According to the process layout, what does the stamping automation system usually contain?

First, the significance of realizing stamping automation

Although the investment of traditional manual production line is relatively small at the initial stage of construction, with the expansion of market demand, its inherent shortcomings such as low efficiency and poor product quality stability are increasingly affecting the development of enterprises. Automated production lines can just solve these problems. The advantages of automatic stamping production line are higher production efficiency, stable product quality and lower production cost under the condition of mass production, which is especially suitable for the production of large body panels. Therefore, at present, the main engine factory will directly consider adopting automation in the early planning stage of large-scale stamping production line.

Second, the composition of automatic stamping line

As far as equipment composition is concerned, automatic stamping line generally includes press and automation system. The automation part is mainly discussed here. Stamping automation system usually includes destacking system, automatic transmission system and tail discharge system.

1. Stacking system

A complete set of stamping automatic unstacking system mainly includes two rail mobile feeding trolleys (each feeding trolley is equipped with 4-8 movable adjustable magnetic separators, usually permanent magnets, for separating plates), unstacking hands (manipulators or robots), conveying devices (mostly magnetic belt conveyors), plate cleaning machines (optional), plate oiler (optional), plate centering table and control system.

After the loading truck loads the stack (including pallet) from the stack changing position to the stack disassembling position, the plate is picked up from the stack by the stack disassembling hand and sent to the centering table through the cleaning machine and oiler through the conveying device. After centering and positioning, the subsequent stamping production can be started.

2. Automatic transmission system

Automatic conveying system is used to transport and convey blanks or workpieces between processes. There are two main transmission mechanisms: manipulator and robot.

With the continuous progress of stamping automation technology, the form of automatic transmission mechanism of manipulator is also changing with each passing day. The form difference of automatic transmission mechanism is also the main difference of different forms of automatic stamping line at present. The parallelogram manipulator structure widely used at the end of last century has been gradually eliminated and replaced by a high-speed, stable single-arm or double-arm cross-bar transmission mechanism. Robobeam of gudel, Switzerland, speedbar of former mw in Germany and h*tl system of Komatsu, Japan are all typical representatives of high-speed stamping automatic line drive mechanism.

In addition, the robot transmission mode is unique because of its own characteristics, and it still has certain application space in the transformation of old lines and production lines with low speed and low investment.

3. Tail discharge system

The tail discharge system consists of discharge conveyor belt, lighting, workpiece inspection table, manual or automatic packaging mechanism and control system. The main task is to transport the finished stamping parts to a suitable position, which is convenient for packaging (or automatic packaging) and provides conditions for stamping parts inspection.

Free consultation: 18924022066

Three, the main forms of automatic stamping line

At present, the forms of automatic stamping line mainly include the following:

1. The form of "common press+robot transmission"

The robot has flexible transmission form, convenient use and low cost, but its stability is poor and its speed is relatively slow, so it is not suitable for mass high-speed production.

2. Transmission form of "common press+single arm manipulator"

The transmission form of single-arm manipulator still has some room for development because of its relatively low cost and flexibility.

3. "High-speed press+cross bar" transmission form (high-speed line)

Crossbar transmission has the characteristics of high speed and high stability, and has been widely used in the production of large panels.

4. Transmission form of "multi-station press+stepping"

The station production line has a history of many years. The transmission mode has developed from the initial mechanical transmission to today's electronic control transmission, and the overall structure has also developed from single slider to the coexistence of single slider and multiple sliders. Because of its high speed and good stability, it is widely used by various main engine plants. In particular, the characteristics of multi-slider and multi-station are basically close to high-speed lines.

Four, the planning and selection principles of stamping production line

What scale production line you choose depends on what kind of stamping parts you need to produce. For super-large stamping parts accounting for 10% of the car body, stamping lines with gross tonnage above t are generally used; About 25% of large and medium-sized stamping parts adopt T-shaped stamping line; About 25% of medium-sized stamping parts adopt T-shaped stamping line; The remaining 40% of small and medium-sized parts basically use production lines below T.

As for the form of stamping line, it depends on the type and output of stamping parts to be produced. Ordinary manual lines are usually used in small batches with few varieties, while high-speed automatic stamping lines are suitable for large batches with many varieties. Figure 4 shows the reference principle of stamping line selection.

Verb (abbreviation of verb) capacity accounting of automatic stamping line

Capacity accounting is one of the most critical links in automatic stamping line planning, and the result of capacity accounting directly determines the input quantity of production line and investment.

According to the product line selection results, combined with the production organization level, and referring to the previous and peer experience, we can get the common production beat (spm), the comprehensive failure rate (the ratio of off-line time caused by equipment and tooling failure to production organization) and the single mold changing time. In addition, according to the actual situation of factory production management, we can know the standard batch (the number of pieces produced in each batch), daily working hours, daily meal off-line time and annual working days.

As long as the annual production capacity is known, combined with the given production procedures and stamping parts types, the number of required production lines can be easily calculated.

Six, the main factors that should be considered in planning automatic stamping line

The planning of automatic stamping production line is a complicated process. In addition to the above capacity calculation, there are many factors to consider.

1. Do you use synchronization technology?

The application of synchronization technology in the field of stamping automation has been widely recognized, which is of great significance to improve the production rhythm.

In the traditional automatic stamping production process, the press has always adopted a "one-off" operation mode. The punching hand (punching manipulator/robot) does not start to move until the press completes the whole stamping cycle and the slider returns to the top dead center, while the feeding hand (feeding manipulator/robot) does not start until the punching hand exits the working area of the press, and the slider of the press does not start to descend until the blanking hand completely exits the working area of the press, so each cycle period is long, which directly affects the production rhythm of the whole line.

Synchronous technology means that in the production process, the press adopts "continuous" operation mode, and through accurate calculation, the loading and unloading are started synchronously with the press slider. The unloader starts to pick up the parts after the slider rises to a certain angle (before returning to the top dead center), and the loader completes the conveying before the slider descends to a certain angle, thus completing the conveying action without interference in the whole process. At the same time, in order to ensure that the blanking hand has enough time to send the workpiece to the next process after picking it up, a reasonable phase difference is always maintained during the movement of the sliders of two adjacent presses, which can relatively extend the working cycle of the blanking hand.

Especially for the stamping production of large-scale panels, the automatic wire feeding synchronization technology of high-speed stamping has more obvious advantages than other methods including single slider multi-station

2. Key parameters of slide stroke of press.

There are many press parameters that need to be considered in production line planning, among which the slider stroke directly affects the feasibility and difficulty of automation, which should be paid attention to in planning.

The selection of slider stroke is directly related to the drawing depth of stamping parts to be produced and the height of end picker. The stroke of the slider determined during planning must ensure that the end pickup keeps enough safe space with the upper die point and the lower die point during the horizontal movement of the workpiece grasped by the loading and unloading device.

Because the drawing depth of large-scale covering parts mostly exceeds 200mm, the slide stroke of large-scale high-speed stamping automatic line is generally above mm.

3. Structure and shape of mold and end picker

In order to obtain a more reasonable interference curve, in addition to the inherent parameters or characteristics of the press, such as slider stroke and speed-acceleration curve, the structural shapes of the die and the end pickup should also be considered. Reasonable die and end pick-up structure can effectively make up for the shortage of automation, thus improving the feasibility of automatic stamping production.

In addition, the mold design should also consider the following contents: (1) the difference of mold closing height in the same production line should not be too large (consistent); As far as possible, the lower die is equipped with sensors so that the parts are in place; The position of the mold installation groove should be unified as much as possible (the number of automatic fixtures can be reduced and the cost can be reduced); Waste can be discharged from the workbench smoothly (some parts with difficult discharge positions are equipped with washing devices); The molding die is equipped with parts ejection device (such as ejector pin or ejector cylinder) and avoids large wedge mechanism, and uses rotating wedge as much as possible.

4. Requirements for steel plate piles

Compared with manual production line, automatic stamping production has stricter requirements on the uniformity of steel slab stacking. If the stacking is not neat enough, it will cause problems such as poor magnetic separation effect (easy to produce double material phenomenon) and inaccurate position of the sheets grabbed by the stacker. Therefore, before the automatic production line is put into production, in order to ensure the production efficiency to reach the target value, it is necessary to clarify the requirements for steel plate stacking.

5. Process layout requirements of stamping parts

(1) The corresponding relationship between the feeding center and the production line center of the same mold is as consistent as possible;

(2) Minimize the rotation of parts during transmission, especially in high-speed stamping line and multi-station to avoid the rotation of parts around Z axis;

(3) In the same production process, the height of the feeding surface should be as consistent as possible (which can effectively reduce the beating loss).

6. Production management requirements

(1) Do off-line maintenance of molds in time to reduce on-line maintenance time;

(2) The mold clamping heights of adjacent production batches are similar (the adjustment time of mold filling height can be shortened);

(3) the blank and the mold are prepared before the production batch is switched;

(4) Transfer finished products in time;

(5) Keep the environment clean;

(6) Standardization of equipment operation and maintenance.

Stamping robot palletizing robot welding robot