A valve standard part robot automatic production system

Abstract

The present application relates to the technical field of intelligent manufacturing, in particular to a valve standard part robot automatic production system, comprising a high platform support 1, a central control layer, a logistics execution layer, a production operation layer and a quality monitoring layer; the central control layer is composed of an MES production management system and an enterprise ERP system, used for receiving production plans and issuing operation instructions to each subsystem, synchronously collecting and storing production data, quality inspection data and logistics data; the logistics execution layer is composed of an AGV scheduling system, a latent lifting AGV trolley 7 and a warehouse connection station; the present application has the advantages of high space utilization, high production efficiency, strong adaptability to multiple varieties, high machining precision, full-process traceable data, high safety and high logistics collaboration efficiency, and can be widely applied to flexible automatic production of various valve standard parts and other similar mechanical standard part machining fields.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing technology, and in particular to an automated robotic production system for standard valve parts. Background Technology

[0002] As a key component industry in the process industry, the valve industry directly affects the safe operation of many downstream fields such as petrochemical, power, water conservancy, and municipal engineering by the processing quality and production efficiency of its standard parts. Forged steel gate valves and globe valves that meet the standards are core pressure-bearing components under high pressure and high temperature conditions, and have extremely stringent requirements for processing accuracy, surface quality, and mechanical properties. At the same time, these products generally have typical characteristics of multi-variety, small-batch production, such as many specifications and models, small batch sizes, and frequent production changes.

[0003] Currently, the production of standard valve parts still relies mainly on traditional manual operation using conventional lathes or CNC lathes. Although a few have introduced single-machine automated equipment, the overall production model still suffers from the following significant drawbacks: 1. Low production efficiency: The time spent on manual loading, unloading, clamping, and inspection is high, and the effective processing time of a single lathe is only about 55%, which makes it difficult to meet the delivery cycle requirements of large-volume orders. 2. Unstable machining accuracy: The consistency of the position of the blank is poor when manually clamped, and the repeatability of the positioning accuracy when the indexing chuck is used for multi-face machining is difficult to guarantee. As a result, the CPK value of the key dimensions of the same batch of products is generally lower than 1.0, and the failure rate is high. 3. Difficulty in switching between multiple product types: Traditional CNC lathes require frequent changes of fixtures, tools and machining programs for valve bodies and covers of different diameters and models. A single changeover can take up to several hours, making it difficult to adapt to the flexible production needs of multiple product types and small batches. IV. Low logistics coordination efficiency: The processes of raw material warehousing, production line material feeding, and finished product warehousing rely on manual handling or semi-automated roller conveyor, which makes it difficult to achieve efficient coordination with the production cycle. Data silos generally exist between the AGV scheduling system and the processing production line. 5. Severe data silos: Production plans, workshop scheduling, processing parameters, inspection data, and inventory data are scattered across multiple heterogeneous systems such as ERP, MES, and DCS, making it impossible to achieve full-process data interoperability, resulting in extensive production management and difficulties in quality traceability; VI. Low site utilization: In traditional production lines, robots, processing equipment, testing equipment, and cleaning equipment are scattered and generally installed on the ground, occupying a large area. Especially in industrial parks in coastal areas of Jiangsu and Zhejiang where factory rents are high, land costs severely restrict enterprises' capacity expansion and automation upgrades. Summary of the Invention

[0004] In view of this, the purpose of this invention is to propose an automated production system for standard valve parts by robots. Through the layout of high-platform upright robots, the design of two-axis dual-station material silos, and the full-process integration of MES and AGV, the system solves the technical problems existing in the production of standard valve parts, such as low efficiency, poor precision, difficulty in product switching, poor logistics coordination, data silos, and low site utilization.

[0005] Based on the above objectives, the present invention provides a robotic automated production system for standard valve parts, including a high platform support, a central control layer, a logistics execution layer, a production operation layer, and a quality monitoring layer: the central control layer consists of an MES production management system and an enterprise ERP system, which is used to receive production plans and issue operation instructions to each subsystem, and synchronously collect and store production data, quality inspection data, and logistics data. The logistics execution layer consists of an AGV scheduling system, a lurking lifting AGV trolley, and a warehouse connection station. It is connected to the MES production management system and is used to schedule the lurking lifting AGV trolley to perform logistics connection tasks such as raw material outbound, production line material loading, and finished product warehousing. The production operation layer consists of a two-axis dual-station material hopper, a high-platform upright industrial robot, and a turning processing unit. The two-axis dual-station material hopper includes a hopper body, an X-axis motion module, a Z-axis motion module, a gripper assembly, and two workstations on the left and right. The X-axis motion module drives the gripper assembly to switch between the two workstations, and the Z-axis motion module drives the gripper assembly to perform lifting and lowering actions to adjust the material picking height. The Z-axis motion module and the X-axis motion module adopt the same type of structural design, for example, a motor drives a lead screw, which works in conjunction with a slider and a slide rail to drive the gripper assembly. The difference is that the X-axis motion module realizes horizontal lateral movement, while the Z-axis motion module realizes vertical movement. The high-platform industrial robot is mounted on a high platform support above the turning unit and reaches down to pick up blanks or place finished products. The turning unit includes an indexing chuck and a CNC lathe. The indexing chuck clamps the workpiece on multiple sides at once to achieve multi-sided one-time machining. An alarm is installed on the top of the CNC lathe to provide feedback and warning of emergencies, giving the user sufficient reaction and processing time. The quality control layer consists of a cleaning mechanism and an inspection mechanism, which are integrated and installed on the turning unit. The cleaning mechanism and the inspection mechanism are respectively located on both sides of the turning unit, and are used for precise positioning of the workpiece, cleaning of surface cutting fluid and iron filings, and automatic detection of machining dimensions. A dedicated material tray for carrying blanks or finished products, the structure of which is adapted to the gripper assembly and the hopper position; The MES production management system interacts with the two-axis dual-station silo, the high-platform upright industrial robot, the turning processing unit, the cleaning mechanism, the testing mechanism, and the AGV scheduling system through an industrial communication network to achieve fully automated operation from order scheduling, production, quality inspection to logistics and warehousing.

[0006] Preferably, the X-axis motion module includes a fixed guide rail fixedly installed inside the chamber. A stepper motor is fixedly installed on one side inside the fixed guide rail. A lead screw is fixedly installed on the output shaft of the stepper motor. The end of the lead screw away from the stepper motor is rotatably installed on the inner wall of the fixed guide rail. An internal threaded sleeve that slides inside the fixed guide rail is threaded onto the surface of the lead screw. A connecting frame is fixedly installed on the top of the internal threaded sleeve.

[0007] Preferably, the gripper assembly includes a mounting bracket fixedly mounted on it. Two opposing stepper motors are fixedly mounted on the inner side of the mounting bracket. A lead screw is fixedly mounted on the output shaft of each stepper motor. The end of the lead screw away from the stepper motor is rotatably mounted on the inner wall of the mounting bracket. An internal threaded sleeve is threaded onto the surface of the lead screw. Multiple T-shaped slide rails are fixedly mounted on the inner wall of one side of the mounting bracket. The internal threaded sleeve is slidably mounted on two T-shaped slide rails. The two stepper motors can also be replaced by dual-axis motors.

[0008] Preferably, two bases are fixedly installed at the bottom of the inner cavity of the hopper, and multiple protrusions are fixedly installed on the top of the two bases. A support plate is placed above two adjacent protrusions, and the lurking lifting AGV trolley is located between two adjacent protrusions.

[0009] Preferably, a clamping arm is fixedly installed on one side of the internal thread sleeve 2, and multiple protrusions are fixedly connected to the opposite sides of the two clamping arms. The special material tray is disposed between the two clamping arms and overlaps on the protrusions on both sides. The special material tray is adapted to the pallet.

[0010] Preferably, the special material tray includes a tray body and several positioning slots. The positioning slots are customized according to the shape of the valve body or valve cover. Each positioning slot corresponds one-to-one with the gripping finger of the gripper assembly. The positioning slots are equipped with error prevention identification codes or RFID tags. The MES production management system identifies the type and quantity of blanks carried on the material tray by scanning the error prevention identification codes or reading the RFID tags.

[0011] Preferably, the high-platform industrial robot is a six-axis or multi-axis articulated robot with a quick-change fixture installed at its end. The quick-change fixture is configured with corresponding gripping fingers according to the shape of the blank or finished product. The MES production management system automatically calls the gripping finger parameters that match the quick-change fixture according to the current processing task.

[0012] A method for automated production of standard valve parts by robot includes the following steps: S: The MES production management system receives external production plans, automatically generates work schedules based on the current production line status, warehouse status, and AGV scheduling status, and issues material retrieval instructions to the AGV scheduling system. S: The warehouse staff places the corresponding blanks on the special material tray according to the instructions of the MES production management system. The lurking lifting AGV trolley loads the special material tray from the warehouse and transports it to the docking station of the two-axis dual-station material silo. After the material tray docking is completed, the lurking lifting AGV trolley leaves. S: The X-axis motion module and Z-axis motion module of the two-axis dual-station hopper work together to make the gripper assembly lift the special material tray to the downward picking height of the high-platform upright industrial robot. S: The high-platform industrial robot picks up the blank from the special material tray and puts it into the clamp of the indexing chuck; S: The indexing chuck clamps the workpiece, and the CNC lathe performs multi-faceted one-time machining on the workpiece; S: After processing, the high-platform industrial robot takes out the finished product and puts it into the cleaning mechanism for surface cleaning and into the testing mechanism for automatic testing. S: The testing agency generates a test report and uploads it to the MES production management system in real time. The high-platform industrial robot puts the qualified finished products back into the original slot of the special material tray. S: After all the blanks on the special material tray are processed, the MES production management system sends an entry instruction to the AGV scheduling system. The lurking lifting AGV trolley moves to the docking station of the two-axis dual-station material bin, loads the finished material tray, and transports it back to the warehouse.

[0013] Preferably, in step S4, before the high-platform industrial robot places the blank into the indexing chuck, the axial and radial positions of the blank are precisely adjusted by the secondary positioning mechanism with an adjustment accuracy of not less than 0.05mm, in order to compensate for the dimensional and positional deviations of the blank generated during the casting or forging process.

[0014] Preferably, the CNC lathe automatically calls the corresponding machining program according to the type of blank and the machining process requirements; in step S7, the detection mechanism performs 100% automatic detection on the key dimensions of the workpiece, and the detection items include at least three of the following: outer diameter, inner diameter, distance from end face to reference surface, sealing surface angle, and thread parameters. The detection data is uploaded to the MES production management system in real time for archiving and analysis.

[0015] The beneficial effects of this invention are: This invention integrates secondary positioning, cleaning, and inspection mechanisms onto a high-platform support structure using a high-platform robot layout. Compared to traditional ground-based layouts, this saves more than 60% of the floor space, making it particularly suitable for industrial parks with limited land resources.

[0016] The two-axis, dual-station material hopper of this invention enables continuous production without stopping the machine, and the effective processing time of a single lathe can reach more than 85%.

[0017] The positioning slot of the special material tray of this invention can be customized, and the specific type of product placed on the material tray can be changed at will, so that small batches of multi-variety products can also be adapted to the production line.

[0018] This invention uses a secondary positioning mechanism to accurately position the blank, and with the multi-faceted one-time clamping of the indexing chuck, the consistency of processing accuracy is significantly improved, and the defect rate can be reduced to below 0.5%.

[0019] This invention integrates the MES production management system with the robotic production line, enabling paperless operation throughout the entire process from order scheduling to production, quality inspection, logistics, and warehousing. Key data such as output and test reports can be uploaded in real time, avoiding human intervention.

[0020] The elevated platform layout of this invention physically separates the manual work area (in front of the lathe) from the robot work area (above the platform), avoiding the safety hazards of human-machine cross-operation.

[0021] This invention integrates the warehousing system with the AGV scheduling system and the MES system to achieve full automation of the logistics connection process from outbound to online to offline to inbound. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only for this invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present invention; Figure 2 This is a three-dimensional assembly diagram of the elevated platform industrial robot according to an embodiment of the present invention; Figure 3 This is a three-dimensional structural diagram of a two-axis, dual-station hopper according to an embodiment of the present invention; Figure 4 This is a partial three-dimensional structural diagram of a two-axis, dual-station hopper according to an embodiment of the present invention; Figure 5 Embodiments of the present invention Figure 4A partial three-dimensional structural diagram of A in the middle; Figure 6 This is a schematic diagram showing the working position of the special material tray according to an embodiment of the present invention; Figure 7 This is a three-dimensional structural assembly diagram of the Z-axis motion module and the X-axis motion module according to an embodiment of the present invention; Figure 8 This is a three-dimensional structural diagram of the X-axis motion module according to an embodiment of the present invention; Figure 9 This is a three-dimensional structural diagram of the special material tray according to an embodiment of the present invention.

[0024] The diagram is marked as follows: 1. High platform support, 2. Turning unit, 3. Inspection mechanism, 4. Cleaning mechanism, 5. Chamber body, 6. High platform upright industrial robot, 7. Hidden lifting AGV trolley, 8. Alarm, 9. Base, 10. Boss, 11. Support plate, 12. Fixed guide rail, 13. Stepper motor one, 14. Lead screw one, 15. Internal threaded sleeve one, 16. Connecting frame, 17. Z-axis motion module, 18. Mounting frame, 19. Stepper motor two, 20. Lead screw two, 21. Internal threaded sleeve two, 22. Clamping arm, 23. Protrusion, 24. Special material tray. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0026] It should be noted that, unless otherwise defined, the technical or scientific terms used in this invention should have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0027] like Figure 1-9As shown, a standard valve component robotic automated production system includes a high platform support 1, a central control layer, a logistics execution layer, a production operation layer, and a quality monitoring layer. The central control layer consists of an MES production management system and an enterprise ERP system, which are used to receive production plans and issue operation instructions to each subsystem, and synchronously collect and store production data, quality inspection data, and logistics data. The logistics execution layer consists of an AGV scheduling system, a lurking lifting AGV trolley 7, and a warehouse connection station. It is connected to the MES production management system and is used to schedule the lurking lifting AGV trolley 7 to perform logistics connection tasks such as blank outbound, production line material loading, and finished product warehousing. The production operation layer consists of a two-axis dual-station material hopper, a high-platform upright industrial robot 6, and a turning processing unit 2. The two-axis dual-station material hopper includes a hopper body 5, an X-axis motion module, a Z-axis motion module 17, a gripper assembly, and two workstations on the left and right. The X-axis motion module drives the gripper assembly to switch between the two workstations. The Z-axis motion module 17 drives the gripper assembly to perform lifting and lowering actions to adjust the material picking height. The Z-axis motion module 17 and the X-axis motion module adopt the same type of structural design. For example, a motor drives a lead screw, which works in conjunction with a slider and a slide rail to drive the gripper assembly. The difference is that the X-axis motion module achieves horizontal lateral movement, while the Z-axis motion module 17 achieves vertical up and down movement. The high-platform industrial robot 6 is mounted on the high-platform support 1 above the turning processing unit 2, and reaches down to pick up blanks or place finished products. The turning unit 2 includes an indexing chuck and a CNC lathe. The indexing chuck clamps the workpiece on multiple sides at one time to achieve multi-sided one-time machining. An alarm 8 is installed on the top of the CNC lathe. The alarm 8 is used to provide feedback and warning of emergencies, providing users with sufficient reaction and processing time. The quality monitoring layer consists of a cleaning mechanism 4 and an inspection mechanism 3, which are integrated and installed on the turning unit 2. The cleaning mechanism 4 and the inspection mechanism 3 are respectively arranged on both sides of the 2, and are used for precise positioning of the workpiece, cleaning of surface cutting fluid and iron filings, and automatic detection of machining dimensions. A dedicated material tray 24 is used to carry blanks or finished products, and its structure is adapted to the gripper assembly and the material bin position. The MES production management system interacts with the two-axis dual-station silo, the high-platform upright industrial robot 6, the turning processing unit 2, the cleaning mechanism 4, the inspection mechanism 3, and the AGV scheduling system through an industrial communication network to achieve fully automated operation from order scheduling, production, quality inspection to logistics and warehousing.

[0028] The X-axis motion module includes a fixed guide rail 12 fixedly installed inside the chamber 5. A stepper motor 13 is fixedly installed on one side inside the fixed guide rail 12. A lead screw 14 is fixedly installed on the output shaft of the stepper motor 13. The end of the lead screw 14 away from the stepper motor 13 is rotatably installed on the inner wall of the fixed guide rail 12. An internal threaded sleeve 15 that slides inside the fixed guide rail 12 is threaded onto the surface of the lead screw 14. A connecting bracket 16 is fixedly installed on the top of the internal threaded sleeve 15.

[0029] The gripper assembly includes a mounting bracket 18 fixedly mounted on 17. Two opposing stepper motors 19 are fixedly mounted on the inner side of the mounting bracket 18. A lead screw 20 is fixedly mounted on the output shaft of each stepper motor 19. The end of the lead screw 20 away from the stepper motor 19 is rotatably mounted on the inner wall of the mounting bracket 18. An internal threaded sleeve 21 is threaded onto the surface of the lead screw 20. Multiple T-shaped slide rails are fixedly mounted on the inner wall of one side of the mounting bracket 18. The internal threaded sleeve 21 is slidably mounted on two T-shaped slide rails. The two stepper motors 19 can also be replaced with dual-axis motors.

[0030] Two bases 9 are fixedly installed at the bottom of the inner cavity of the hopper 5. Multiple protrusions 10 are fixedly installed on the top of the two bases 9. A tray 11 is placed above two adjacent protrusions 10. The lurking lifting AGV trolley 7 is located between two adjacent protrusions 10.

[0031] A clamping arm 22 is fixedly installed on one side of the internal thread sleeve 21. Multiple protrusions 23 are fixedly connected to the opposite side of the two clamping arms 22. The special material tray 24 is disposed between the two clamping arms 22 and overlaps on the protrusions 23 on both sides. The special material tray 24 is adapted to the support plate 11.

[0032] The special material tray includes a tray body and several positioning slots. The positioning slots are customized according to the shape of the valve body or valve cover. Each positioning slot corresponds one-to-one with the gripping finger of the gripper assembly. The positioning slots are equipped with error prevention identification codes or RFID tags. The MES production management system identifies the type and quantity of blanks carried on the material tray by scanning the error prevention identification codes or reading the RFID tags.

[0033] The high-platform industrial robot is a six-axis or multi-axis articulated robot with a quick-change fixture installed at its end. The quick-change fixture is configured with corresponding gripping fingers according to the shape of the blank or finished product. The MES production management system automatically calls the gripping finger parameters that match the quick-change fixture according to the current processing task.

[0034] A method for automated production of standard valve parts by robot includes the following steps: S1: The MES production management system receives external production plans, automatically generates work schedules based on the current production line status, warehouse status, and AGV scheduling status, and issues material retrieval instructions to the AGV scheduling system. S2: The warehouse staff places the corresponding blanks on the special material tray 24 according to the instructions of the MES production management system. The lurking lifting AGV trolley 7 loads the special material tray 24 from the warehouse and transports it to the docking station of the two-axis dual-station material bin. After the material tray docking is completed, the lurking lifting AGV trolley 7 leaves. S3: The X-axis motion module and Z-axis motion module 17 of the two-axis dual-station hopper work together to make the gripper assembly lift the special material tray 24 to the downward picking height of the high-platform upright industrial robot 6. S4: The high-platform industrial robot 6 picks up the blank from the special material tray 24 and puts it into the clamp of the indexing chuck; S5: The indexing chuck clamps the workpiece, and the CNC lathe performs multi-faceted one-time machining on the workpiece; S6: After processing, the high-platform industrial robot 6 takes out the finished product and puts it into the cleaning mechanism 4 for surface cleaning and into the testing mechanism 3 for automatic testing. S7: The testing agency 3 generates a test report and uploads it to the MES production management system in real time. The high-platform industrial robot 6 puts the qualified finished products back into the original slot of the special material tray 24. S8: After all the blanks on the special material tray 24 have been processed, the MES production management system sends an entry instruction to the AGV scheduling system. The lurking lifting AGV trolley 7 moves to the docking station of the two-axis dual-station material bin, loads the finished material tray, and transports it back to the warehouse.

[0035] In step S4, before the high-platform industrial robot places the blank into the indexing chuck, it first uses the secondary positioning mechanism to precisely adjust the axial and radial positions of the blank, with an adjustment accuracy of not less than 0.05mm, in order to compensate for the dimensional and positional deviations of the blank generated during the casting or forging process.

[0036] The CNC lathe automatically calls the corresponding machining program according to the type of blank and the machining process requirements; in step S7, the detection mechanism performs 100% automatic detection of the key dimensions of the workpiece. The detection items include at least three of the following: outer diameter, inner diameter, distance from end face to reference surface, sealing surface angle, and thread parameters. The detection data is uploaded to the MES production management system in real time for archiving and analysis.

[0037] Example 1: The central control layer consists of the MES production management system and the enterprise ERP system. It receives production plans and issues work instructions to various subsystems, and synchronously collects and stores production data, quality inspection data, and logistics data. It is deployed on an industrial server (Intel Xeon E-2278G processor, 64GB DDR4 ECC memory, 2×1.92TB SSD RAID1 storage array) at the edge of the production line. The operating system is Windows Server 2019 + SQL Server 2019 database. It deploys the self-developed valve flexible production line MES software V3.2, and its main functional modules include: production scheduling APS module (using an improved genetic algorithm for production scheduling optimization, population size 100, iteration number 200, crossover probability 0.85, mutation probability 0.05, objective function is to minimize total completion time + minimize changeover time); equipment status monitoring module (polling cycle 500ms); quality statistical analysis SPC module (Xbar-R control chart, CPK real-time calculation); and production traceability module (traceability granularity down to individual workpieces, response time ≤2s). The MES system integrates with the ERP system to achieve automatic order synchronization and communicates with downstream subsystems using the OPC UA protocol.

[0038] Example 2: The logistics execution layer consists of an AGV scheduling system, 7 lurking lifting AGV carts (rated load 500kg, self-weight 180kg, lifting stroke 1.2m, positioning accuracy ±5mm, navigation method is laser SLAM + QR code assisted positioning, driving speed adjustable from 0-1.5m / s, battery capacity 60Ah / 48V lithium battery, 8 hours of battery life, 2 hours of charging time), and warehouse connection workstations. It communicates with the MES production management system and is used to schedule the lurking lifting AGV carts 7 to perform logistics connection tasks such as raw material outbound, production line loading, and finished product warehousing. The AGV scheduling system adopts a time window-based dynamic path planning algorithm (A* algorithm + DWA dynamic window method fusion), with a scheduling cycle of 1s, and can simultaneously manage 8 AGVs in a single scheduling. The AGV-to-warehouse connection adopts a dual confirmation mechanism of visual alignment + torque detection, with an alignment time ≤15s.

[0039] Example 3: The production operation layer consists of a two-axis, dual-station material hopper, a high-platform mounted industrial robot 6, and a turning processing unit 2. The two-axis, dual-station material hopper includes a hopper body 5, an X-axis motion module (1500mm travel, 1.5kW servo motor power, positioning accuracy ±0.1mm, maximum speed 1m / s), a Z-axis motion module 17 (1500mm travel, 1.5kW servo motor power, positioning accuracy ±0.1mm, maximum speed 0.8m / s), a gripper assembly, and two workstations on the left and right. The X-axis switching time is ≤2.5s. The Z-axis lifting time is ≤3.5s, and the gripper assembly clamping force is adjustable from 50-200N. The X-axis motion module drives the gripper assembly to switch between the left and right workstations. The Z-axis motion module 17 drives the gripper assembly to perform lifting and lowering actions to adjust the material picking height. The Z-axis motion module 17 and the X-axis motion module adopt the same type of structural design. For example, the motor drives the lead screw, which works in conjunction with the slider and slide rail to drive the gripper assembly. The difference is that the X-axis motion module realizes horizontal lateral movement, while the Z-axis motion module 17 realizes vertical movement. The elevated platform industrial robot 6 is mounted on the elevated platform support 1 above the turning processing unit 2. It reaches down to pick up blanks or place finished products. The elevated platform industrial robot 6 adopts the KUKA KR 16 R1610 six-axis articulated robot (load 16kg, working radius 1610mm, repeatability ±0.05mm, TCP maximum speed 2m / s), and is mounted on the elevated platform support 1 with a height of 2.8m. The end effector is equipped with a quick-change fixture (change time ≤3s). The turning unit 2 includes an indexing chuck and a CNC lathe. The indexing chuck clamps the workpiece from multiple sides at once to achieve multi-sided one-time machining. An alarm 8 is installed on the top of the CNC lathe. The alarm 8 is used to report and warn of emergencies, providing the user with sufficient reaction and processing time. The turning unit 2 uses a CK6140 CNC lathe (spindle power 7.5kW, maximum speed 2500rpm, X / Z axis travel 260 / 500mm, repeatability ±0.005mm) + a four-position hydraulic indexing chuck (clamping force 5-15kN adjustable, indexing accuracy ±0.01°, indexing time ≤1.5s).

[0040] Example 4: The quality monitoring layer consists of a cleaning mechanism 4 and an inspection mechanism 3, which are integrated and installed on the turning unit 2. The cleaning mechanism 4 and the inspection mechanism 3 are respectively arranged on both sides of the unit 2, and are used for precise positioning of the workpiece, cleaning of surface cutting fluid and iron filings, and automatic detection of machining dimensions. The cleaning mechanism 4 adopts a combination of high-pressure spray (pressure 0.6MPa, flow rate 20L / min) + air blowing (pressure 0.4MPa), with a cleaning time ≤15s. The inspection mechanism 3 adopts a three-coordinate measuring module (measurement accuracy MPE=2.1+L / 333μm, measurement items: outer diameter, inner diameter, length, sealing surface angle, thread pitch diameter, measurement time ≤45s) + vision inspection module (2-megapixel CCD camera, ring LED light source, defect recognition accuracy ≥99.5%) dual module. The inspection data automatically generates PDF+XML dual format reports and uploads them to the MES system in real time via the MQTT protocol. A dedicated material tray 24, which carries raw blanks or finished products, has a structure adapted to the gripper assembly and material hopper, such as... Figure 9 As shown, the special material tray 24 includes a tray body and several positioning slots. The tray body is welded from Q235 steel and has dimensions of 1200mm×800mm×150mm. The maximum load capacity is 300kg. It should be noted that the positioning slot can also be customized according to the shape of the valve body or valve cover. The positioning slot is equipped with an error-proof identification code or RFID tag 93. The MES production management system 1 identifies the type and quantity of blanks carried on the tray by scanning the code or reading the tag, thus avoiding the risk of incorrect material selection caused by manual identification.

[0041] In summary, the effective machining time of a single lathe accounts for ≥88%, the product defect rate is ≤0.4%, the production line floor space is reduced by 65% ​​compared to traditional production lines, labor costs are reduced by 70%, and the production cycle time is: machining time for a single small-diameter valve body ≤180s, machining time for a single medium-diameter valve cover ≤240s, material tray switching time ≤8s, AGV single pick-up / feed time ≤90s, full-process data collection integrity rate is 100%, and the overall equipment efficiency (OEE) of the system is ≥85%. It has the advantages of high space utilization, high production efficiency, strong adaptability to multiple varieties, high machining accuracy, full data traceability, high security, and efficient logistics collaboration. It can be widely used in the flexible automated production of various valve standard parts, especially suitable for the machining of valve bodies and valve covers of forged steel gate valves and globe valves conforming to API602 standards, and can also be extended to other similar mechanical standard parts machining fields.

[0042] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the invention (including the claims) is limited to these examples; within the framework of the invention, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of the different aspects of the invention as described above, which are not provided in detail for the sake of brevity.

[0043] This invention is intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A robotic automated production system for standard valve parts, characterized in that, Including the high platform support (1), central control layer, logistics execution layer, production operation layer, and quality monitoring layer: The central control layer consists of the MES production management system and the enterprise ERP system, which is used to receive production plans and issue operation instructions to each subsystem, and synchronously collect and store production data, quality inspection data and logistics data. The logistics execution layer consists of an AGV scheduling system, a lurking lifting AGV trolley (7), and a warehouse connection station. It is connected to the MES production management system and is used to schedule the lurking lifting AGV trolley (7) to perform logistics connection tasks such as blank outbound, production line material delivery, and finished product inbound. The production operation layer consists of a two-axis dual-station hopper, a high-platform upright industrial robot (6), and a turning processing unit (2). The two-axis dual-station hopper includes a hopper body (5), an X-axis motion module, a Z-axis motion module (17), a gripper assembly, and two workstations on the left and right. The X-axis motion module drives the gripper assembly to switch between the two workstations on the left and right. The Z-axis motion module (17) drives the gripper assembly to perform lifting and lowering actions to adjust the material picking height. The Z-axis motion module (17) and the X-axis motion module adopt the same type of structural design. For example, the motor drives the lead screw, which works in conjunction with the slider and slide rail to drive the gripper assembly. The difference is that the X-axis motion module achieves horizontal lateral movement, while the Z-axis motion module (17) achieves vertical up and down movement. The high-platform industrial robot (6) is installed on the high-platform support (1) above the turning processing unit (2) and reaches down to pick up blanks or place finished products. The turning unit (2) includes an indexing chuck and a CNC lathe. The indexing chuck clamps the workpiece on multiple sides at one time to achieve multi-sided one-time machining. An alarm (8) is installed on the top of the CNC lathe. The alarm (8) is used to provide feedback and warning of emergencies, providing users with sufficient reaction and processing time. The quality monitoring layer consists of a cleaning mechanism (4) and an inspection mechanism (3), which are integrated and installed on the turning unit (2). The cleaning mechanism (4) and the inspection mechanism (3) are respectively arranged on both sides of the turning unit (2) and are used for precise positioning of the workpiece, cleaning of surface cutting fluid and iron filings, and automatic detection of machining dimensions. A special material tray (24) is used to carry blanks or finished products, and its structure is adapted to the gripper assembly and the hopper position. The MES production management system interacts with the two-axis dual-station silo, the high-platform upright industrial robot (6), the turning processing unit (2), the cleaning mechanism (4), the testing mechanism (3), and the AGV scheduling system through an industrial communication network to realize the full-process automated operation from order scheduling, production, quality inspection to logistics and warehousing.

2. The automated production system for standard valve parts by robot according to claim 1, characterized in that: The X-axis motion module includes a fixed guide rail (12) fixedly installed inside the chamber (5). A stepper motor (13) is fixedly installed on one side inside the fixed guide rail (12). A lead screw (14) is fixedly installed on the output shaft of the stepper motor (13). The end of the lead screw (14) away from the stepper motor (13) is rotatably installed on the inner wall of the fixed guide rail (12). An internal threaded sleeve (15) that slides inside the fixed guide rail (12) is threaded on the surface of the lead screw (14). A connecting frame (16) is fixedly installed on the top of the internal threaded sleeve (15).

3. The automated production system for standard valve parts by robot according to claim 2, characterized in that: The gripper assembly includes a mounting bracket (18) fixedly mounted on (17). Two opposing stepper motors (19) are fixedly mounted on the inner side of the mounting bracket (18). A lead screw (20) is fixedly mounted on the output shaft of the stepper motor (19). The end of the lead screw (20) away from the stepper motor (19) is rotatably mounted on the inner wall of the mounting bracket (18). An internal thread sleeve (21) is threaded onto the surface of the lead screw (20). Multiple T-shaped slide rails are fixedly mounted on the inner wall of one side of the mounting bracket (18). The internal thread sleeve (21) is slidably mounted on two T-shaped slide rails. The two stepper motors (19) can also be replaced by dual-axis motors.

4. The automated production system for standard valve parts by robot according to claim 3, characterized in that: Two bases (9) are fixedly installed at the bottom of the inner cavity of the hopper (5). Multiple bosses (10) are fixedly installed on the top of the two bases (9). A tray (11) is placed above two adjacent bosses (10). The lurking lifting AGV trolley (7) is located between two adjacent bosses (10).

5. The automated production system for standard valve parts by robot according to claim 4, characterized in that: A clamping arm (22) is fixedly installed on one side of the internal thread sleeve (21). Multiple protrusions (23) are fixedly connected to the opposite side of the two clamping arms (22). The special material tray (24) is set between the two clamping arms (22). The (24) overlaps on the protrusions (23) on both sides. The special material tray (24) is compatible with the pallet (11).

6. The automated production system for standard valve parts by robot according to claim 5, characterized in that: The special material tray includes a tray body and several positioning slots. The positioning slots are customized according to the shape of the valve body or valve cover. Each positioning slot corresponds one-to-one with the gripping finger of the gripper assembly. The positioning slots are equipped with error prevention identification codes or RFID tags. The MES production management system identifies the type and quantity of blanks carried on the material tray by scanning the error prevention identification codes or reading the RFID tags.

7. The automated production system for standard valve parts by robot according to claim 6, characterized in that: The high-platform industrial robot is a six-axis or multi-axis articulated robot with a quick-change fixture installed at its end. The quick-change fixture is configured with corresponding gripping fingers according to the shape of the blank or finished product. The MES production management system automatically calls the gripping finger parameters that match the quick-change fixture according to the current processing task.

8. A method for automated production of standard valve parts by a robot, applied to an automated production system for standard valve parts by a robot according to any one of claims 1-7, characterized in that: Includes the following steps: S1: The MES production management system receives external production plans, automatically generates work schedules based on the current production line status, warehouse status, and AGV scheduling status, and issues material retrieval instructions to the AGV scheduling system. S2: The warehouse staff places the corresponding blanks on the special material tray (24) according to the instructions of the MES production management system. The lurking lifting AGV trolley (7) loads the special material tray (24) from the warehouse and transports it to the docking station of the two-axis dual-station material silo. After the material tray docking is completed, the lurking lifting AGV trolley (7) leaves. S3: The X-axis motion module and Z-axis motion module (17) of the two-axis dual-station hopper work together to make the gripper assembly lift the special material tray (24) to the downward picking height of the high-platform upright industrial robot (6); S4: The high-platform industrial robot (6) picks up the blank from the special material tray (24) and puts it into the clamp of the indexing chuck; S5: The indexing chuck clamps the workpiece, and the CNC lathe performs multi-faceted one-time machining on the workpiece; S6: After processing, the high-platform industrial robot (6) takes out the finished product, puts it into the cleaning mechanism (4) for surface cleaning, and puts it into the testing mechanism (3) for automatic testing. S7: The testing agency (3) generates a test report and uploads it to the MES production management system in real time. The high-platform industrial robot (6) puts the qualified finished products back into the original slot of the special material tray (24). S8: When all blanks on the special material tray (24) are processed, the MES production management system sends an entry instruction to the AGV scheduling system. The lurking lifting AGV trolley (7) moves to the docking station of the two-axis dual-station material silo, loads the finished material tray, and transports it back to the warehouse.

9. A method for automated production of standard valve parts by robot according to claim 8, characterized in that: In step S4, before the high-platform industrial robot places the blank into the indexing chuck, it first uses the secondary positioning mechanism to precisely adjust the axial and radial positions of the blank, with an adjustment accuracy of not less than 0.05mm, in order to compensate for the dimensional and positional deviations of the blank generated during the casting or forging process.

10. The automated production method for standard valve parts by robot according to claim 9, characterized in that: The CNC lathe automatically calls the corresponding machining program according to the type of blank and the machining process requirements; in step S7, the detection mechanism performs 100% automatic detection of the key dimensions of the workpiece. The detection items include at least three of the following: outer diameter, inner diameter, distance from end face to reference surface, sealing surface angle, and thread parameters. The detection data is uploaded to the MES production management system in real time for archiving and analysis.

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