Intelligent Automation Integration
❷Connecting Rod Fine Boring, Large & Small Hole Honing Production Line
On the basis of the existing equipment, additional devices, systems and mechanisms have been added to realize the automation of this production line.
Test Bench Description
This machine tool is manufactured in Japan with outdated control system and bed body, and no relevant technical documents are retained. It is specially used for precision grinding of connecting rod end faces, equipped with 20 working stations in total, including 10 stations for side A precision grinding and another 10 stations for side B precision grinding. The original mechanical feeding mechanism needs to move synchronously with the rotary table and flip workpieces during operation.
Equipment Fault Solution
The swing arm of the equipment is driven by a servo motor equipped with an RV80E reducer. During operation, the customer reported frequent reducer failures. The RV reducer needs to be replaced every 3 to 6 months. Our company has conducted a comprehensive discussion on this issue and formulated the effective solutions as follows.
Cause Analysis：By adjusting the installation angle of the reducer, the torque and bending moment of the manipulator main arm are shared by two bearings, which optimizes the operating conditions of the reducer. This improvement has greatly extended its service life, and no reducer failure has been reported up to now.
This inspection equipment is introduced by a connecting rod manufacturer for high-end connecting rod production. It can detect slag falling within the 1×2mm range on the fracture surface of connecting rods and check end face misalignment after fracturing and bolt tightening, and also support automatic line connection of the connecting rod production line.
❷ Automotive Interior Foam Bonding (Fastener Nut Installation)
Two sliding table jigs are adopted to fix two pairs of workpieces for foam bonding and fastener nut installation. A six-axis robot grips foam pads and fastener nuts and assembles them at designated positions. The dual-sliding-table structure is designed to improve robot utilization and maximize production efficiency.
During operation, workers only need to place foam pads into the foam storage bin and put nuts into the vibration feeder. Subsequently, only the loading and unloading of injection-molded parts is required to complete foam bonding and fastener nut installation. The jig can be simply replaced for product changeover.
The equipment is divided into four process sections: feeding section, workpiece inspection section, defective workpiece rejection section, and flux coating section. During operation, workers place the jigs loaded with workpieces in a fixed direction at the feeding section. This station is equipped with an error-proofing function; the jigs cannot be conveyed to the inspection section if the placement direction is incorrect. Workers press the confirm button after correct placement.
When the jig at the inspection station passes the origin, the pushing cylinder at the feeding station pushes the jig to the origin of the inspection section. The servo moving device at the inspection station then transports the jig sequentially past two vision cameras, and finally delivers the inspected jig to the origin of the defective rejection station. The system transmits the serial numbers of defective workpieces on the jig to the control system.
At this time, the servo moving device of the inspection station returns to the original position to carry the uninspected workpiece jig. Meanwhile, the servo moving device at the rejection station conveys the inspected jig from its home position. Defective workpieces pass through the rejecting unit one by one and are sorted out.
After all defective products are removed, the jig is automatically transferred to the starting position of the flux coating section. The servo mechanism at the rejection station then resets to convey the next batch of jigs.
When the jig enters the flux coating area, the flux tank is lifted steadily by the servo motor to apply flux evenly on workpieces. Upon completion of coating, the workpieces are delivered to the feeding position of the soldering equipment.
