In a large number of industrial applications, we need to deal with the surface treatment and processing of many non-standard parts. Due to its surface complexity and diversity, in many cases manpower cannot be operated, and the programmable robot is also subject to the characteristics of the body. Restrictions, so the design of dedicated non-standard robots or machines has become a very important technical field, and often the application of this field requires a certain technical content. It is well known that the higher the degree of automated production, the more convenient the planning management of production, so the use of flexible general-purpose equipment is a method that is conducive to production.
Due to the individualized pursuit of people, the appearance of aluminum alloy electroplated automobile hubs tends to be complicated and diversified, and the replacement is fast. At present, in the polishing process of wheel hub production, the manufacturer uses artificial polishing, which takes up about 35% of the time and labor of the entire wheel production, and relies on skilled manual polishing workers (1 to 3/day). The large amount of dust generated during polishing jeopardizes the health of workers and causes environmental pollution. Its extremely low production efficiency and high labor intensity seriously restrict the development of enterprises.
Therefore, Nachi has developed a cost-effective polishing and polishing robot system for the automotive wheel industry. The system has high polishing efficiency and can replace the workload of 3~4 workers; high reliability, 80,000h continuous operation without failure; good product quality, with the torque belt machine developed by our company, can meet most of the process Requirements, the yield rate can reach up to 99.2%; the system is flexible, and the robot offline software developed by our company is patented. As shown in Figure 1, it only needs to stop production for 30 minutes to complete the teaching of new workpieces. Other company products need 7~ 8 days; low labor intensity, a set of polishing robot workstations only need to be loaded and unloaded every 8h, no need for worker intervention for the rest of the time; low overall cost, relative to the polished workers, 2 to 3 years of workers are enough to buy a robot system. As long as one worker is loaded and unloaded, it can work 724 hours without interruption, increasing production while improving the competitiveness of the company.
figure 1
The polishing methods commonly used in processing and production mainly include: electropolishing, ultrasonic polishing, jet polishing, magnetic polishing, mechanical polishing and chemical polishing. After years of research experience and experimental comparison by our technicians, it is more feasible to use mechanical polishing and chemical polishing for wheel hub polishing.
Chemical Mechanical Polishing (CMP) is a process in which a workpiece to be polished is pressed against a rotating or flowing polishing slurry, and the polishing slurry continuously flows between the workpiece and the abrasive during processing. The processed product on the surface of the workpiece being polished is continuously peeled off, the new polishing slurry is replenished, and the reaction product is carried away by the polishing slurry. The newly exposed workpiece plane undergoes a chemical reaction, and the product is peeled off and reciprocated, forming a bright and smooth surface under the combined action of the workpiece, abrasive grains and chemical reactants. In order to obtain a polished surface of good quality, it is necessary to achieve a balance between chemical corrosion and mechanical grinding during polishing. If the chemical corrosion effect is greater than the mechanical polishing effect, corrosion pits and orange peels will be generated on the surface of the polishing sheet; on the contrary, the mechanical polishing effect is greater than the chemical corrosion effect, which will cause the surface to have a high damage layer.
The automobile aluminum alloy wheel polishing machine utilizes the characteristics of the flexible mechanical structure to automatically conform to the complex curved surface of the wheel hub. The grinding force can be controlled in real time and can be polished, as shown in Fig. 2. Processing hubs range from 12 to 22 inches. The equipment has 6 polishing stations, one clamping station, and a total of 7 rotation tables. The machine is equipped with different polishing heads, and the robot can grab different grinding heads according to different processes. The equipment is also equipped with a dust removal device to make the equipment work more environmentally friendly.
figure 2
The control system can program the robot offline, and can generate robot programs through the 3D drawings of the hub, eliminating the hassle of teaching. The offset and deformation of the workpiece can be obtained by the monitoring system and corrected in real time, as shown in Figure 3.
In general, the concept and system of the robot is not limited to the robot body. In practical applications, the different shapes and structures of the machine can be changed to meet the different requirements of different stations. Due to Nachi's unique off-line programming software and torque-controlled belt machine, the flexible industrial robot application technology will be more powerful in the future for the continuous updating and improvement of the application system functions.
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Baoji Shengyuan Metal Material Co., Ltd. , https://www.baojisymetal.com