120 valve assembly silicone oil automatic filling device

Abstract

The utility model discloses 120 valve assembly silicon oil automatic filling device belongs to silicon oil automatic filling technical field, including support box, be equipped with sliding mechanism in support box, the sliding mechanism top extends support box top, the sliding mechanism top is connected with the supporting mechanism, support box one side is connected with filling device, the filling device includes spray valve, the spray valve top is provided with miniature nut, and the bottom is connected with the filling head, the filling head is installed with photoelectric sensor, has solved the technical problem that the present filling equipment is difficult to accurately control silicon oil filling quantity.

Description

Technical Field

[0001] This utility model belongs to the field of automatic silicone oil dispensing technology, specifically relating to an automatic silicone oil dispensing device with a 120 valve assembly. Background Technology

[0002] The 120 valve is a core component of the train braking system, directly affecting the safety and reliability of train operation. During train operation, the 120 valve precisely regulates the air pressure within the brake lines to achieve precise control of braking and release. Its performance directly impacts the responsiveness and reliability of the train's braking. Abnormal operation of the 120 valve can lead to insufficient braking force or brake failure, seriously threatening operational safety. Simultaneously, stable operation of the 120 valve ensures a smooth braking process and effectively protects other components of the braking system from damage caused by overpressure or pressure leakage, extending the equipment's service life. Therefore, the 120 valve has a crucial impact on the safety, efficiency, passenger experience, and equipment maintenance costs of train operation, making it an indispensable and vital component of the train braking system.

[0003] Currently, the 120 valve, as a key component of the train braking system, requires strict lubrication of the working surfaces of components such as the spool valve, control valve, spool valve seat, and spool valve spring during its assembly process. Methyl silicone oil must be added in precise amounts of 1.4mL, 0.6mL, 2.6mL, and 0.4mL. However, in existing technology, various vehicle depots commonly use medical syringes for manual application. This manual application method has significant shortcomings: firstly, the amount added relies entirely on human experience, making it difficult to guarantee accuracy and easily leading to over- or under-lubrication; secondly, manual operation is inefficient and lacks repeatability, affecting production consistency and product quality. To address these problems, this invention proposes an automatic silicone oil application device for 120 valve assembly, aiming to achieve precise control, automated operation, and standardized production of the application process, thereby improving the assembly quality of the 120 valve and reducing the failure rate. Utility Model Content

[0004] In order to overcome the shortcomings of the prior art, the purpose of this utility model is to provide a 120-valve assembled silicone oil automatic filling device to solve the technical problem that existing filling equipment is difficult to accurately control the amount of silicone oil added.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] This utility model provides an automatic silicone oil filling device with a 120-valve assembly, including a support box. The support box is provided with a sliding mechanism. The top of the sliding mechanism extends out of the top of the support box. A support mechanism is connected above the sliding mechanism. A filling device is connected to one side of the support box. The filling device includes a spray valve. A miniature nut is provided at the top of the spray valve. A filling head is connected to the bottom of the spray valve. A photoelectric sensor is installed inside the filling head.

[0007] Preferably, the nozzle of the spray valve is a long needle-shaped dot. A long needle-shaped dot means that the nozzle structure of the spray valve adopts a slender needle-like design and sprays dot-shaped lubricant.

[0008] Preferably, a horizontal support rod is connected to one side of the spray valve, and a vertical support rod is vertically connected below the horizontal support rod, with the bottom end of the vertical support rod connected to the support box.

[0009] Preferably, the length of the vertical support rod is 320mm and the length of the horizontal support rod is 80mm.

[0010] Preferably, the sliding mechanism includes a slide table, a lead screw passing through the bottom of the slide table, and a stepper motor connected to one end of the lead screw.

[0011] Preferably, the lead screw is a dual-axis ball screw.

[0012] Preferably, the supporting mechanism is equipped with a number of limit switches.

[0013] Preferably, the top of the support box is provided with a sliding groove for the sliding mechanism to slide.

[0014] Preferably, the structure of the support mechanism is matched with the 120 valve.

[0015] Preferably, the bottom of the support box is equipped with four anti-slip bases.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] This utility model discloses an automatic silicone oil dispensing device for a 120-valve assembly. It employs a spray valve in conjunction with a micro-nut to precisely control the silicone oil output. The threaded adjustment in the micro-nut controls the cross-sectional area of ​​the silicone oil channel, improving dispensing accuracy. This structural design allows for flexible adjustment of the silicone oil dispensing volume according to different process requirements, meeting various dispensing needs and ensuring accuracy at each dispensing step. A photoelectric sensor is installed inside the dispensing head. When it detects that the valve core of the 120-valve has been stationary in the support mechanism for a specific period, it automatically triggers the dispensing process, achieving fully automated operation. This innovation effectively reduces human intervention and improves the automation and accuracy of the dispensing process. The sliding mechanism achieves millimeter-level positioning, further enhancing the positioning accuracy of the 120-valve. The support mechanism carries the 120-valve, ensuring the stability and precise positioning of the valve body during dispensing. In summary, this device, by employing an automated filling technology that combines a sliding mechanism, a spray valve, a miniature nut, and a photoelectric sensor, replaces the traditional manual filling method. This significantly improves filling efficiency and accuracy, eliminates errors and instabilities inherent in manual operation, ensures that the filling volume meets standard requirements each time, and guarantees consistency in the filling process and product quality.

[0018] Furthermore, the long needle-shaped spray valve breaks through the traditional atomization spraying method, realizing fixed-point and quantitative dispensing, improving the fine-tuning accuracy, and this design can achieve precise local coating without causing over-spraying or diffusion.

[0019] Furthermore, the vertical and horizontal support rods eliminate vibration errors through vertical structural design. The stable support structure helps ensure that the filling device does not shift during operation, thus guaranteeing the accuracy and consistency of silicone oil filling.

[0020] Furthermore, the length of the vertical support rods ranges from 300mm to 350mm, and the length of the horizontal support rods ranges from 70mm to 100mm, to accommodate different installation requirements and improve the compatibility and adaptability of the device. Adjusting the length range of the support rods can optimize the stress distribution and reduce vibration and displacement during operation.

[0021] Furthermore, by driving the lead screw to rotate via a stepper motor, the slide table can move with high precision and stability, ensuring positioning accuracy under heavy loads.

[0022] Furthermore, a ball screw is used because it has high precision and load capacity, which meets the stable filling requirements of the 120 valve core and can withstand a maximum load of 30kg, ensuring stability and safety during the filling process.

[0023] Furthermore, the support mechanism is equipped with limit switches to sense the valve core's placement status in real time. When the valve core is correctly positioned, the limit switch sends a signal to confirm that the position meets the requirements, thereby triggering the subsequent filling operation. This design effectively avoids filling errors caused by improper valve core positioning, ensuring the accuracy and reliability of the filling process.

[0024] Furthermore, the support mechanism is precisely designed to match the dimensions of the 120 valve body and its structure, ensuring that the valve core is firmly placed during filling and preventing any shaking or displacement.

[0025] Furthermore, the anti-slip base effectively prevents the equipment from shifting due to vibration or external forces during operation, thereby improving operational safety and stability. Simultaneously, the anti-slip base also provides shock absorption, reducing the impact of the refueling device on the ground and extending its service life. Attached Figure Description

[0026] Figure 1 This is a structural diagram of the present utility model;

[0027] Figure 2 This is a front view of the support base of this utility model;

[0028] Figure 3 This is a rear view of the support base of this utility model;

[0029] Figure 4 This is a structural diagram of the filling device of this utility model;

[0030] Figure 5 This is a structural diagram of the sliding mechanism of this utility model;

[0031] Figure 6 This is a structural diagram of the sliding mechanism of this utility model placed in the support box;

[0032] Figure 7 This is a structural diagram of the support mechanism of this utility model;

[0033] Figure 8 This is a structural diagram of the 120 valve of this utility model placed in the support mechanism;

[0034] Figure 9 This is the control flowchart of this utility model;

[0035] Figure 10 This is a flowchart of the filling process of this utility model;

[0036] Among them, 1-support box; 2-filling device; 3-sliding mechanism; 4-supporting mechanism; 5-120 valve; 6-anti-slip base; 7-spray valve; 8-filling head; 9-valve core; 10-photoelectric sensor; 11-vertical support rod; 12-horizontal support rod; 13-lead screw; 14-slide table; 15-stepper motor; 16-limit switch; 17-miniature nut. Detailed Implementation

[0037] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. 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 should fall within the protection scope of the present invention.

[0038] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this utility model are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the utility model described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0039] This invention relates to a filling device suitable for the filling process of precision components such as 120 valves, particularly in industrial production processes requiring high-precision control. By transforming the traditional manual filling method into an automated filling system, it significantly improves work efficiency and filling accuracy. The device employs micro-control adjustment technology, enabling milliliter-level precision filling, ensuring that each filling volume strictly conforms to predetermined standards, eliminating errors and instabilities inherent in manual operation. Automated control not only improves the consistency of the filling process and product quality but also reduces the risks associated with human intervention, lowering the likelihood of malfunctions caused by improper filling. Furthermore, automated operation reduces the workload of operators, optimizes the working environment, and further enhances the stability and overall efficiency of the production line. This device is particularly suitable for manufacturing fields requiring high precision, stability, and efficiency, and has significant application value in demanding industries such as braking systems and hydraulic systems. In summary, this device demonstrates significant beneficial effects in terms of precision, efficiency, and ease of operation, and possesses broad application prospects. The filling device is suitable for filling high-viscosity (1-100,000 cps) and various lubricating media (such as methyl silicone oil), with a wide air pressure range (4-7 kgf / cm). 2 It can meet different process requirements, has strong adaptability and broad application prospects, and is especially suitable for fields with high precision requirements such as braking systems and hydraulic systems.

[0040] The present invention will now be described in further detail with reference to the accompanying drawings:

[0041] Example 1

[0042] like Figures 1 to 4 As shown, the 120 valve assembly silicone oil automatic filling device includes a support box 1. The support box 1 is provided with a sliding mechanism 3. The top of the sliding mechanism 3 extends out of the top of the support box 1. A support mechanism 4 is connected above the sliding mechanism 3. A filling device 2 is connected to one side of the support box 1. The filling device 2 includes a spray valve 7. A miniature nut 17 is provided at the top of the spray valve 7. A filling head 8 is connected to the bottom. A photoelectric sensor 10 is installed inside the filling head 8.

[0043] Preferably, the support structure 4 is made of high-strength aluminum alloy or steel, which has strong load-bearing capacity and durability, and can ensure long-term stable operation in high-frequency production environments. The support structure 4 has a simple design, making it easy to install and replace.

[0044] Preferably, the support box 1 is made of 10mm thick 6061-T6 aluminum alloy. The support box 1 is the basic supporting structure of this filling device and has the characteristics of being lightweight, high-strength, corrosion-resistant and having good processing performance.

[0045] A further preferred embodiment has a support box 1 with dimensions of 37000mm in length and 22000mm in width, and the front side is as shown. Figure 2 As shown, this ensures overall stability and load-bearing capacity. The back side is as follows... Figure 3 As shown, the support box 1 has four holes on one side for laying cables, air ducts and silicone oil supply pipes.

[0046] Preferably, the nozzle of the spray valve 7 is a long needle-shaped dot. "Long needle" indicates that the nozzle is elongated, allowing it to reach deep into the fine areas requiring lubrication, improving the accuracy of application, and is particularly suitable for lubrication in confined spaces. "Dot" indicates that the spray method is a non-atomized, small-area, targeted spray, rather than a large-area diffused spray, thus ensuring precise application and preventing silicone oil waste or contamination of the surrounding area.

[0047] Preferably, a horizontal support rod 12 is connected to one side of the spray valve 7, and a vertical support rod 11 is vertically connected below the horizontal support rod 12. The bottom end of the vertical support rod 11 is connected to the support box 1. A certain adjustment space can be reserved between the vertical support rod 11 and the horizontal support rod 12, so that the filling device can be quickly adapted when upgraded or replaced in the future without the need for additional modification of the support structure.

[0048] Preferably, the vertical support rod 11 and the horizontal support rod 12 are made of square steel to provide good rigidity for the filling device.

[0049] Preferably, the length of the vertical support rod 11 is 300mm-350mm, and the length of the horizontal support rod 12 is 70mm-100mm.

[0050] Preferred, such as Figure 5 As shown, the sliding mechanism 3 includes a slide table 14, a lead screw 13 passing through the bottom of the slide table 14, and a stepper motor 15 connected to one end of the lead screw 13.

[0051] In a further preferred embodiment, the stepper motor 15 is connected to the lead screw 13 via a coupling, controlling the rotation of the lead screw 13, thereby driving the slide table 14 to move smoothly along the guide rail formed by the lead screw 13.

[0052] More preferably, the lead screw 13 is mounted on the lower support base, which facilitates the improvement of the stability of the sliding mechanism.

[0053] Further preferably, the accuracy of the slide table 14 can reach 0.03mm-0.05mm, ensuring that the error is controlled within 0.03mm when the slide table 14 moves to the same target position multiple times, thereby improving the consistency of filling.

[0054] Furthermore, the stepper motor 15 is a single-step pulse control, which enables more precise displacement adjustment and ensures that the filling head 8 can be accurately positioned.

[0055] Preferably, the lead screw 13 is a dual-axis ball screw.

[0056] More preferably, the lead screw 13 is a preloaded ball screw to eliminate backlash and improve positioning stability.

[0057] Preferably, the dual-axis ball screw is made of high-strength bearing steel, which has excellent wear resistance and stability and is suitable for long-term high-load operation; the guide rail and slide body formed by the dual-axis ball screw are made of aluminum alloy, which takes into account both lightweight and high strength, and ensures that the filling device can still maintain precise control when moving at high speed.

[0058] Preferred, such as Figures 6 to 8 As shown, the supporting mechanism 4 is equipped with several limit switches.

[0059] More preferably, several of the limit switches are connected to a PLC controller.

[0060] More preferably, the limit switch is a photoelectric sensor limit switch, which determines whether the valve core is correctly placed by detecting whether the valve core is blocking the light beam. When the valve core is correctly placed, the limit switch will change from a no-signal state to a signal state, and the PLC controller will send a signal to the stepper motor 15 upon receiving the signal.

[0061] A further preferred embodiment uses a Simatic S7-1200 PLC controller, employs an air source as the power source for the entire filling device, and uses a stainless steel pressure tank as the silicone oil storage device. The entire system consists of four parts, such as... Figure 9 As shown.

[0062] The specific logic design of the PLC controller is as follows: When the valve core of valve 120 is placed on the support mechanism 4, the limit switch detects the change in the valve core's position. After receiving the signal, the PLC controller determines that the valve core is in place. Next, the PLC controller sends a signal to the sliding mechanism 3, starting the stepper motor 15 and driving the dual-axis ball screw to control the slide table 14 to move to the preset filling position. After reaching the target position, the photoelectric sensor 10 inside the filling head 8 detects that the valve core has remained stationary for more than 1 second, and then starts the filling process, completing the filling according to the set amount of silicone oil. After filling is complete, the system waits for 1 second for stabilization control, and then the PLC sends a signal to the stepper motor to drive the slide table to move the filled valve core off the filling table, completing the entire filling process.

[0063] Furthermore, the support mechanism 4 can also be equipped with an anti-slip design, which further improves its safety and stability during use.

[0064] Preferably, the top of the support box 1 is provided with a sliding groove for the sliding mechanism 3 to slide.

[0065] Preferably, the support mechanism 4 is matched with the structure of the 120 valve.

[0066] Preferably, the bottom of the support box 1 is equipped with four anti-slip bases 6.

[0067] like Figure 10 The following describes the method of using the filling device of this utility model:

[0068] 1) Supporting mechanism 4 is ready to receive the valve core of valve 120;

[0069] 2) After the valve core is placed on the support mechanism 4, the limit switch detects the change;

[0070] 3) After receiving the signal, the PLC starts the stepper motor 15;

[0071] 4) Stepper motor 15 drives slide 14 to move accurately to the filling position;

[0072] 5) The photoelectric sensor 10 detected that the valve core remained stationary for 1 second;

[0073] 6) Activate spray valve 7 to precisely add the set amount of silicone oil;

[0074] 7) After filling, wait 1 second to ensure stability;

[0075] 8) The PLC controller sends a signal to the stepper motor 15, which drives the stepper motor 15 to control the slide table 14 to move out of the valve core after filling.

[0076] 9) The process is complete. Wait for the next operation.

[0077] The above content is only for illustrating the technical concept of this utility model and should not be construed as limiting the scope of protection of this utility model. Any modifications made to the technical solution based on the technical concept proposed in this utility model shall fall within the scope of protection of the claims of this utility model.

Claims

1. 120 valve assembly silicone oil automatic filling device, characterized in that, The device includes a support box (1), a sliding mechanism (3) inside the support box (1), the top of the sliding mechanism (3) extending out of the top of the support box (1), a support mechanism (4) connected above the sliding mechanism (3), a filling device (2) connected to one side of the support box (1), the filling device (2) including a spray valve (7), a micro nut (17) provided at the top of the spray valve (7), a filling head (8) connected to the bottom end, and a photoelectric sensor (10) installed inside the filling head (8).

2. The automatic silicone oil dispensing device for a 120-valve assembly according to claim 1, characterized in that, The nozzle of the spray valve (7) is a long needle-shaped dot.

3. The automatic silicone oil dispensing device for a 120-valve assembly according to claim 1, characterized in that, A horizontal support rod (12) is connected to one side of the spray valve (7), and a vertical support rod (11) is vertically connected below the horizontal support rod (12). The bottom end of the vertical support rod (11) is connected to the support box (1).

4. The 120 valve assembly silicone oil automatic filling device according to claim 3, characterized in that, The length of the vertical support rod (11) is 300mm-350mm, and the length of the horizontal support rod (12) is 70mm-100mm.

5. The automatic silicone oil dispensing device for a 120-valve assembly according to claim 1, characterized in that, The sliding mechanism (3) includes a slide table (14), a lead screw (13) is provided at the bottom of the slide table (14), and a stepper motor (15) is connected to one end of the lead screw (13).

6. The automatic silicone oil dispensing device for a 120-valve assembly according to claim 5, characterized in that, The lead screw (13) is a double optical axis ball screw.

7. The automatic silicone oil dispensing device for a 120-valve assembly according to claim 1, characterized in that, The supporting mechanism (4) is equipped with several limit switches.

8. The 120 valve assembly silicone oil automatic filling device according to claim 1, characterized in that, The top of the support box (1) is provided with a sliding groove for the sliding mechanism (3) to slide.

9. The automatic silicone oil filling device for a 120-valve assembly according to claim 1, characterized in that, The structure of the support mechanism (4) is matched with the 120 valve.

10. The automatic silicone oil dispensing device for a 120-valve assembly according to claim 1, characterized in that, The bottom of the support box (1) is equipped with four anti-slip bases (6).

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