A high-precision metal plate manufacturing belt wheel pattern forming device

Abstract

The utility model discloses a kind of high-precision metal plate manufacturing pulley pattern forming equipment, base frame assembly, blank pretreatment component, accurate positioning assembly, embossing forming assembly and quality detection component;The base frame assembly includes high rigidity bed and work platform, the blank pretreatment component includes several groups of spray head being lifted and arranged on the work platform, and the swabbing mechanism of reversible being arranged at the side of the workbench;The utility model is positioned by using accurate positioning assembly using the axial cooperative positioning mechanism of embossing punch positioning ring and positioning block, when working, positioning block is accurately inserted into the bottom center hole of embossing blank cylinder, and embossing punch positioning ring is synchronously embedded into top center, forming upper and lower double reference constraints;The positioning precision of the present scheme is improved by more than 50%, product pass rate breaks through 95%, and manual intervention rework is not needed, directly reduces comprehensive production cost by 20%. Meet the stringent demand of intelligent manufacturing to high consistency, high efficiency.

Description

Technical Field

[0001] This utility model is a high-precision sheet metal pulley pattern forming equipment, belonging to the field of pulley pattern forming technology. Background Technology

[0002] High-precision sheet metal pulley pattern forming equipment is specifically designed for the precision manufacturing of pulleys—core components of mechanical transmission systems. In the automotive, industrial automation, and high-end equipment sectors, pulleys require high-precision patterns, such as petal-shaped embossed textures, to enhance belt engagement performance, ensure transmission efficiency, reduce noise, and extend service life. As manufacturing moves towards intelligent and highly consistent processes, traditional low-precision processes can no longer meet the stringent requirements of modern equipment for pulley dimensional tolerances and surface forming quality.

[0003] Existing equipment mostly relies on simple mechanical clamps and lacks dedicated positioning components, such as the embossing punch positioning ring and positioning block collaborative system. It is easily affected by vibration and thermal deformation, causing the pattern to shift or become asymmetrical, which directly affects the belt meshing stability and leads to transmission slippage or premature wear.

[0004] Furthermore, traditional equipment is not equipped with automated nozzles and a flip-over wiping mechanism, so oil stains and oxide layers on the surface of the blank cannot be effectively removed, causing the embossed pieces to stick together or the pattern to become blurred during embossing, which significantly increases the surface defect rate (accounting for more than 15%) and results in a low product qualification rate. Utility Model Content

[0005] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a high-precision sheet metal pulley pattern forming equipment to solve the problems of the existing technology.

[0006] To achieve the above objectives, this utility model is implemented through the following technical solution:

[0007] A high-precision sheet metal pulley pattern forming equipment includes a basic frame component, a blank pretreatment component, a precision positioning component, an embossing component, and a quality inspection component;

[0008] The basic frame assembly includes a high-rigidity bed and a work platform, and the blank pretreatment assembly includes several sets of nozzles that are lifted and arranged on the work platform and a flip-up wiping mechanism arranged on one side of the worktable.

[0009] The embossing component includes an upper module, flower petal protrusions disposed below the upper module, and a lower module installed in the middle of the worktable;

[0010] The precise positioning component includes an embossing punch positioning ring located in the lower center of the upper module, a positioning block located in the upper center of the lower module, and a guide mechanism for controlling the upper module to move vertically. An embossing blank cylinder is placed on the working platform, and the positioning block is inserted into the lower center of the embossing blank cylinder. During embossing, the embossing punch positioning ring is inserted into the upper center of the embossing blank cylinder, and the flower petal protrusions press against the upper surface of the embossing blank cylinder.

[0011] As a further improvement, the pre-treatment assembly for the blank includes an annular groove on the working platform, an annular body embedded in the annular groove, a first electric guide rod for controlling the lifting and lowering of the annular body, and a nozzle embedded in several of the annular bodies. The nozzle opening is opened on the inner side of the annular body. Through the cooperation of the annular body, the first electric guide rod, and the nozzle, an oil film is sprayed onto the outer annular surface of the embossed blank cylinder.

[0012] As a further improvement, the wiping mechanism includes a wiping assembly rotatably mounted on one side of the work platform. The wiping assembly includes a second electric guide rod rotatably mounted on one side of the work platform, a fixed plate fixedly mounted on the top of the electric guide rod, a wiping disc rotatably disposed on the fixed plate facing the work platform, a first motor driving the wiping disc to rotate, and a second motor mounted below the side of the work platform. The second motor drives the second electric guide rod to rotate.

[0013] As a further improvement, the surface of the scrubbing disc is spirally fitted with support strips from the inside out, absorbent sheets are covered on the outer surface of the support strips, and scrubbing cloth is covered on the outer surface of the absorbent sheets.

[0014] As a further improvement, the support strip is made of silicone material, the absorbent sheet is made of sponge material, and the scrubbing cloth is made of non-woven fabric material.

[0015] As a further improvement, the spiral installation direction of the support bar is consistent with the rotation direction of the wiping disc, which can wipe the oil on the upper surface of the embossed blank cylinder from the inside out.

[0016] As a further improvement, the quality inspection component includes a conveyor belt installed on one side of the work platform, an arched frame mounted on the high-rigidity bed above the conveyor belt, and a detection sensor located in the middle below the arched frame, which detects the embossed surface of the embossed blank cylinder on the conveyor belt.

[0017] As a further improvement, the guiding mechanism includes a hydraulic press mounted on the high-rigidity bed and an output head mounted on the output end of the hydraulic press. The upper module is fixedly mounted below the output head by bolts, and the upper module is raised and lowered by the hydraulic press.

[0018] As a further improvement, the embossing punch positioning ring is made of Cr12MoV mold steel, with a heat treatment hardness of HRC58-60, an inner diameter tolerance controlled within -0.005 to 0 mm, and a surface roughness of Ra0.2 μm, forming a precise 0.05 mm interference fit with the outer diameter of the embossing blank cylinder.

[0019] Beneficial effects:

[0020] This utility model employs a precise positioning component with an axial collaborative positioning mechanism of the embossing punch positioning ring and the positioning block. During operation, the positioning block is precisely inserted into the center hole at the bottom of the embossing blank cylinder, and the embossing punch positioning ring is simultaneously embedded into the top center, forming a double reference constraint at the top and bottom.

[0021] The guiding mechanism strictly controls the vertical movement trajectory of the upper module, eliminates vibration and thermal deformation interference, and ensures that the axial alignment error is ≤ ±0.01mm when the flower petal protrusions are pressed, thus completely solving the problems of flower offset and asymmetry and ensuring the stability of belt meshing.

[0022] The pre-treatment assembly for raw materials integrates a lifting nozzle with a tilting wiping mechanism. The nozzle rises and falls according to a program to spray cleaning fluid, effectively removing oil and oxide layers from the surface of the raw materials.

[0023] The wiping mechanism automatically flips and scrapes away residual liquid film, achieving surface cleanliness standards (Ra≤0.8μm), eliminating the adhesion of protrusions and blurring of patterns, and reducing the surface defect rate from more than 15% to less than 3%.

[0024] During operation, the pre-treatment component for the blank is first activated: the nozzle rises and falls to complete surface cleaning, and the wiping mechanism flips to dry the blank; then, the blank cylinder is placed on the work platform, and the positioning block is automatically inserted into its bottom center; in the embossing stage, the upper module descends vertically under the guidance of the guide mechanism, the embossing punch positioning ring is precisely embedded in the top of the blank, and the flower petal protrusions are simultaneously pressed and formed; finally, the quality inspection component determines the flower outline tolerance and surface quality online. The entire process is automated, reducing the production cycle of a single piece by 30%.

[0025] By suppressing forming deformation through a high-rigidity bed and integrating closed-loop positioning and pretreatment, the pattern contour tolerance is achieved to ≤±0.02mm, and surface consistency reaches the industry's top standard. The dual-reference positioning mechanism ensures stable repeatability accuracy for each forming operation, and the high-rigidity frame exhibits no elastic deformation under high pressure, avoiding localized tearing. Automated pretreatment eliminates human error, significantly improving product lifespan and transmission efficiency.

[0026] Compared to existing equipment that relies on simple fixtures, resulting in large positioning deviations (tolerance > ±0.05mm) and inherent defects such as high defect rates due to lack of pre-processing, this solution improves positioning accuracy by more than 50%, achieves a product qualification rate exceeding 95% (industry average <92%), and eliminates the need for manual rework, directly reducing overall production costs by 20%. It meets the stringent requirements of intelligent manufacturing for high consistency and high efficiency. Attached Figure Description

[0027] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0028] Figure 1 This is a three-dimensional structural diagram of a high-precision sheet metal pulley pattern forming equipment according to this utility model.

[0029] Figure 2 This is a partially enlarged structural diagram of a high-precision sheet metal pulley pattern forming equipment according to this utility model.

[0030] Figure 3 This is a schematic diagram of the main structure of a high-precision sheet metal pulley pattern forming method and equipment.

[0031] Figure 4 yes Figure 2 A schematic diagram of the raised ring structure of the middle amplification section.

[0032] Figure 5 This is a schematic diagram of the cross-sectional structure of the bottom of the scrubbing disc and the partially enlarged support strip, absorbent sheet, and scrubbing cloth of this utility model.

[0033] Figure 6 This is a structural schematic diagram of an embossing component according to the present invention.

[0034] Figure 7 This is a schematic diagram of a long and short flower-shaped cylindrical workpiece structure according to the present invention.

[0035] Figure 8 This is a schematic diagram of a uniformly patterned cylindrical workpiece structure according to this utility model.

[0036] Figure 9 This is a module connection diagram of a high-precision sheet metal pulley pattern forming equipment according to this utility model.

[0037] 1. Basic frame components; 2. Raw material pretreatment components; 3. Precision positioning components; 4. Embossing components; 5. Quality inspection components; 6. Embossing raw material cylinder; 7. Control module; 8. Limiting module; 9. Painting module;

[0038] 11. High-rigidity bed; 12. Work platform;

[0039] 21. Nozzle; 22. Annular groove; 23. Annular body; 24. First electric guide rod; 25. Second electric guide rod; 26. Fixing plate; 27. Scrubbing disc; 28. First motor; 29. ​​Second motor; 271. Support bar; 272. Absorbent sheet; 273. Scrubbing cloth;

[0040] 31. Embossing punch positioning ring; 32. Positioning block; 33. Hydraulic press; 34. Output head;

[0041] 41. Upper module; 42. Flower petal protrusions; 43. Lower module; 51. Conveyor belt; 52. Arched frame; 53. Detection sensor;

[0042] 61. Long and short patterned cylindrical workpieces; 62. Uniform patterned cylindrical workpieces; 63. Leaving grooves. Detailed Implementation

[0043] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this utility model, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model. Therefore, the following detailed description of the embodiments of this utility model provided in the accompanying drawings is not intended to limit the scope of the claimed utility model, but merely represents selected embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model.

[0044] In the description of this utility model, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0045] Reference Figure 1-9As shown, a high-precision sheet metal pulley pattern forming equipment includes: a basic frame component 1, a blank pretreatment component 2, a precision positioning component 3, an embossing component 4, and a quality inspection component 5;

[0046] The basic frame component 1 includes a high-rigidity bed 11 and a work platform 12. The blank pretreatment component 2 includes several sets of nozzles 21 that are lifted and mounted on the work platform 12 and a flip-up wiping mechanism mounted on one side of the worktable.

[0047] The embossing component 4 includes an upper module 41, a flower petal protrusion 42 disposed below the upper module 41, and a lower module 43 installed in the middle of the workbench;

[0048] The precise positioning component 3 includes an embossing punch positioning ring 31 located in the lower middle part of the upper module 41, a positioning block 32 located in the upper middle part of the lower module 43, and a guide mechanism for controlling the upper module 41 to move in the vertical direction. An embossing blank cylinder 6 is placed on the working platform 12, and the positioning block 32 is inserted into the lower middle part of the embossing blank cylinder 6. During embossing, the embossing punch positioning ring 31 is inserted into the upper middle part of the embossing blank cylinder 6, and the flower petal protrusions 42 squeeze the upper surface of the embossing blank cylinder 6.

[0049] The outer diameter of the embossing punch positioning ring 31 and positioning block 32 forms a 0.05mm interference fit with the inner diameter of the embossing blank cylinder 6.

[0050] The precise positioning component 3 and the embossing component 4 work together to ensure the concentricity of the center of the embossing blank and the center of the flower petal outline through the embossing punch positioning ring 31. This forces the punch to squeeze the material outward evenly during the embossing process. When the outflowing material reaches the preset level, the outflowing material on the embossing surface is affected by the reaction force of the embossing punch positioning ring 31, which increases and prevents the material from flowing outward further, thus ensuring that the embossed petal surface is full and firm.

[0051] By allowing excess material to be accommodated according to the thickness of the embossed surface material in the groove 63, the rebound of the embossed surface is reduced.

[0052] This enables high-precision flower forming with a petal surface contour within 0.015mm, a total flower shape surface contour within 0.04mm, and a flower shape radius R0.5±0.5.

[0053] The finished embossed blank cylinder 6 includes long and short patterned cylinder workpieces or uniform patterned cylinder workpieces.

[0054] To address the core issues of insufficient positioning accuracy in existing equipment and lack of pre-processing of blanks leading to pattern offset and high surface defect rate (over 15%), a precise positioning component is adopted, employing an axial collaborative positioning mechanism between the embossing punch positioning ring and the positioning block.

[0055] During operation, the positioning block is precisely inserted into the center hole at the bottom of the embossing blank cylinder, and the embossing punch positioning ring is simultaneously embedded into the top center, forming a double reference constraint at the top and bottom.

[0056] The guiding mechanism strictly controls the vertical movement trajectory of the upper module, eliminates vibration and thermal deformation interference, and ensures that the axial alignment error is ≤ ±0.01mm when the flower petal protrusions are pressed, thus completely solving the problems of flower offset and asymmetry and ensuring the stability of belt meshing.

[0057] The pre-treatment assembly for raw materials integrates a lifting nozzle with a tilting wiping mechanism. The nozzle rises and falls according to a program to spray cleaning fluid, effectively removing oil and oxide layers from the surface of the raw materials.

[0058] The wiping mechanism automatically flips and scrapes away residual liquid film, achieving surface cleanliness standards (Ra≤0.8μm), eliminating the adhesion of protrusions and blurring of patterns, and reducing the surface defect rate from more than 15% to less than 3%.

[0059] During operation, the pre-treatment component for the blank is first activated: the nozzle rises and falls to complete surface cleaning, and the wiping mechanism flips to dry the blank; then, the blank cylinder is placed on the work platform, and the positioning block is automatically inserted into its bottom center; in the embossing stage, the upper module descends vertically under the guidance of the guide mechanism, the embossing punch positioning ring is precisely embedded in the top of the blank, and the flower petal protrusions are simultaneously pressed and formed; finally, the quality inspection component determines the flower outline tolerance and surface quality online. The entire process is automated, reducing the production cycle of a single piece by 30%.

[0060] By suppressing forming deformation through a high-rigidity bed and integrating closed-loop positioning and pretreatment, the pattern contour tolerance is achieved to ≤±0.02mm, and surface consistency reaches the industry's top standard. The dual-reference positioning mechanism ensures stable repeatability accuracy for each forming operation, and the high-rigidity frame exhibits no elastic deformation under high pressure, avoiding localized tearing. Automated pretreatment eliminates human error, significantly improving product lifespan and transmission efficiency.

[0061] Compared to existing equipment that relies on simple fixtures, resulting in large positioning deviations (tolerance > ±0.05mm) and inherent defects such as high defect rates due to lack of pre-processing, this solution improves positioning accuracy by more than 50%, achieves a product qualification rate exceeding 95% (industry average <92%), and eliminates the need for manual rework, directly reducing overall production costs by 20%. It meets the stringent requirements of intelligent manufacturing for high consistency and high efficiency.

[0062] To fundamentally address the issues of uncontrolled central hole diameter and unstable material flow, the central hole diameter must be precisely controlled to 0.39 times the edge diameter of the petal outline during the blank preparation process in the preceding stage. This ensures that the inner diameter of the blank cylinder forms a 0.05mm interference fit with the embossing punch positioning ring 31 and positioning block 32 of the precision positioning component 3.

[0063] The blank center is forced to be concentric with the flower pattern outline, eliminating the uneven radial stress caused by eccentricity;

[0064] Meanwhile, the blank pretreatment component 2 thoroughly removes the residual stretching oil from the embossed surface through the lifting nozzle 21, and uses the flip-over wiping mechanism to apply stretching oil only in a directional manner on the outer diameter of the cylinder, precisely controlling the material outflow rate and avoiding flow instability caused by thickness fluctuations (0.9–1.1 times the thickness of the raw material).

[0065] During the embossing process, the upper module 41 is pressed vertically downward under the control of the guiding mechanism. The embossing punch positioning ring 31 and the positioning block 32 are inserted into the blank cylinder simultaneously, and the 0.05mm interference fit ensures that the concentricity is ≤0.01mm. When the flower petal protrusions 42 extrude the blank, the material flows out evenly to the critical point, and the reaction force of the embossing punch positioning ring 31 increases sharply, which immediately suppresses excessive outflow, ensuring that the petal surface is full and firm, and preventing material accumulation or thinning caused by loose positioning in existing equipment.

[0066] The lower module 43 integrates a relief groove 63, whose mold surface precisely matches the outline of long and short flower shapes, dynamically accommodating excess material with uneven embossing surface thickness. This design reduces forming rebound stress by more than 40% through orderly material distribution, ensuring that the petal outline is stable within 0.015mm, and the R-angle is precisely formed within the R0.5±0.5 tolerance zone, completely solving the outline distortion caused by insufficient relief in existing technologies.

[0067] The embossed blank is placed on the work platform 12, the blank pretreatment component 2 is started, the nozzle 21 is raised and sprayed with cleaning agent to remove oil stains from the embossed surface, and the wiping mechanism is flipped to apply stretching oil only to the outer diameter of the cylinder.

[0068] The blank is lowered to the positioning block 32, and the upper module 41 descends to insert the embossing punch positioning ring 31 above the blank. The 0.05mm interference fit automatically corrects the concentricity.

[0069] The upper module 41 continues to press down, and the flower petal protrusions 42 squeeze the blank, and the material flows out evenly. When the outflow reaches the critical point, the reaction force of the embossing punch positioning ring 31 locks the outflow, and the flower groove 63 simultaneously absorbs the excess material.

[0070] The quality inspection component 5 scans the flower pattern outline in real time and feeds back the data to the control system to ensure that the radius and outline meet the standards.

[0071] Through a breakthrough in the three-in-one design of precise positioning, controllable flow, and dynamic yielding, the precision of material outflow control is improved by 50% through interference fit and reaction force mechanism, eliminating the chain reaction of flow instability, and increasing the yield of high value-added products to over 98% (compared to <85% for existing equipment).

[0072] The 63mm spacer groove and thickness-adaptive design suppress the forming rebound to within 0.005mm, directly achieving the ISO 10099 out-of-tolerance standard and breaking through the industry's 0.05mm bottleneck.

[0073] Vibration is suppressed by the high-rigidity bed 11 of the basic frame, and the pre-treatment of the blank and the embossing component 4 are linked, reducing manual intervention and shortening the single-piece molding cycle by 20%, which is suitable for mass production of high-end transmission components such as new energy vehicles.

[0074] Existing equipment lacks the ability to coordinate control of the central hole, directional surface treatment, and dynamic clearance, resulting in uncontrollable material flow and positioning drift, creating a vicious cycle.

[0075] By precisely positioning the 0.05mm interference fit of component 3, the critical reaction force mechanism of the embossing punch positioning ring 31, and the diversion of the relief groove 63, the multi-stage problem is transformed into a systematic solution, which not only eliminates the out-of-tolerance profile and R-angle failure, but also improves the overall accuracy by more than 3 times.

[0076] By controlling the thickness of the embossed surface material and the length of the flower pattern, the excess material is accommodated by the relief groove 63 between the flower petal protrusions in the upper module 41. The length of the relief groove on the upper module 41 corresponds to the length of the flower pattern on the workpiece, which facilitates the flow of excess material to the relief groove 63, reduces the rebound of the flower pattern forming, and finally achieves high-precision flower pattern forming with a petal surface contour within 0.015mm, a total flower pattern surface contour within 0.04mm, and a flower pattern R angle R0.5±0.5.

[0077] The pre-treatment assembly 2 for the blank includes an annular groove 22 disposed on the working platform 12, an annular body 23 embedded inside the annular groove 22, a first electric guide rod 24 for controlling the lifting and lowering of the annular body 23, and a nozzle 21 embedded inside several of the annular bodies 23. The nozzle of the nozzle 21 is opened on the inner side of the annular body 23. Through the cooperation of the annular body 23, the first electric guide rod 24, and the nozzle 21, an oil film is sprayed onto the outer annular surface of the embossed blank cylinder 6.

[0078] The pretreatment component 2 for the blank adopts an integrated structure of annular groove 22, ring body 23 and first electric guide rod 24, which aims to solve the problem of material flow instability caused by inaccurate application of stretching oil in existing equipment.

[0079] In traditional processes, stretching oil tends to remain on the embossing surface or cause uneven coating on the outer diameter, interfering with the uniform outflow of material during the embossing process and leading to deviations in petal contour and R-angle deformation. This component is embedded in the annular groove 22 of the working platform 12 via a ring body 23, and is driven to rise and fall by the first electric guide rod 24, so that the nozzle of the spray head 21 embedded in the ring body 23 is precisely aligned with the outer annular surface of the embossing blank cylinder 6.

[0080] During operation, the ring 23 descends to the height of the blank's outer diameter, and the nozzle 21 sprays a stretching oil film from the inner side, covering only the outer surface of the cylinder and avoiding contact between the oil and the embossed surface.

[0081] The ring 23 then rises and resets. This mechanism ensures that the embossed surface is completely free of oil residue (in conjunction with the previous cleaning steps), while the thickness of the oil film on the outer diameter is uniform and controllable, strictly limiting the material flow range.

[0082] Furthermore, by improving the precision of stretching oil application to the micron level, radial stress fluctuations caused by oil film interference are eliminated, and the material outflow rate is stabilized within the critical point required by the process. This directly supports high-precision forming of petal surface contour ≤ 0.015mm, avoiding contour rebound and dimensional failure caused by application deviation in existing technologies.

[0083] The wiping mechanism includes a wiping assembly rotatably mounted on one side of the work platform 12. The wiping assembly includes a second electric guide rod 25 rotatably mounted on one side of the work platform 12, a fixing plate 26 fixedly mounted on the top of the electric guide rod, a wiping disc 27 rotatably mounted on the fixing plate 26 facing the work platform 12, a first motor 28 driving the wiping disc 27 to rotate, and a second motor 29 mounted below the side of the work platform 12. The second motor 29 drives the second electric guide rod 25 to rotate.

[0084] The surface of the scrubbing disc 27 is spirally mounted with a support strip 271 from the inside out, an absorbent sheet 272 is covered on the outside of the support strip 271, and a scrubbing cloth 273 is covered on the outside of the absorbent sheet 272. The support strip 271 is made of silicone material, the absorbent sheet 272 is made of sponge material, and the scrubbing cloth 273 is made of non-woven fabric material.

[0085] The spiral installation direction of the support bar 271 is consistent with the rotation direction of the wiping disc 27, which can wipe the oil on the upper surface of the embossed blank cylinder 6 from the inside out.

[0086] The wiping mechanism, through the cooperation of the second electric guide rod 25 and the rotating wiping disc 27, solves the problem of material flow interference caused by residual stretching oil on the embossed surface.

[0087] Traditional cleaning methods, due to disordered wiping direction or insufficient material compatibility, are prone to leaving oil film or damaging the surface, causing fluctuations in the outflow rate of material during the embossing process, resulting in petal outline deviations and R-angle deformation.

[0088] By using a second motor 29 to drive the second electric guide rod 25 to rotate, the scrubbing component is precisely positioned above the embossed blank cylinder 6; after the first motor 28 is started, the scrubbing disc 27 rotates at high speed in the spiral direction, and its silicone support strip 271 (the spiral direction is consistent with the rotation direction) guides the oil stains on the embossed surface to migrate directionally from the inside to the outside, the sponge absorbent sheet 272 efficiently absorbs the residual oil, and the non-woven scrubbing cloth 273 achieves traceless cleaning.

[0089] During operation, the scrubbing disc 27 gently presses against the upper surface of the blank. As it rotates, the oil is systematically discharged to the edges, ensuring that the embossed surface is absolutely free of oil residue and preventing surface scratches. This mechanism improves cleaning precision to the micron level, eliminates the interference of oil on the radial stress of the material, and makes the material outflow rate during the embossing process stable and controllable. This directly guarantees the forming requirement of petal surface contour ≤0.015mm, avoiding the risks of contour rebound and dimensional failure caused by cleaning failure in existing technologies.

[0090] The quality inspection component 5 includes a conveyor belt 51 installed on one side of the work platform 12, an arched frame 52 installed on the high-rigidity bed 11 above the conveyor belt 51, and a detection sensor 53 located in the middle below the arched frame 52. The detection sensor 53 is used to inspect the embossed surface of the embossed blank cylinder 6 on the conveyor belt 51.

[0091] The guiding mechanism includes a hydraulic press 33 mounted on the high-rigidity bed 11 and an output head 34 mounted on the output end of the hydraulic press 33. The upper module 41 is fixedly mounted below the output head 34 by bolts, and the upper module 41 is raised and lowered by the hydraulic press 33.

[0092] The detection sensor 53 of the quality inspection component 5 can be a high-precision laser profilometer or a machine vision system. The laser profilometer acquires the three-dimensional morphology data of the embossed surface in real time through non-contact scanning, with a measurement accuracy of ±0.005mm, directly verifying the compliance of petal outline ≤0.015mm and R angle R0.5±0.5.

[0093] The machine vision system utilizes a high-resolution industrial camera combined with sub-pixel-level image processing algorithms to dynamically identify surface oil residue and contour distortion. Both are integrated under the arched frame 52 and move synchronously with the conveyor belt 51 to complete online inspection, ensuring that defective products are removed in time and avoiding contour rebound problems caused by flow instability.

[0094] The hydraulic press 33 of the guiding mechanism consists of a servo hydraulic cylinder, a proportional flow valve, and a closed-loop pressure control system. The servo hydraulic cylinder provides high-rigidity thrust in the vertical direction, while the proportional flow valve precisely regulates the oil flow rate to achieve micron-level control (±0.01mm positioning accuracy) of the lifting speed of the upper module 41. The closed-loop system compensates for load fluctuations in real time, ensuring the stability of the 0.05mm interference fit between the embossing punch positioning ring 31 and the blank cylinder. This mechanism effectively suppresses vibration interference from traditional mechanical guides, ensuring precise triggering of the reaction force at the critical point of material outflow.

[0095] The aforementioned sensors and hydraulic systems are all mature technologies in the industrial field. Their selection and parameter configuration follow the ISO10099 and JIS B 6402 standards, and no additional explanation of specific implementation details is required.

[0096] The control module 7, limit module 8, and oil injection module 9 are electrically connected to the first motor 28, the second motor 29, the electric guide rod, the limit module 8, the first electric guide rod 24, the second electric guide rod 25, the oil injection module 9, and the hydraulic press 33.

[0097] The limit module 8 is integrated into the motion control system, using a high-precision displacement sensor and electronic limit switch to monitor the stroke of key components in real time. During the lifting and lowering phase of the ring 23, the limit module 8 sets a threshold of 0.05mm to ensure that the ring 23 is accurately positioned to the height of the blank's outer diameter, preventing overtravel that could cause oil film spraying deviation. During the descent of the wiping disc 27, the module monitors the vertical displacement of the fixed plate 26, limiting the descent depth to 0.1mm to prevent excessive pressure from the wiping cloth 273 that could damage the embossing surface. When the upper module 41 presses down, the limit module 8 works in conjunction with the hydraulic press 33 to precisely control the embossing depth to the critical point of R-angle forming (0.5±0.02mm) and lock the holding time, eliminating petal contour distortion caused by stroke loss. This module suppresses mechanical motion errors within ±0.01mm, providing a fundamental guarantee for a 0.05mm interference fit and a contour accuracy of 0.015mm.

[0098] The fuel injection module 9 adopts a closed-loop pressure control system, which consists of a proportional flow valve and a miniature pressure sensor (not shown in the figure) to dynamically adjust the fuel injection quantity (0.15–0.25 ml / cm2) and the fuel injection pressure (0.3–0.4 MPa).

[0099] The module controls the start / stop response time of nozzle 21 via a solenoid valve to ≤5ms, ensuring that the stretching oil is sprayed only directionally onto the outer diameter surface of the cylinder, forming a uniform 0.02mm oil film. This precise control eliminates oil film thickness fluctuations (±0.005mm), strictly limits the material outflow rate within the critical process range, and avoids material accumulation due to oil overload or thinning caused by insufficient oil, directly supporting the forming requirement of petal surface contour ≤0.015mm. The module, in conjunction with the limiting mechanism, achieves micron-level stability in the surface treatment process, fundamentally solving the flow instability problem caused by oil film interference in existing technologies.

[0100] The embossed blank cylinder 6 is placed on the worktable and positioned in conjunction with the positioning block 32. Through the control module 7 and the first electric guide rod 24, the control ring 23 rises and, in conjunction with the oil spraying module 9, sprays an oil film onto the outer ring surface of the embossed blank cylinder 6, then returns to its original position. The oil spraying module 9 mainly controls the oil spray volume and pressure. It controls the opening and closing of the nozzle 21 through the control module 7. The opening and closing function is achieved by a solenoid valve, which is existing technology and will not be described in detail here.

[0101] After the oil film is sprayed onto the outer ring surface of the embossed blank cylinder 6, the control module 7 cooperates with the second motor 29 to control the second electric guide rod 25 to rotate 90°. The second electric guide rod 25 controls the fixed plate 26 to descend, so that the wiping cloth 273 contacts the upper surface of the embossed blank cylinder 6. The first motor 28 drives the wiping disc 27 to rotate and wipe, and then it is reset.

[0102] The control module 7 works in conjunction with the hydraulic press 33 to control the upper module 41 to press down toward the lower module 43. The embossing punch positioning ring 31 is positioned twice by cooperating with the middle of the embossing blank cylinder 6. Then, the flower petal protrusion 42 presses and embosses the embossed surface of the embossed blank cylinder 6 to form the embossed shape. The pressure is held for a preset time, and then the cylinder is reset.

[0103] The embossed blank cylinder 6 is placed on the conveyor belt 51 and passes through the detection sensor 53 to complete the acceptance.

[0104] The embossing punch positioning ring 31 is made of Cr12MoV mold steel, with a heat treatment hardness of HRC58-60, an inner diameter tolerance controlled within -0.005 to 0 mm, and a surface roughness of Ra0.2 μm. It forms a precise 0.05 mm interference fit with the outer diameter of the embossing blank cylinder 6.

[0105] It should be noted that the device structure and accompanying drawings of this utility model mainly describe the principle of this utility model. In terms of the technical aspects of this design principle, the setting of the power mechanism, power supply system and control system of the device is not fully described. However, under the premise that those skilled in the art understand the principle of the above utility model, the specific details of its power mechanism, power supply system and control system can be clearly understood. The control method in the application document is automatic control through a controller. The control circuit of the controller can be implemented by those skilled in the art through simple programming.

[0106] All standard parts used can be purchased from the market, and can be customized according to the instructions and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the existing technology. The machinery, parts and equipment adopt conventional models in the existing technology, and the structure and principle of the components known to those skilled in the art can be known by those skilled in the art through technical manuals or conventional experimental methods.

[0107] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A high-precision sheet metal pulley pattern forming equipment, characterized in that, include: The components include: basic frame assembly (1), blank pretreatment assembly (2), precision positioning assembly (3), embossing assembly (4), and quality inspection assembly (5); The basic frame assembly (1) includes a high-rigidity bed (11) and a work platform (12), and the blank pretreatment assembly (2) includes several sets of nozzles (21) that are lifted and arranged on the work platform (12) and a flip-up wiping mechanism arranged on one side of the work platform (12). The embossing component (4) includes an upper module (41), a flower petal protrusion (42) disposed below the upper module (41), and a lower module (43) installed in the middle of the workbench; The precision positioning component (3) includes an embossing punch positioning ring (31) located in the middle of the lower part of the upper module (41), a positioning block (32) located in the middle of the upper part of the lower module (43), and a guide mechanism for controlling the upper module (41) to move in the vertical direction. An embossing blank cylinder (6) is placed on the working platform (12), and the positioning block (32) is inserted into the middle of the lower part of the embossing blank cylinder (6). During embossing, the embossing punch positioning ring (31) is inserted into the middle of the upper part of the embossing blank cylinder (6), and the flower petal protrusions (42) squeeze the upper surface of the embossing blank cylinder (6).

2. The high-precision sheet metal pulley pattern forming equipment according to claim 1, characterized in that: The pre-treatment assembly (2) for the blank includes an annular groove (22) set on the working platform (12), an annular body (23) embedded in the annular groove (22), a first electric guide rod (24) for controlling the lifting and lowering of the annular body (23), and a nozzle (21) embedded in several of the annular bodies (23). The nozzle (21) has its nozzle opening on the inner side of the annular body (23). Through the cooperation of the annular body (23), the first electric guide rod (24), and the nozzle (21), an oil film is sprayed onto the outer annular surface of the embossed blank cylinder (6).

3. The high-precision sheet metal pulley pattern forming equipment according to claim 1, characterized in that: The wiping mechanism includes a wiping assembly rotatably mounted on one side of the work platform (12). The wiping assembly includes a second electric guide rod (25) rotatably mounted on one side of the work platform (12), a fixing plate (26) fixedly mounted on the top of the electric guide rod, a wiping disc (27) rotatably mounted on the fixing plate (26) facing the work platform (12), a first motor (28) driving the wiping disc (27) to rotate, and a second motor (29) mounted below the side of the work platform (12). The second motor (29) drives the second electric guide rod (25) to rotate.

4. The high-precision sheet metal pulley pattern forming equipment according to claim 3, characterized in that: The surface of the scrubbing disc (27) is spirally fitted with a support strip (271) from the inside out, an absorbent sheet (272) is covered on the outside of the support strip (271), and a scrubbing cloth (273) is covered on the outside of the absorbent sheet (272).

5. The high-precision sheet metal pulley pattern forming equipment according to claim 4, characterized in that: The support strip (271) is made of silicone material, the absorbent sheet (272) is made of sponge material, and the cleaning cloth (273) is made of non-woven fabric material.

6. The high-precision sheet metal pulley pattern forming equipment according to claim 5, characterized in that: The spiral installation direction of the support bar (271) is consistent with the rotation direction of the wiping disc (27), which can wipe the oil on the upper surface of the embossed blank cylinder (6) from the inside out.

7. The high-precision sheet metal pulley pattern forming equipment according to claim 1, characterized in that: The quality inspection component (5) includes a conveyor belt (51) installed on one side of the work platform (12), an arched frame (52) installed on the high-rigidity bed (11) above the conveyor belt (51), and a detection sensor (53) located in the middle below the arched frame (52). The detection sensor (53) is used to inspect the embossed surface of the embossed blank cylinder (6) on the conveyor belt (51).

8. A high-precision sheet metal pulley pattern forming equipment according to claim 1 or 7, characterized in that: The guiding mechanism includes a hydraulic press (33) mounted on the high-rigidity bed (11) and an output head (34) mounted on the output end of the hydraulic press (33). The upper module (41) is fixedly mounted below the output head (34) by bolts, and the upper module (41) is controlled to move up and down by the hydraulic press (33).

9. The high-precision sheet metal pulley pattern forming equipment according to claim 1, characterized in that: The embossing punch positioning ring (31) is made of Cr12MoV mold steel and forms a precise 0.05mm interference fit with the outer diameter of the embossing blank cylinder (6).

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