CN111229907B - Intelligent detection system for performance of press machine - Google Patents
Intelligent detection system for performance of press machine Download PDFInfo
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- CN111229907B CN111229907B CN202010106037.8A CN202010106037A CN111229907B CN 111229907 B CN111229907 B CN 111229907B CN 202010106037 A CN202010106037 A CN 202010106037A CN 111229907 B CN111229907 B CN 111229907B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/02—Stamping using rigid devices or tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M99/00—Subject matter not provided for in other groups of this subclass
- G01M99/005—Testing of complete machines, e.g. washing-machines or mobile phones
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M99/00—Subject matter not provided for in other groups of this subclass
- G01M99/008—Subject matter not provided for in other groups of this subclass by doing functionality tests
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Abstract
The invention relates to the field of press machine performance testing, in particular to an intelligent detection system for press machine performance. The invention provides an intelligent detection system for the performance of a press, which comprises an online detection end and an offline processing end, wherein the online detection end comprises the following components: the online detection end comprises a loading device, a signal acquisition device and a signal transmission device, wherein the loading device applies a working load to the press, the signal acquisition device acquires pressure and displacement signals in the working process, and the signal transmission device transmits the acquired signals to the offline processing end; and the offline processing terminal receives the signal of the online detection terminal, calculates the signal and visually presents the calculation result. The intelligent detection system for the performance of the press machine can realize comprehensive, accurate and efficient measurement of multiple performances of the press machine, provides important basis for installation, debugging, matching, maintenance and maintenance of the press machine and rapid die moving of a stamping die, and realizes comprehensive measurement of the performance of the press machine by one set of equipment.
Description
Technical Field
The invention relates to the field of press machine performance testing, in particular to an intelligent detection system for press machine performance.
Background
The press is an important device for stamping and manufacturing the vehicle body and plays a key role in the quality and efficiency of stamping and manufacturing. In order to obtain a stable stamping process, the performance of the press should be kept stable and consistent as much as possible. However, in actual production, the automotive mainframe factory inevitably faces the problem of press changes: from the mould debugging to batch production, same set of mould needs to match with different presses, if: a die supplier trial die press, a host factory mass production press, etc. Each time the press is replaced, it may cause instability in the stamping process, inducing part defects.
In this regard, the current solutions are: the difference of the performance of the press machine is made up by changing the die, so that the consistency of the stamping process is realized. Although the method can alleviate the problems, the cost of manpower and material resources consumed by changing the die is high, the changing period is long, and the method cannot adapt to increasingly severe industry competition.
The consistency of the performances of different presses is improved, and reasonable classification and matching optimization are carried out according to the performances of the presses, so that the problem can be fundamentally solved, but the premise is that the performances of the presses are comprehensively measured and evaluated.
Fig. 1 shows a structure of a press forming system in the prior art, and a single-action mechanical press which is most commonly used in the press forming of a car body as shown in fig. 1 is taken as an example, and main working components thereof include: a press slide 201, a press table 202, a lower air cushion top bar 203, a lower air cushion 204, etc. The upper concave die 101 of the stamping die is arranged on the press sliding block 201, the lower concave die 103 of the stamping die is arranged on the press table 202, and the lower air cushion 204 applies controllable pressure to the blank holder 102 of the stamping die through the lower air cushion ejector rod 203. During stamping, the press ram 201 moves downward through the pressure of the parts of the die to plastically deform the web 300 to form the desired part.
The press properties involved here include: the working pressure of the slide block/air cushion, the deflection deformation of the slide block/table surface, the parallelism of the slide block/table surface, the loading characteristic of the lower air cushion and the like.
At present, in order to carry out comprehensive measurement to the press performance, need adopt many sets of equipment to carry out a lot of measurements, equipment transportation, dismouting are very loaded down with trivial details, consume a large amount of manpower and materials, measure with high costs, cycle length, inefficiency. The stamping industry urgently needs a specialized device which can detect the performance of the press machine comprehensively, efficiently and accurately.
Disclosure of Invention
The invention aims to provide an intelligent detection system for the performance of a press machine, which solves the problems of incomplete function, low measurement efficiency and insufficient measurement precision of the conventional detection system for the press machine and comprehensively, efficiently and accurately measures and evaluates the performance of the press machine.
In order to achieve the purpose, the invention provides an intelligent detection system for the performance of a press, which comprises an online detection end and an offline processing end, wherein the online detection end comprises:
the online detection end comprises a loading device, a signal acquisition device and a signal transmission device, wherein the loading device applies a working load to the press, the signal acquisition device acquires pressure and displacement signals in the working process, and the signal transmission device transmits the acquired signals to the offline processing end;
and the offline processing terminal receives the signal of the online detection terminal, calculates the signal and visually presents the calculation result.
In one embodiment, the loading device comprises an upper base frame, a middle pressure plate, a lower base frame and a loading cylinder group;
the upper base frame is arranged on the press sliding block and moves along the stamping direction along with the press sliding block;
the middle pressure plate is of a wall plate structure with an upper layer and a lower layer, the upper layer space is used for accommodating the pressure sensor group, and the lower layer space is used for accommodating the loading cylinder group and the lower base frame;
the lower base frame is arranged on the table surface of the pressing machine;
the signal acquisition device comprises an auxiliary support, a pressure sensor group, a static displacement sensor group and a dynamic displacement sensor group.
In one embodiment, the middle pressure plate is a floating pressure plate, and the loading device further comprises an auxiliary component, wherein the auxiliary component comprises a pre-tightening cylinder group and a suspension mechanism:
in the opening state, the middle pressure plate is suspended on the suspension mechanism of the upper base frame and separated from the pressure sensor group;
under the closing state, the middle pressure plate is separated from the suspension mechanism, is supported by the lower pre-tightening cylinder group, is pressed together with the upper base frame and the pressure sensor group under the action of pre-tightening force, and moves along the stamping direction along with the press sliding block.
In one embodiment, the bottom of the middle pressure plate is provided with a top bar group, and the top bar group is contacted with the lower air cushion top bar and transmits the contact force to the pressure sensor group during the operation of the press sliding block.
In one embodiment, a boss structure is provided in a middle region of the lower pedestal, and the load cylinder group is mounted on the boss structure.
In one embodiment, the loading cylinder group is composed of a plurality of nitrogen springs, a certain air pressure value is pre-charged according to specifications, the nitrogen springs have compression strokes, and self-adaptive matching of various contact profiles between the middle pressure plate and the loading cylinder group and adjustment of contact pressure are achieved.
In one embodiment, a pressure block and an adjusting shim are arranged between the middle pressure plate and the loading cylinder group, and the contact state between each loading cylinder of the loading cylinder group and the middle pressure plate is changed through adjustment of the pressure block and the shim.
In one embodiment, a guide mechanism is arranged between the upper base frame and the lower base frame and adopts a guide plate for guiding;
a guide mechanism is arranged between the upper base frame and the middle pressure plate, and the guide mechanism is guided by combining a guide plate and a guide pillar.
In one embodiment, the auxiliary support is I-shaped, is divided into an upper part and a lower part, is respectively arranged on the upper base frame and the lower base frame and is used for installing a static displacement sensor group and detecting the deflection deformation of the press sliding block and the press table board.
In one embodiment, the pressure sensor group is arranged between the upper base frame and the middle pressure plate and used for measuring the pressure of the press slide block;
the static displacement sensor group is arranged on the auxiliary bracket and used for measuring deflection deformation at different positions;
the dynamic displacement sensor group comprises a dynamic displacement sensor I group and a dynamic displacement sensor II group, the dynamic displacement sensor I group is arranged between the upper base frame and the lower base frame and used for measuring the displacement of the press sliding block, and the dynamic displacement sensor II group is arranged between the lower base frame and the lower air cushion ejector rod and used for measuring the displacement of the lower air cushion.
In one embodiment, in the first working condition, the lower air cushion and the lower air cushion ejector rod are lifted in the initial state and have a certain stroke, and in the process that the press sliding block moves downwards, the middle pressure plate is sequentially contacted with the pre-tightening cylinder group, the lower air cushion ejector rod and the loading cylinder group, so that the dynamic characteristic of the press is detected.
In one embodiment, the dynamic characteristics include the slider pressure before the bottom of the press slider, the lower air cushion pressure, the slider movement, the lower air cushion movement, and the parallelism between each two;
z direction of press slide blockDisplacement zsZ-direction speed v of press slidesParallelism q between measuring points between the press slide and the press tableijLower cushion Z-direction displacement ZkLower air cushion Z-direction velocity vkThe calculation formula is as follows:
zs＝0.25(z1+z2+z3+z4)；
vs＝zs′；
qij＝max(zi–zj)/(dij)；(i＝1,2,3,4；j＝1,2,3,4，i≠j)；
zk＝0.25(z5+z6+z7+z8)；
vk＝zk′；
wherein z is1～z4The detection values of the group I of the dynamic displacement sensors are obtained; dijIs the horizontal spacing between the ith and jth; z is a radical of5～z8The detection value of the dynamic displacement sensor II group is obtained;
press ram pressure Fs＝∑pi，piThe detected value of the ith sensor in the pressure sensor group is obtained;
lower cushion pressure FkThe calculation formula is as follows: fk＝Fs+G-Fpre，FsFor press ram pressure, FpreThe pre-tightening force is provided for the suspension mechanism, and G is the weight of the pressure plate.
In one embodiment, in the second working condition, the lower air cushion and the lower air cushion ejector rod are not lifted up in the initial state and have no stroke, and the middle pressure plate is sequentially contacted with the pre-tightening cylinder group and the loading cylinder group in the process of moving down the press slide block, so that the static characteristic of the press is detected.
In one embodiment, the static characteristics include press ram pressure after press ram bottoming, deflection deformation of the ram, press table deflection deformation:
press ram pressure Fs＝∑pi，piThe detected value of the ith sensor in the pressure sensor group is obtained;
press slideDeflection deformation f of block x directionxsY-direction deflection deformation f of press slide blockysX-direction deflection deformation f of press tablextY-direction deflection deformation f of press tableytThe calculation formula is as follows:
fxs＝0.5(d3+d8)-0.25(d1+d5+d6+d10)；
fyt＝d13–0.5(d3+d8)；
fxt＝0.5(d16+d21)-0.25(d14+d18+d19+d23)；
fyt＝d26–0.5(d16+d21)；
wherein d is1～d26The detection value of the static displacement sensor group is obtained;
after the slide block is bottomed, the pressure F of the press table surfacetWith pressure F of the slidesEquilibrium, i.e. Ft＝Fs。
In one embodiment, the offline processing end includes an editing module, a monitoring module, a computing module, a visualization module, a management module, and a signal transmission module:
the editing module is connected with the signal transmission module and is used for inputting basic information of the press to be tested and the test working condition;
the monitoring module is connected with the signal transmission module and is used for monitoring whether the corresponding sensor and the corresponding electric element work normally or not;
the calculation module is connected with the signal transmission module and the editing module and is used for calculating and processing the pressure and displacement signals acquired by the sensor to obtain basic mechanical performance parameters of the press;
the visualization module is connected with the signal transmission module and the calculation module and used for visually presenting the detection calculation result in a chart form;
the management module is connected with the signal transmission module and the calculation module and is used for managing the measurement data of detection calculation;
and the signal transmission module is connected with the online detection end and is used for carrying out data transmission and signal communication.
Aiming at the problems of incomplete function, low measurement efficiency and insufficient measurement precision of the current press performance measurement device, the invention provides a special press performance intelligent detection system, which can realize comprehensive, accurate and efficient measurement of multiple performances of a press, provides important basis for installation, debugging, matching, maintenance and fast die moving of a press and realizes comprehensive measurement of multiple press performances by one set of equipment.
The intelligent detection system for the performance of the press machine, provided by the invention, has the following beneficial effects:
1) the suspended pressure plate structure is provided, so that the uncontrollable interference of the restraining force of the traditional fastening structure is eliminated, and the measurement accuracy is improved;
2) an intelligent signal processing subsystem is constructed, automatic calculation and visual processing are carried out on the measured data, and the measuring efficiency and the intuitiveness of the measuring result are improved.
Drawings
The above and other features, properties and advantages of the present invention will become more apparent from the following description of the embodiments with reference to the accompanying drawings in which like reference numerals denote like features throughout the several views, wherein:
FIG. 1 discloses a prior art press forming system block diagram;
FIG. 2 is a schematic block diagram illustrating a basic configuration of an intelligent detection system for press performance according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of an on-line detection end according to an embodiment of the present invention;
FIG. 4 discloses a schematic structural view of a middle pressure plate according to an embodiment of the present invention;
FIG. 5a discloses a schematic view of a middle pressure plate in an open state according to an embodiment of the invention;
FIG. 5b discloses a schematic view of a middle pressure plate in a closed state according to an embodiment of the invention;
FIG. 6a discloses a first schematic view of a force analysis of a fastened middle pressure plate;
FIG. 6b discloses a second schematic view of a force analysis of a fastened middle pressure plate;
FIG. 7 discloses a force analysis diagram of a suspended central pressure plate;
FIG. 8 illustrates a schematic structural view of a lower pedestal and load cylinder block according to an embodiment of the present invention;
FIG. 9 is a schematic view of an auxiliary stand according to an embodiment of the present invention;
FIG. 10 illustrates a stroke diagram of an intelligent detection system for press performance according to an embodiment of the invention;
FIG. 11 illustrates an editing module according to an embodiment of the invention;
FIG. 12 discloses a schematic diagram of a monitoring module according to an embodiment of the invention;
FIG. 13 discloses a schematic diagram of a visualization module according to an embodiment of the invention;
FIG. 14 is a diagram of a management module according to an embodiment of the invention.
The meanings of the reference symbols in the figures are as follows:
101, mounting a female die;
102 a blank holder;
103, a lower male die;
201 press slide block;
202 pressing machine table board;
203 lower air cushion top rod;
204 lower air cushion;
300 pieces of material;
400 on-line detection terminal
41 loading device
411 an upper pedestal;
412 a middle pressure plate;
413a lower pedestal;
413a boss;
413b boss;
414 load the cylinder bank;
415 an auxiliary component;
416 pretensioning the cylinder bank;
417 damping limit bolt
418 a set of top bars;
419 setting an air cushion detection rod;
42 a signal acquisition device;
421 an auxiliary support;
422 pressure sensor group;
423 static displacement sensor group;
424 group I dynamic displacement sensors;
425 dynamic displacement sensor group II;
43 signal transmission means;
500 off-line processing terminal;
501, editing a module;
502 a monitoring module;
503 a calculation module;
504 a visualization module;
505 a management module;
506 a signal transmission module.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Fig. 2 is a schematic block diagram illustrating a basic structure of an intelligent detecting system for press performance according to an embodiment of the present invention, and in the embodiment illustrated in fig. 2, the intelligent detecting system for press performance according to the present invention includes an online detecting end 400 and an offline processing end 500.
The main function of the online detection end 400 is to apply a working load to the press, collect signals such as pressure and displacement during the working process, and transmit the collected signals to the offline processing end 500.
The off-line processing terminal 500 has the main functions of receiving the signal of the on-line detection terminal 400, performing calculation processing on the received signal, and visually presenting the calculation result visually and vividly.
Furthermore, the offline processing end 500 also has basic system management functions such as file saving, reading, and data exporting.
The embodiment shown in fig. 2 is used in conjunction with the punch forming system shown in fig. 1 to describe the online detection end 400 of the intelligent detection system for press performance according to the present invention in detail. The coordinate system is a vehicle body coordinate system, and the Z direction is defined as the vehicle height direction, the Y direction is the vehicle width direction, and the X direction is the vehicle length direction.
Fig. 3 shows a schematic structural diagram of an online detection terminal according to an embodiment of the present invention, and as shown in fig. 2 and fig. 3, the online detection terminal 400 further includes: loading device 41, signal acquisition device 42 and signal transmission device 43.
The loading device 41 applies a working load to the press, and mainly includes: an upper base frame 411, an intermediate pressure plate 412, a lower base frame 413, a loading cylinder block 414, and an auxiliary component 415.
The auxiliary component 415 further includes: a pre-tightening cylinder set 416, a bolt with a shock-absorbing limit 417 and the like.
The signal acquisition device 42 acquires pressure and displacement signals in the working process, and mainly comprises: auxiliary support 421, pressure sensor group 422, static displacement sensor group 423, dynamic displacement sensor I group 424, dynamic displacement sensor II group 425.
The signal transmission device 43 transmits the collected signals to the offline processing terminal 500 in a wireless/wired transmission manner.
The individual components of the loading device 41 are described further below.
The upper base frame 411 is mounted on the press slide 201, can move along the stamping direction along with the press slide 201, and is a mounting base for other components on the upper portion.
The upper base frame 411 is of a wall plate structure and is matched with a hollow design to obtain light weight and a large internal arrangement space. The integrated casting lug of upper portion bed frame 411 to acquire better handling intensity and simple operation nature.
The middle pressure plate 412 is a key component for transmitting pressure, and has a great influence on the measurement accuracy of the working pressure.
In order to improve the measurement accuracy, the present invention provides a middle pressure plate 412 of a suspension structure, fig. 4 shows a schematic structural diagram of the middle pressure plate according to an embodiment of the present invention, and as shown in fig. 4, the middle pressure plate 412 adopts a two-layer wall structure for accommodating the pressure sensor group, the loading cylinder group 414, the lower base frame 413, the boss, and the related components.
The upper space of the middle pressure plate 412 is used to house the pressure sensor group and associated components, and the lower space is used to house the loading cylinder group 414 and the lower pedestal 413 and boss. The large-area hollow design of the wall plate is used for reducing the hanging weight.
The top bar set 418 is mounted to the bottom of the middle pressure plate 412.
During the operation of the press ram 201, the top bar set 418 contacts the bottom air cushion top bar 203 and transmits the contact force during the operation to the pressure sensor set 422.
Fig. 5a and 5b disclose schematic views of an open state and a closed state of a middle pressure plate according to an embodiment of the invention, as shown in fig. 5a and 5b, respectively, the working principle of the middle pressure plate is as follows:
in the open position, as shown in fig. 5a, the middle pressure plate 412 is suspended by gravity from the suspension mechanism of the upper base frame 411, leaving a gap with the pressure sensor set 422, and the two are separated. The suspension mechanism is provided with a shock-absorbing limit bolt 417. The pressure sensor 422 is mounted on the upper base frame 411.
As shown in fig. 5b, when the press ram 201 moves downward, the middle pressure plate 412 follows downward, and gradually disengages from the suspension mechanism after being supported by the lower pre-tensioning cylinder group 416, and the gap between the middle pressure plate 412 and the pressure sensor group 422 gradually decreases until the middle pressure plate is completely closed. After the pressing plate is completely closed, the middle pressure plate 412, the upper base frame 411 and the pressure sensor group 422 are pressed together under the action of a pretightening force and move downwards along with the press sliding block 201. The pressure sensor cluster 422 is mounted on the upper pedestal 411.
In the closed state, the middle pressure plate 412 is supported by the lower pre-tightening cylinder group 416, is separated from the cylinder with the shock-absorbing limit bolt 107, has no gap with the pressure sensor group 422, and is in a pressing state.
Compared with the traditional fastening type middle pressure plate, the suspension type middle pressure plate provided by the invention has higher measurement accuracy.
The reason is that the middle pressure plate of the traditional fastening structure is sequentially from top to bottom: the pressure sensor comprises an upper base frame, a pressure sensor and a middle pressure plate, wherein the upper base frame is fastened and connected by fasteners such as bolts, and the pressure sensor is clamped between the upper base frame and the pressure sensor. A problem with a fastened central pressure plate is that it generates an uncontrollable restraining force.
Compared with the above, the suspended middle pressure plate has the advantages that: uncontrollable constraint force generated by a traditional fastening structure is replaced by controllable pretightening force, so that the measuring result is more accurate.
Fig. 6a and 6b are schematic diagrams of force analysis of a fastening type middle pressure plate, and fig. 7 is a comparison of force conditions of a suspended type middle pressure plate. Wherein, FmMeasuring force for pressure sensor group, FaIs the actual working pressure of the middle pressure plate, FprePretightening force provided for the suspension mechanism, FadThe restraining force provided by the fastener, G, is the weight of the middle pressure plate.
For a fastened middle pressure plate, when Fa<G, as shown in FIG. 6a, i.e. the working pressure FaThe restraining force F being insufficient to balance the weight G of the pressure plateadOpposite to the direction of gravity, i.e. vertically upwards.
For a fastened middle pressure plate, when Fa>G, as shown in FIG. 6b, i.e. the working pressure FaSufficient to balance the weight G of the pressure plateadIn the same direction as gravity, i.e. vertically downwards.
It can be seen that, for the fastening type middle pressure plate, the restraining force F is generated under different working conditionsadWill change in direction. Furthermore, a restraining force FadAlso receiveThe influence of uncontrollable factors such as structural deformation interference, temperature change, molded surface contact consistency, assembly stress, stress deformation of a die and the like.
Thus, for a fastened central pressure plate, an additional restraining force FadAre uncontrollable and unpredictable. This disturbs the measurement of the pressure FmWith working pressure FaThe stability relationship between them affects the measurement accuracy.
For the suspension type middle pressure plate provided by the invention, due to the structural characteristics, as shown in fig. 7, the pretightening force F ispreThe vertical direction is always vertical upwards, the size of the cylinder can be preset and controlled by the pre-tightening cylinder group 416, and according to the stress analysis, the following results can be obtained:
Fa＝Fm+G-Fpre；
due to G and FpreAre all stable and controllable quantities, measuring force FmAnd the actual working pressure FaA stable corresponding relation can be established between the two, and the measurement precision is improved.
Fig. 8 is a schematic structural view of a lower base frame and a loading cylinder group according to an embodiment of the present invention, and as shown in fig. 8, a lower base frame 413 is mounted on a press workbench, which is a mounting base of other components, and adopts a wall plate structure and is matched with a hollow design to obtain a light weight.
Lower part bed frame 413 middle part region has boss structure characteristic, and its effect lies in:
1) lowering the height of the loaded cylinder bank 414, improving the stability of the compression loading;
2) the thickness of the middle pressure plate 412 is reduced, and the hanging weight is reduced;
3) the internal arrangement space of the lower base frame 413 is increased, and the space utilization rate is improved.
The arrangement form of the lug boss can be an integral lug boss or a plurality of split lug bosses. In the embodiment shown in fig. 8, to avoid the structural interference with the auxiliary support 421, the boss is divided into 2 symmetrical split bosses, which are divided into a boss 413a and a boss 413b, and the middle gap region is used for arranging the middle cross beam of the auxiliary support 421.
The loading cylinder block 414 is mounted on a boss of the lower base frame 413.
The loading cylinder bank 414 consists of a plurality of nitrogen springs pre-charged to a certain air pressure value according to specifications.
The nitrogen spring has a compression stroke, which allows for adaptive matching of the contact profiles and adjustment of the contact pressure between the intermediate pressure plate 412 and the loading cylinder bank 414.
In the open state, the loading cylinder bank 414 is in a disengaged state from the intermediate pressure plate 412 and the loading cylinder bank 414 is in an inactive state.
In the closed condition, the loading cylinder bank 414 is in contact with the intermediate pressure plate 412 and the loading cylinder bank 414 is in the active condition.
A pressure block and a shim plate are mounted between the intermediate pressure plate 412 and the loading cylinder bank 414, preferably in the lower bottom area of the intermediate pressure plate 412.
By adjusting the pressure block and the gasket, the contact state between each loading cylinder of the loading cylinder group 414 and the pressure plate can be changed, so that the activation state of each cylinder can be independently controlled, and different loading effects can be realized.
For a single cylinder, if it is in contact with the middle pressure plate 412, its state is active; if the cylinder is not in contact with the middle pressure plate 412, the state is inactive.
To ensure the correct relative motion between the parts of the assembly, a guide mechanism is provided between the moving parts.
A guide mechanism, preferably a guide plate guide, is disposed between the upper base frame 411 and the lower base frame 413. The guide plates are arranged at the end positions of two sides of the detection device.
A guiding mechanism is arranged between the upper base frame 411 and the middle pressure plate 412, preferably in a guiding manner of combining a guide plate and a guide column. The guide plates and guide posts are disposed at the four corners of the middle pressure plate 412.
The various components of the signal acquisition device 42 are described further below.
Fig. 9 shows a schematic structural diagram of an auxiliary support according to an embodiment of the present invention, and as shown in fig. 9, the auxiliary support 421 is designed in an "i-shaped" shape.
The auxiliary supports 421 are divided into 2 upper and lower parts, have similar structure, installation form and function, and are respectively installed on the upper base frame 411 and the lower base frame 413 for detecting the deflection deformation of the press sliding block 201 and the press table 202.
Four corners of the upper and lower auxiliary supports 421 are respectively fastened to the upper and lower base frames 411 and 413.
A static displacement sensor set 423 is arranged on the auxiliary support 421 for measuring deflection deformation at different positions, d1～d26Is the detected value of the group 423 of static displacement sensors.
A set 424 of dynamic displacement sensors is arranged between upper pedestal 411 and lower pedestal 413, preferably mounted at the end regions on both sides of lower pedestal 413, facing upper pedestal 411, for measuring the displacement of press ram 201.
A group 425 of dynamic displacement sensors II is arranged between the lower pedestal 413 and the lower air cushion top rod 203, preferably mounted on a support stand of the lower pedestal 413, towards the lower air cushion detection rod 419. The lower air cushion probe rod 419 is fixed externally to the lower base frame 413 and movable internally through the lower base frame 413 and the press table 202 to contact the lower air cushion top rod 203 and follow up and down with the lower air cushion 204. The dynamic displacement sensors II 425 are used to detect the displacement of the lower air cushion 204.
A pressure sensor set 422 is disposed between the upper pedestal 411 and the intermediate pressure plate 412, preferably mounted on the upper pedestal 411.
Fig. 10 is a stroke diagram of an intelligent detecting system for press performance according to an embodiment of the invention, and the operation of the on-line detecting terminal 400 will be described with reference to fig. 10
The intelligent detection system for the performance of the press machine provided by the invention can respectively operate according to the following two working conditions according to different measurement requirements:
working condition 1: in the initial state, the lower cushion 204 and the lower cushion top rod 203 are lifted up and have a certain stroke. During the downward movement of the press slide 201, the middle pressure plate 412 is in contact with the pre-tightening cylinder set 416, the lower cushion top rod 203 and the loading cylinder set 414 in sequence.
Working condition 2: in the initial state, the lower cushion 204 and the lower cushion top rod 203 are not lifted, and there is no stroke. During the downward movement of the press ram 201, the middle pressure plate 412 is in contact with the pre-tensioning cylinder set 416 and the loading cylinder set 414 in sequence.
And setting different detection working conditions according to different detection requirements.
For dynamic detection, working condition 1 is adopted for detection, and the dynamic characteristics of the slider pressure before the bottom of the press slider, the pressure of a lower air cushion, the movement of the slider, the movement of the lower air cushion, the parallelism between every two sliders and the like are mainly detected.
For static detection, after the slide block of the press is at the bottom, the static characteristics of the pressure of the slide block of the press, the deflection deformation of the slide block, the deflection deformation of the table top of the press and the like under the static balance condition are mainly detected by adopting the working condition 2. The actual stroke of the press slide 201 is H4, and for better measurement, the dwell time can be increased after the press slide is bottomed.
The dynamic detection and the static detection need to be carried out under different lower air cushion setting conditions, and the dynamic detection and the static detection cannot be carried out simultaneously in one detection cycle.
The operation process of the intelligent detection system for the performance of the press machine provided by the invention is described in detail in the following with reference to working condition 1.
Initial state: the stroke positions of the press sliding block 201, the pre-tightening cylinder group 416, the lower air cushion 204 and the loading cylinder group 414 are respectively H1, H2, H3 and H4, H1 is H2, H3 is H4, and the stroke position of the bottom dead center of the press sliding block 201 is defined as a zero position.
When the press slide 201 moves down to the stroke H2:
the middle pressure plate 412 is acted upon by the lower pretension cylinder bank 416 to initiate the pretensioning stroke. The gap between the middle pressure plate 412 and the pressure sensor set 422 is gradually eliminated. Before the press slide 201 reaches the stroke H3, the middle pressure plate 412 has been fully closed. The force of the pre-tensioned cylinder pack 416 is present throughout the subsequent stroke.
When the press slide 201 moves down to the stroke H3:
the top bar set 108 comes into contact with the lower air cushion top bar 203 to start the dynamic detection stroke. The dynamic displacement sensors I424 measure the displacement of the press ram 201, the dynamic displacement sensors II 425 detect the displacement of the lower air bearing 204, and the pressure sensors 422 measure the force applied to the lower air bearing 204.
When the press slide 201 moves down to the stroke H4:
the middle pressure plate 412 begins to contact the loading cylinder bank 414 and the dynamic sensing stroke ends and the static sensing stroke begins. And when the stroke of the press sliding block 201 reaches the zero position of the bottom dead center, the static detection is finished. To obtain a stable measurement result, a proper pressure holding can be performed at the bottom dead center zero position. Pressure sensor set 422 measures total pressure and static displacement sensor set 423 measures deflection deformation.
The embodiment shown in fig. 2 is used in conjunction with the punch forming system shown in fig. 1 to describe the offline processing end 500 of the intelligent detection system for press performance according to the present invention in detail.
The offline processing terminal 500 mainly receives the signal of the online detection terminal, performs calculation processing on the received signal, and visually presents the calculation result visually and vividly.
In the embodiment shown in fig. 2, the offline processing end 500 may be implemented by combining hardware and software, for example, hardware is used to perform data acquisition, and software is used to perform data processing and display, or a computer program developed by performing post-computation on the acquired data or a mobile end program such as a mobile phone may be installed in a portable communication device compatible with an Android/iOS system or a portable computer compatible with a windows operating system.
The offline processing end 500 further includes: editing module 501, monitoring module 502, computing module 503, visualization module 504, management module 505, and signal transmission module 506.
The editing module 501 is connected to the signal transmission module 506 and is configured to enter basic information of the press to be tested, test conditions, and the like.
Fig. 11 is a schematic diagram of an editing module according to an embodiment of the present invention, and as shown in fig. 11, the basic information of the editing module 501 includes: the press comprises a press number, a press brand, a press model, an installation date, an installation place, historical detection maintenance records, service life, basic technical parameters of the press, detection date, operator information, environment temperature and other basic information.
The monitoring module 502 is connected to the signal transmission module 506, and is configured to monitor whether all sensors and other electrical components of the system are working normally. Further, the monitoring module 502 is further configured to define a start point and an end point of signal acquisition.
Fig. 12 discloses a schematic diagram of a monitoring module according to an embodiment of the present invention, such as the monitoring module 502 shown in fig. 12, which operates according to the following principle: and acquiring signals of each sensor and electrical components, comparing the signals with preset values, and judging the working state of the sensor.
The calculation module 503 is connected to the signal transmission module 506 and the editing module 501, and is configured to perform calculation processing on the pressure and displacement signals collected by the sensor to obtain basic mechanical property parameters of the press.
The basic mechanical property parameters of the press comprise:
1) x-direction deflection deformation f of press slide blockxsY-direction deflection deformation f of press slide blockysX-direction deflection deformation f of press tablextY-direction deflection deformation f of press tableyt；
2) Z-direction displacement Z of press slide blocksZ-direction speed v of press slidesParallelism q between measuring points between the press slide and the press tableijLower cushion Z-direction displacement ZkLower air cushion Z-direction velocity vk；
3) Press slide forming force FsLower cushion pressure FkPressure of press table Ft。
X-direction deflection deformation f of press slide blockxsY-direction deflection deformation f of press slide blockysX-direction deflection deformation f of press tablextY-direction deflection deformation f of press tableytThe calculation formula is as follows:
fxs＝0.5(d3+d8)-0.25(d1+d5+d6+d10)；
fyt＝d13–0.5(d3+d8)；
fxt＝0.5(d16+d21)-0.25(d14+d18+d19+d23)；
fyt＝d26–0.5(d16+d21)；
wherein d is1～d26The detection values of the static displacement sensor group 423 are distributed as shown in fig. 9;
z-direction displacement Z of press slide blocksZ-direction speed v of press slidesParallelism q between measuring points between the press slide and the press tableijLower cushion Z-direction displacement ZkLower air cushion Z-direction velocity vkThe calculation formula is as follows:
zs＝0.25(z1+z2+z3+z4)；
vs＝zs′；
qij＝max(zi–zj)/(dij)；(i＝1,2,3,4；j＝1,2,3,4，i≠j)；
zk＝0.25(z5+z6+z7+z8)；
vk＝zk′；
wherein z is1～z4The detected values of the group I424 of dynamic displacement sensors; dijIs the horizontal spacing between the ith and jth; z is a radical of5～z8The detection values of group II dynamic displacement sensors 425 can be measured under the condition of working condition 1.
Slider forming force FsThe calculation formula is as follows:
Fs＝∑pi；
wherein p isiThe detection value of the ith sensor in the pressure sensor group 411 can be detected under the condition of the working condition 1.
Lower cushion pressure FkThe following can be measured under the condition of the working condition 1:
before the press slide 201 bottoms, the lower air cushion pressure FkSlide pressure FsPretightening force F provided by suspension mechanismpreThe weight G of the pressure plate is in balance, and the pressure F of the lower air cushionkThe calculation formula is as follows: fk＝Fs+G-Fpre。
Wherein the press ram pressure FsForming force and pre-tightening force F for slide blockprePreset control may be provided by the pre-tensioned cylinder bank 416.
Pressure F of press tabletThe following can be measured under the condition of the working condition 2:
after the slide block is bottomed, the pressure F of the press table surfacetWith pressure F of the slidesEquilibrium, i.e. Ft＝Fs。
The visualization module 504 is connected to the signal transmission module 506 and the calculation module 503, and performs visualization presentation on the detection calculation result in a chart form.
Fig. 13 discloses a schematic diagram of a visualization module according to an embodiment of the invention, such as the visualization module 504 shown in fig. 13, comprising: and forming a chart form for the detection calculation result, such as a deflection deformation cloud chart, a displacement curve, a speed curve, a forming force curve, a parallelism cloud chart, a pressure distribution chart and the like, and comparing, analyzing and evaluating different detection results.
The management module 505 is connected to the signal transmission module 506 and the calculation module 503, and manages the measurement data obtained by detection and calculation.
Fig. 14 is a schematic diagram of a management module according to an embodiment of the present invention, and the management module 505 shown in fig. 14 performs functions of file saving, file reading, data export, format conversion, system shutdown, preference setting, cloud data upload, and the like on measurement data.
The offline processing end is equipped with a signal transmission module 506, which can transmit signals to the online detection end 400 in a wireless/wired transmission manner.
Aiming at the problems of incomplete function, low measurement efficiency and insufficient measurement precision of the current press performance measurement device, the invention provides a special press performance intelligent detection system, which can realize comprehensive, accurate and efficient measurement of multiple performances of a press, provides important basis for installation, debugging, matching, maintenance and fast die moving of a press and realizes comprehensive measurement of multiple press performances by one set of equipment.
The intelligent detection system for the performance of the press machine, provided by the invention, has the following beneficial effects:
1) the suspended pressure plate structure is provided, so that the uncontrollable interference of the restraining force of the traditional fastening structure is eliminated, and the measurement accuracy is improved;
2) an intelligent signal processing subsystem is constructed, automatic calculation and visual processing are carried out on the measured data, and the measuring efficiency and the intuitiveness of the measuring result are improved.
While, for purposes of simplicity of explanation, the methodologies are shown and described as a series of acts, it is to be understood and appreciated that the methodologies are not limited by the order of acts, as some acts may, in accordance with one or more embodiments, occur in different orders and/or concurrently with other acts from that shown and described herein or not shown and described herein, as would be understood by one skilled in the art.
As used in this application and the appended claims, the terms "a," "an," "the," and/or "the" are not intended to be inclusive in the singular, but rather are intended to be inclusive in the plural unless the context clearly dictates otherwise. In general, the terms "comprises" and "comprising" merely indicate that steps and elements are included which are explicitly identified, that the steps and elements do not form an exclusive list, and that a method or apparatus may include other steps or elements.
The embodiments described above are provided to enable persons skilled in the art to make or use the invention and that modifications or variations can be made to the embodiments described above by persons skilled in the art without departing from the inventive concept of the present invention, so that the scope of protection of the present invention is not limited by the embodiments described above but should be accorded the widest scope consistent with the innovative features set forth in the claims.
Claims (13)
1. The utility model provides a press performance intellectual detection system which characterized in that, includes online detection end and off-line processing end:
the off-line processing terminal receives the signal of the on-line detection terminal, calculates the signal and visually presents the calculation result;
the online detection end comprises a loading device, a signal acquisition device and a signal transmission device, wherein the loading device applies a working load to the press, the signal acquisition device acquires pressure and displacement signals in the working process, and the signal transmission device transmits the acquired signals to the offline processing end;
the signal acquisition device comprises an auxiliary support, a pressure sensor group, a static displacement sensor group and a dynamic displacement sensor group;
the loading device comprises an upper base frame, a middle pressure plate, a lower base frame, an auxiliary component and a loading cylinder group;
the upper base frame is arranged on the press sliding block and moves along the stamping direction along with the press sliding block;
the middle pressure plate is a suspension pressure plate and has a wall plate structure with an upper layer and a lower layer, the upper layer space is used for accommodating the pressure sensor group, and the lower layer space is used for accommodating the loading cylinder group and the lower base frame;
the lower base frame is arranged on the table surface of the pressing machine;
the auxiliary component comprises a pre-tightening cylinder group and a suspension mechanism;
in the opening state, the middle pressure plate is suspended on the suspension mechanism of the upper base frame and separated from the pressure sensor group;
under the closing state, the middle pressure plate is separated from the suspension mechanism, is supported by the lower pre-tightening cylinder group, is pressed together with the upper base frame and the pressure sensor group under the action of pre-tightening force, and moves along the stamping direction along with the press sliding block.
2. The intelligent detection system for the performance of the press machine according to claim 1, characterized in that: and the bottom of the middle pressure plate is provided with a top bar group, and the top bar group is contacted with the bottom air cushion top bar and transmits the contact force to the pressure sensor group in the operation process of the press sliding block.
3. The intelligent detection system for the performance of the press machine according to claim 1, characterized in that: and a boss structure is arranged in the middle area of the lower base frame, and the loading cylinder group is arranged on the boss structure.
4. The intelligent detection system for the performance of the press machine according to claim 1, characterized in that: the loading cylinder group consists of a plurality of nitrogen springs, a certain air pressure value is pre-charged according to specifications, and the nitrogen springs have compression strokes, so that the self-adaptive matching of various contact profiles between the middle pressure plate and the loading cylinder group and the adjustment of contact pressure are realized.
5. The intelligent detection system for the performance of the press machine according to claim 1, characterized in that: and a pressure block and an adjusting gasket are arranged between the middle pressure plate and the loading cylinder group, and the contact state between each loading cylinder of the loading cylinder group and the middle pressure plate is changed by adjusting the pressure block and the gasket.
6. The intelligent detection system for the performance of the press machine according to claim 1, characterized in that:
a guide mechanism is arranged between the upper base frame and the lower base frame and adopts a guide plate for guiding;
a guide mechanism is arranged between the upper base frame and the middle pressure plate, and the guide mechanism is guided by combining a guide plate and a guide pillar.
7. The intelligent detection system for the performance of the press machine according to claim 1, characterized in that: the auxiliary support is I-shaped, is divided into an upper part and a lower part, is respectively arranged on the upper part base frame and the lower part base frame and is used for installing a static displacement sensor group and detecting the deflection deformation of the press sliding block and the press table board.
8. The intelligent detection system for the performance of the press machine according to claim 1, characterized in that:
the pressure sensor group is arranged between the upper base frame and the middle pressure plate and is used for measuring the pressure of the press slide block;
the static displacement sensor group is arranged on the auxiliary bracket and used for measuring deflection deformation at different positions;
the dynamic displacement sensor group comprises a dynamic displacement sensor I group and a dynamic displacement sensor II group, the dynamic displacement sensor I group is arranged between the upper base frame and the lower base frame and used for measuring the displacement of the press sliding block, and the dynamic displacement sensor II group is arranged between the lower base frame and the lower air cushion ejector rod and used for measuring the displacement of the lower air cushion.
9. The system for intelligently detecting the performance of the press machine according to claim 8, wherein:
in the first working condition, the lower air cushion and the lower air cushion ejector rod are lifted in the initial state and have a certain stroke, and in the process that a press sliding block moves downwards, the middle pressure plate is sequentially contacted with the pre-tightening cylinder group, the lower air cushion ejector rod and the loading cylinder group, so that the dynamic characteristic of the press is detected.
10. The system for intelligently detecting the performance of the press machine according to claim 9, wherein: the dynamic characteristics comprise the pressure of a slide block before the slide block of the press is bottomed, the pressure of a lower air cushion, the motion of the slide block, the motion of the lower air cushion and the parallelism between every two slide blocks;
z-direction displacement Z of press slide blocksZ-direction speed v of press slidesParallelism q between measuring points between the press slide and the press tableijLower cushion Z-direction displacement ZkLower air cushion Z-direction velocity vkThe calculation formula is as follows:
zs＝0.25(z1+z2+z3+z4)；
vs＝zs'；
qij＝max(zi–zj)/(dij)；(i＝1,2,3,4；j＝1,2,3,4，i≠j)；
zk＝0.25(z5+z6+z7+z8)；
vk＝zk'；
wherein z is1～z4The detection values of the group I of the dynamic displacement sensors are obtained; dijIs the horizontal spacing between the ith and jth; z is a radical of5～z8The detection value of the dynamic displacement sensor II group is obtained;
press ram pressure Fs＝∑pi，piThe detected value of the ith sensor in the pressure sensor group is obtained;
lower cushion pressure FkThe calculation formula is as follows: fk＝Fs+G-Fpre，FsFor press ram pressure, FpreThe pre-tightening force is provided for the suspension mechanism, and G is the weight of the pressure plate.
11. The system for intelligently detecting the performance of the press machine according to claim 8, wherein:
in the second working condition, the lower air cushion and the lower air cushion ejector rod are not lifted up in the initial state and have no stroke, and the middle pressure plate is sequentially contacted with the pre-tightening cylinder group and the loading cylinder group in the downward moving process of the press slide block to detect the static characteristic of the press.
12. The system of claim 11, wherein the static characteristics include press ram pressure after press ram bottoming, deflection deformation of the ram, press table deflection deformation:
press ram pressure Fs＝∑pi，piThe detected value of the ith sensor in the pressure sensor group is obtained;
x-direction deflection deformation f of press slide blockxsY-direction deflection deformation f of press slide blockysX-direction deflection deformation f of press tablextY-direction deflection deformation f of press tableytThe calculation formula is as follows:
fxs＝0.5(d3+d8)-0.25(d1+d5+d6+d10)；
fyt＝d13–0.5(d3+d8)；
fxt＝0.5(d16+d21)-0.25(d14+d18+d19+d23)；
fyt＝d26–0.5(d16+d21)；
wherein d is1～d26The detection value of the static displacement sensor group is obtained;
after the slide block is bottomed, the pressure F of the press table surfacetWith pressure F of the slidesEquilibrium, i.e. Ft＝Fs。
13. The intelligent detection system for the performance of the press machine according to claim 1, wherein the offline processing end comprises an editing module, a monitoring module, a calculating module, a visualization module, a management module and a signal transmission module:
the editing module is connected with the signal transmission module and is used for inputting basic information of the press to be tested and the test working condition;
the monitoring module is connected with the signal transmission module and is used for monitoring whether the corresponding sensor and the corresponding electric element work normally or not;
the calculation module is connected with the signal transmission module and the editing module and is used for calculating and processing the pressure and displacement signals acquired by the sensor to obtain basic mechanical performance parameters of the press;
the visualization module is connected with the signal transmission module and the calculation module and used for visually presenting the detection calculation result in a chart form;
the management module is connected with the signal transmission module and the calculation module and is used for managing the measurement data of detection calculation;
and the signal transmission module is connected with the online detection end and is used for carrying out data transmission and signal communication.
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| CN117753819B (en) * | 2023-12-29 | 2024-06-21 | 利维智能（深圳）有限公司 | Automobile hardware stamping die nitrogen spring air pressure monitoring system |
| CN118417397B (en) * | 2024-04-18 | 2024-10-01 | 佳仕德精密五金(广东)有限公司 | Intelligent automatic stamping process |
| CN118492188B (en) * | 2024-07-18 | 2024-10-11 | 贵州贵铝新材料股份有限公司 | Integrated unmanned aluminum foil processing and forming system based on module combination |
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