding mechanism is located below the spring. The upper grinding mechanism and the lower grinding mechanism each include a grinding motor and a grinding wheel. The grinding motor drives the grinding wheel to rotate at high speed to perform synchronous grinding on the bottom of both ends of the spring.

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