Double-station automatic flexible grinding equipment for large aluminum alloy low-pressure castings

Abstract

The utility model relates to a large aluminum alloy low-pressure casting double-station automatic flexible polishing device which comprises a robot mechanism, a shuttle table mechanism is arranged on the opposite side of the robot mechanism, the shuttle table mechanism comprises a shuttle table rack, and a product detection assembly and a servo rotating frame are arranged on the shuttle table rack. The product detection assembly comprises a product detection sensor, and a grinding tool is installed on the servo rotating frame. The trimming device is specially used for polishing and removing the trimmings on the large-scale aluminum alloy low-pressure casting, and is used for improving the appearance of a product and reducing the manual operation cost.

Description

Technical Field

[0001] The utility model relates to a grinding device for aluminum alloy low-pressure castings, in particular to a double-station automatic flexible grinding device for large aluminum alloy low-pressure castings, and belongs to one of the auxiliary devices for the production of low-pressure casting products. Background Art

[0002] After large aluminum alloy low-pressure castings are cast, there are more or less flash at the parting line part. Even if trimming equipment is used, the flash still cannot be completely removed, and there are residues or the trimming equipment cannot cut to it, resulting in poor product appearance. At present, in the industry, the flash that cannot be cut by the trimming equipment is mainly removed manually. However, due to the large weight of the product, it is difficult to turn over, the grinding and removal time is long, and the operation difficulty is great.

[0003] Therefore, there is a continuous need in the field to develop a device dedicated to grinding and removing the flash on castings to improve product appearance and reduce manual operation costs. The present utility model is thus produced. Summary of the Utility Model

[0004] In view of the above technical problems in the prior art, the purpose of the present utility model is to provide a double-station automatic flexible grinding device for large aluminum alloy low-pressure castings, which is dedicated to grinding and removing the flash on large aluminum alloy low-pressure castings to improve product appearance and reduce manual operation costs.

[0005] To achieve the above purpose, the present utility model is realized by the following technical solutions:

[0006] A double-station automatic flexible grinding device for large aluminum alloy low-pressure castings includes a robot mechanism. A shuttle table mechanism is arranged on the opposite side of the robot mechanism. The shuttle table mechanism includes a shuttle table frame. A product detection component and a servo rotating frame are arranged on the shuttle table frame. The product detection component includes a product detection sensor. A grinding tooling is installed on the servo rotating frame.

[0007] The shuttle table mechanism includes a left shuttle table mechanism and a right shuttle table mechanism, and the left shuttle table mechanism and the right shuttle table mechanism are arranged oppositely; the grinding tooling includes a first grinding tooling and a second grinding tooling. The first grinding tooling is installed on the right shuttle table mechanism, and the second grinding tooling is installed on the left shuttle table mechanism.

[0008] The left shuttle table mechanism corresponds to an upper and lower part station one, and the right shuttle table mechanism corresponds to an upper and lower part station two.

[0009] The shuttle table mechanism is provided with an operation button box, and both the product detection component and the servo rotating frame are associated with the operation button box.

[0010] The described robotic mechanism includes a robot body, a 2D camera is installed on the sixth axis of the robot body, a support plate is connected below the 2D camera, and a floating flexible spindle and a fixed spindle are installed below the support plate.

[0011] The fixed spindle is a high-torque fixed spindle, and the torque of the high-torque fixed spindle is 7 - 9 N·m.

[0012] A milling cutter is replaceably installed on the floating flexible spindle, and a conical milling cutter is fixedly installed on the fixed spindle.

[0013] The described grinding tooling is provided with a No. 1 cylinder, a No. 2 cylinder, a No. 3 cylinder and a No. 4 cylinder.

[0014] A protective workshop mechanism is arranged outside the robotic mechanism. A wire groove mechanism is arranged on the inner wall of the protective workshop mechanism, and a tool rest mechanism is arranged at the entrance and exit of the protective workshop mechanism.

[0015] The beneficial effects of the double-station automatic flexible grinding equipment for large aluminum alloy low-pressure castings of the present utility model are as follows:

[0016] 1. The present utility model is configured with a 2D camera on the robotic mechanism to take pictures of deformed products, and the offset value is obtained through the algorithm of the software and given to the robotic mechanism, realizing the automatic correction of the grinding trajectory. Moreover, the robot trajectory completely adopts a new mode from offline programming to actual use, and with the help of some auxiliary tools, the point positions are checked to complete the application of the grinding trajectory.

[0017] 2. The robotic mechanism in the present utility model is equipped with two spindles. One is a high-torque fixed spindle with a torque of up to 7 - 9 N·m, which can complete the cleaning of large and thick flash on the product; the other is a floating and replaceable tool flexible spindle, which can automatically select tools according to different residual flash on the product for flash grinding of the product. And the floating and replaceable tool flexible spindle is configured with an automatic quick-change tool device, which can select different tools for product grinding according to different flash burrs on the product. The automatic quick-change tool device controls the broaching mechanism in the spindle pneumatically, loosens the original tool holder, the original tool holder falls on the tool change seat, then moves the spindle with the empty tool holder above the new tool holder, and controls the broaching mechanism in the spindle pneumatically to lock the tool holder again.

[0018] 3. The shuttle table mechanism in the present utility model is provided with a servo rotating table, which can rotate the angle according to the grinding needs, can process the flash on the six sides of the product, namely up, down, left, right, front, and can complete the residual flash burrs on the surfaces of most products. And a product detection sensor is provided to judge the grinding tool. After each grinding is completed, the robot moves to the tool breakage detection position to detect whether the tool is broken.

[0019] 4. The utility model has a loading and unloading station one and a loading and unloading station two, which can be operated by one person. The grinding of the two stations does not interfere with each other, saving labor costs and improving grinding efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is a three-dimensional structural schematic diagram of the utility model;

[0021] Figure 2 is a front view structural schematic diagram of the utility model;

[0022] Figure 3 is Figure 2 a sectional structural schematic diagram in the B-B direction of

[0023] Figure 4 is Figure 3 a sectional structural schematic diagram in the A-A direction of

[0024] Figure 5 is a structural schematic diagram of the right shuttle table mechanism in the utility model;

[0025] Figure 6 is a structural schematic diagram of the first grinding tooling in the utility model;

[0026] Figure 7 is Figure 6 an enlarged structural schematic diagram of part A in

[0027] Figure 8 is a schematic diagram of the installation position of the product detection sensor in the utility model;

[0028] Figure 9 is a structural schematic diagram of the robot mechanism in the utility model;

[0029] Figure 10 is a schematic diagram of the installation position relationship between the floating flexible spindle and the fixed spindle in the utility model;

[0030] Figure 11 is a structural schematic diagram of the floating flexible spindle in the utility model;

[0031] Figure 12 is a schematic diagram of the installation position of the hundred-leaf wheel in the utility model;

[0032] Figure 13 is a schematic diagram of the installation position of the tool presence / absence detection sensor in the utility model;

[0033] Figure 14 is a schematic diagram of the installation position of the protective cover;

[0034] Among them, 1 is the wire groove mechanism, 2 is the tool rest mechanism, 3 is the second grinding tooling, 4 is the right shuttle table mechanism, 5 is the left shuttle table mechanism, 6 is the robot mechanism, 7 is the protective workshop mechanism, 8 is the first grinding tooling, 9 is the first loading and unloading station, 10 is the second loading and unloading station, 11 is the product detection component, 12 is the servo rotating rack, 13 is the operation button box, 14 is the shuttle table mechanism frame, 15 is the No. 1 cylinder, 16 is the No. 2 cylinder, 17 is the No. 3 cylinder, 18 is the No. 4 cylinder, 19 is the robot body, 20 is the 2D camera, 21 is the support plate, 22 is the fixed main shaft, 23 is the floating flexible main shaft, 24 is the pneumatic control box, 25 is the product detection sensor, 26 is the planetary reducer, 27 is the synchronous belt, 28 is the servo motor, 29 is the RV reducer, 30 is the broaching mechanism, 31 is the tool holder, 32 is the flap wheel, 33 is the tool presence / absence detection sensor, 34 is the tool changer guard cylinder, 35 is the guard. Detailed implementation mode

[0035] The following further illustrates the present utility model in conjunction with specific embodiments, but the protection scope of the present utility model is not limited thereto.

[0036] As Figures 1-14 shown, the double-station automatic flexible grinding equipment for large aluminum alloy low-pressure castings of the present utility model includes a robot mechanism 6. A shuttle table mechanism is provided on the opposite side of the robot mechanism 6. The shuttle table mechanism includes a shuttle table frame 14. A product detection component 11 and a servo rotating rack 12 are provided on the shuttle table frame 14. A grinding tooling is installed on the servo rotating rack 12. The servo rotating rack 12 can rotate by an angle according to the grinding needs, can process the flash on the six sides of the product, namely up, down, left, right, and front, and can complete the flash burr residues on most of the product surfaces. The product detection component 11 includes a product detection sensor 25, which is used to judge the grinding tool. After each grinding is completed, the robot moves to the tool breakage detection position to detect whether the tool is broken. The shuttle table mechanism is provided with an operation button box 13. The product detection component 11 and the servo rotating rack 12 are both associated with the operation button box 13.

[0037] Furthermore, in order to enable one person to operate, the two workstations do not interfere with each other, save labor costs, and improve the grinding efficiency, the present utility model has a first loading and unloading station 9 and a second loading and unloading station 10. Among them, the shuttle table mechanism includes a left shuttle table mechanism 5 and a right shuttle table mechanism 4 with the same structure. The left shuttle table mechanism 5 and the right shuttle table mechanism 4 are arranged oppositely; the grinding tooling includes a first grinding tooling 8 and a second grinding tooling 3 with the same structure. The first grinding tooling 8 is installed on the right shuttle table mechanism 4, and the second grinding tooling 3 is installed on the left shuttle table mechanism 5. The left shuttle table mechanism 5 corresponds to the first loading and unloading station 9, and the right shuttle table mechanism 4 corresponds to the second loading and unloading station 10.

[0038] Furthermore, the robot mechanism 6 in the present utility model includes a robot body 19. A 2D camera 20 is installed on the six-axis of the robot body 19 to take pictures of the deformed products. The offset value is obtained through the algorithm of the software and given to the robot mechanism 6, realizing the automatic deviation correction of the grinding trajectory. Moreover, the robot trajectory completely adopts a new mode from offline programming to actual use, and the application of the grinding trajectory is completed by using some auxiliary tools for point checking. A support plate 21 is connected below the 2D camera 20. A floating flexible spindle 23 and a fixed spindle 22 are installed below the support plate 21, and the components in the robot mechanism 6 are controlled by a pneumatic control box 24.

[0039] Among them, the fixed spindle 22 is a high-torque fixed spindle with a torque up to 7 - 9 N·m, such as 7 N·m, 8.5 N·m, 9 N·m, etc., which can complete the cleaning of large and thick flash on the products. A milling cutter is replaceably installed on the floating flexible spindle 23, and it can automatically select tools according to different residual flashes of the products for flash grinding. A conical milling cutter is fixedly installed on the fixed spindle 22. An automatic quick-change tool device is provided on the floating flexible spindle 23. The automatic quick-change tool device includes a broaching mechanism 30 in the spindle controlled by pneumatic pressure to loosen the original tool holder. The original tool holder falls on the tool change seat, and then the spindle with the empty tool holder is moved above the new tool holder. The broaching mechanism 30 in the spindle controlled by pneumatic pressure locks the tool holder 31 again.

[0040] Furthermore, a No. 1 cylinder 15, a No. 2 cylinder 16, a No. 3 cylinder 17 and a No. 4 cylinder 18 are provided on the grinding tooling in the present utility model. The present utility model has a tooling pressing program, that is, after the product is installed on the fixture, it is pressed by 4 cylinders. When machining near the gripper, the gripper will loosen to make way for the grinding tool, and at the same time, the other three cylinders always remain in the clamped state to ensure the stability and integrity of the product during grinding. The meaning of always keeping three cylinders clamped is: when machining near a certain gripper, the gripper cylinder of this gripper will loosen, but the other three gripper cylinders still remain in the clamped state; when machining other positions (not near the gripper), the 4 gripper cylinders are in the clamped state.

[0041] During use, the robot mechanism 6 serves as the main body of the entire grinding unit and is fixed on the steel frame platform on the ground by screws. The left shuttle table mechanism 5 and the right shuttle table mechanism 4 are also fixed on the same steel frame platform, ensuring the relative positions between the robot mechanism 6, the left shuttle table mechanism 5 and the right shuttle table mechanism 4, and effectively preventing poor grinding effect caused by foundation loosening in the later stage. The grinding tooling is fixed on the servo rotating frame 12 by screws and positioning pins, and the positioning pins ensure the consistency of the installation and disassembly positions of the tooling each time it is replaced.

[0042] Outside the robot mechanism 6, there is a protective workshop mechanism 7. The protective workshop mechanism 7 is located entirely on the ground, enclosing the entire robot mechanism 6, the tool rest mechanism 2, and the steel frame platform. The tool rest mechanism 2 is fixed to the same steel frame platform by screws and is placed near the door of the protective workshop mechanism 7 for easy manual tool replacement. There is a notch at one corner of the protective workshop mechanism 7, which is just right for placing the control cabinet required by the equipment, making the entire grinding unit look more square and integral. The two grinding stations are inside the protective workshop mechanism 7, which can prevent aluminum chips from splashing everywhere during the grinding process, effectively reducing noise pollution and dust pollution. The wire groove mechanism 1 is mainly installed inside the protective workshop mechanism 7, and the main body is mounted on the upper edge of the inner wall of the protective workshop mechanism 7, which can effectively prevent the wire groove from being damaged by workers and aluminum chips from entering the wire groove.

[0043] The working principle of the present utility model is as follows:

[0044] The servo rotating frame 12 on the right shuttle table mechanism 4 is controlled by a servo motor 28 and an RV reducer 29 to rotate to the horizontal position, and then the servo rotating frame 12 is moved to the loading station through the transmission of the servo motor 28, planetary reducer 26, and synchronous belt 27.

[0045] Manually use a jib crane or a crane to transport the casting to be ground to the grinding tooling on the servo rotating frame 12. After manual confirmation is correct and the product detection sensor 25 detects a product, press the operation button box 13 beside it and start with both hands.

[0046] At this time, the cylinder lifting door on the protective workshop mechanism 7 opens, and the product on the servo rotating frame 12 is moved to the grinding station through the transmission of the servo motor 28, planetary reducer 26, and synchronous belt 27. After moving in place, the lifting door on the door of the protective workshop mechanism 7 closes.

[0047] The robot mechanism 6 starts to work. First, the robot mechanism 6 uses the 2D camera 20 installed on the six-axis to take pictures of the product. Through software algorithms, the product obtained by taking pictures is compared with the products in the model library to obtain the product deformation offset value. The robot mechanism 6 adjusts the corresponding compensation value to the original grinding trajectory program according to the offset value, thereby realizing automatic correction of the grinding trajectory.

[0048] Subsequently, according to the corrected program, the robot mechanism 6 first uses the conical milling cutter on the high-torque fixed spindle 22 to clean the flash of the product, and then uses the milling cutter on the floating flexible spindle 23 to clean the flash of the product for the second time. During the cleaning process, the servo rotating frame 12 will rotate relatively to make the cleaning angle of the tool more reasonable.

[0049] In the present utility model, a tool presence / absence detection sensor 33 is used to detect the tool, and then the robot mechanism 6 replaces the tool on the tool rest mechanism 2. First, the protective cover 35 on the tool rest mechanism 2 is opened by the tool rest protective cover cylinder 34. The robot mechanism 6 moves the tool shank on the floating flexible spindle 23 to the empty tool rest. The solenoid valve is opened to let air in, and the tool pulling mechanism 30 on the spindle releases the tool shank, which then falls onto the empty tool rest. Then, the floating flexible spindle 23 is moved above the tool shank equipped with a hundred-leaf wheel 32. The solenoid valve is closed to cut off the air supply, and the tool pulling mechanism 30 on the spindle re-fixes the new tool shank to the spindle. The robot mechanism 6 moves the spindle away, and the protective cover 35 on the tool rest mechanism 2 is closed by the tool rest protective cover cylinder 34 to prevent aluminum chips from entering.

[0050] Finally, the robot mechanism 6 uses the hundred-leaf wheel 32 on the floating flexible spindle 23 to grind the flash and raised burrs of the product, making the appearance of the product more beautiful.

[0051] After the grinding is completed, the servo rotating frame 12 turns the product back to the horizontal position, and then moves the product to the next work station to wait for manual unloading. During this period, the robot mechanism 6 automatically replaces the tool on the floating flexible spindle 23 with a milling cutter again, and starts to grind and clean the product on the left shuttle table mechanism 5.

[0052] The present utility model is specifically used for grinding and removing the flash on large aluminum alloy low-pressure castings, to improve the appearance of the product and reduce the manual operation cost.

[0053] The above embodiments are only used to explain the inventive concept of the present utility model, rather than limiting the protection scope of the rights of the present utility model. Any non-substantive modification made to the present utility model using this concept shall fall within the protection scope of the present utility model.

Claims

1. A double-station automatic flexible grinding device for large aluminum alloy low-pressure castings, characterized in that: It includes a robot mechanism, and a shuttle table mechanism is provided on the opposite sides of the robot mechanism. The shuttle table mechanism includes a shuttle table frame, a product detection component and a servo rotating frame are provided on the shuttle table frame. The product detection component includes a product detection sensor, and a grinding tooling is installed on the servo rotating frame.

2. The double-station automatic flexible grinding equipment for large aluminum alloy low-pressure castings according to claim 1, characterized in that: The shuttle table mechanism includes a left shuttle table mechanism and a right shuttle table mechanism, and the left shuttle table mechanism and the right shuttle table mechanism are arranged oppositely; the grinding tooling includes a first grinding tooling and a second grinding tooling. The first grinding tooling is installed on the right shuttle table mechanism, and the second grinding tooling is installed on the left shuttle table mechanism.

3. The double-station automatic flexible grinding equipment for large aluminum alloy low-pressure castings according to claim 2, characterized in that: The left shuttle table mechanism corresponds to an upper and lower part station one, and the right shuttle table mechanism corresponds to an upper and lower part station two.

4. The double-station automatic flexible grinding equipment for large aluminum alloy low-pressure castings according to claim 1, characterized in that: The shuttle table mechanism is provided with an operation button box, and both the product detection component and the servo rotating frame are associated with the operation button box.

5. The double-station automatic flexible grinding equipment for large aluminum alloy low-pressure castings according to claim 1, characterized in that: The robot mechanism includes a robot body, a 2D camera is installed on the sixth axis of the robot body, a support plate is connected below the 2D camera, and a floating flexible spindle and a fixed spindle are installed below the support plate.

6. The double-station automatic flexible grinding equipment for large aluminum alloy low-pressure castings as described in claim 5, characterized in that: The fixed spindle is a high-torque fixed spindle, and the torque of the high-torque fixed spindle is 7-9 N·m.

7. The double-station automatic flexible grinding equipment for large aluminum alloy low-pressure castings according to claim 5, characterized in that: A milling cutter is replaceably installed on the floating flexible spindle, and a conical milling cutter is fixedly installed on the fixed spindle.

8. The double-station automatic flexible grinding equipment for large aluminum alloy low-pressure castings according to claim 1, characterized in that: The grinding tooling is provided with a No. 1 cylinder, a No. 2 cylinder, a No. 3 cylinder and a No. 4 cylinder.

9. The double-station automatic flexible grinding equipment for large aluminum alloy low-pressure castings according to claim 1, wherein: A protective workshop mechanism is provided outside the robot mechanism. A wire groove mechanism is provided on the inner wall of the protective workshop mechanism, and a tool rest mechanism is provided at the entrance and exit of the protective workshop mechanism.

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