An intelligent processing production line integrating robots and CNC numerical control equipment

With the continuous growth of national income and GDP, as well as the rapid development of urbanization; residents’ demand for household appliances is increasing; coupled with fierce market competition, companies continue to develop new processes, new technologies, and new products to upgrade. Promote the development of home appliance products to the trend of mass, specialization, continuity, and automation; however, there are many problems in the manufacture of parts and components of home appliance enterprises: there are many types, but the differences are small, the production plan needs to be careful; the single order batch is large , The delivery time is short, and the manufacturing assembly line has strict requirements on the timeliness and matching of parts and materials supply, and has strong real-time; high precision of parts and components, high requirements for one-time pass rate, compatible interchangeability, and assurance of assembly quality consistency ; The production of hardware parts is continuous, the batch is large and the pace is fast, the per capita productivity is high, and the dependence on the labor force is strong;

In view of the above-mentioned problems, the development of the home appliance manufacturing industry will require the use of electronic technology to transform the production methods of the enterprise, the application of manipulators, automation equipment and flexible production systems, to further improve the automation level and adaptability of the enterprise, and to change products in a short time Varieties, multiple products can also be produced on the same production line at the same time. Therefore, the development of a flexible manufacturing line integrating robots and CNC equipment is an inevitable trend to solve the current problems of the enterprise and promote the transformation and upgrading of the manufacturing industry.

This case takes the processing and assembly plane, drilling, tapping, and testing production technology of hardware parts of small household appliances as examples. The manual flow operation before the transformation and the robot flexible processing production after the upgrade are compared and analyzed;

 

 

 

 

 

 

Comparative analysis of manual production and integrated robot system production

A

Gap in production efficiency

In manual production operations, each worker can only be responsible for the production of one CNC equipment; when the CNC processing is completed, the manual has to complete the disassembly of the finished hardware processing parts in the CNC machine tool and the installation of the unfinished products back to the fixture for fixed positioning. At the same time, frequent and long-time manual work is easy to work in the machine. As a result, it takes up too much CNC equipment production time, which affects production efficiency and productivity.

B

Production cost and quality gap

In the process of manual production, it is necessary to periodically check the product size tolerance, and operate the CNC equipment to adjust the cutting compensation amount of the tool, the cutting fluid concentration and other inspections. It is often due to human reasons that the product is unqualified and the production cost is increased. , Including waste of raw materials. At the same time, there are too many factors that can affect the work efficiency of workers and the quality judgment standard; and the application of intelligent detection equipment can automatically detect the dimensional tolerance of the parts, and automatically adjust the tool compensation amount, and the detection and judgment standards are consistent to ensure the quality of product processing;

C

Disadvantages in labor costs

In manual production operations, each worker can only be responsible for the production of one CNC equipment, and technology and experience are important factors that determine the quality of the product; and an integrated robot can handle three CNC processing equipment at the same time for one or more A variety of products are produced and can be operated continuously for 24 hours; the whole set of equipment needs to be equipped with 4 workers/shift from manual production to only 1 worker for centralized product collection after automatic transformation;

Secondly, in order to retain these skilled workers, companies have to invest more in labor costs. If these skilled workers are lost, they will have to retrain new personnel. On the contrary, the movement process of integrated robot automated production is repeated cyclic work, so the quality of the products produced is guaranteed, product data can be collected and traced, product stability is strong, and one-time investment, long-term return, saves a lot of labor costs.

Therefore, it is necessary to design an intelligent processing production line that integrates robots and CNC equipment based on the production characteristics of household electrical appliance enterprises.

 

 

 

 

Robot integrated application solution

A

Overall layout of production line

This equipment is an intelligent processing production line integrating robots and CNC equipment. The entire production line is composed of GSK-RB15 robot system, CNC numerical control processing system, detection and identification system, cleaning system, double-speed chain conveyor system, and GSK manufacturing execution system; and According to the different production needs of users, flexible mixed production of one or more products can be carried out at the same time; products with different processes and models can be quickly and flexibly converted to produce, improve production efficiency and ensure product quality.

 

 

B

GSK-RB15 robot + manipulator fixture

The system adopts the GSK-RB15L robot, which has high repeat positioning accuracy, fast speed, flexible control and large service radius; suitable for this system to handle the continuous production of 3 CNC numerical control equipment for loading and unloading and positioning of pallets;

Aiming at the complexity of the application conditions and the specific application environment. The manipulator clamp is designed with a self-positioning side pin clamping method; Design advantages: a. Breaking the traditional laborious grasping mechanism that is clamped by external friction force, only need to design 2 ACQ20 small cylinders to grasp a pallet with a load of 10kg Workpiece, avoiding the friction coefficient of the pallet surface and reducing the clamping force factor due to the influence of cutting fluid, etc., truly achieve four or two shifts; b. The side positioning pin is clamped, and the robot grasps the pallet space movement and placement to perform the XYZ axial secondary precise positioning; c. The design of the entire fixture is simple and compact, which reduces the robot's selection and operating load; d. It has the function of self-protection of gas and power failure to prevent accidental gas failure and power failure during the operation of the robot.

C

Pallet double-speed chain conveyor system

The dedicated pallet automatic circulation chain adopts double-speed chain conveying design, which is easy to realize accumulation and transportation, and can be used for parts assembly and storage, positioning and transportation of pallet materials;

Designed with 1 pallet recycling line, 1 parts assembly line, 1 pallet automatic circulation line and 3 pallet queuing output positioning lines; it can meet 1-3 kinds of pallets loaded with different parts at the same time queuing, conveying and sorting, ensuring that the robot is capable of CNC Material supply of machine tools;

The system implants RFID non-contact automatic identification function for each pallet, which can quickly identify different pallets and send data to the GSK general control system. The system conveys, queues, sorts and distributes the pallets to the designated CNC numerical control equipment for loading and processing. Processing parts can be detected, measured, data statistics and other information output online in real time;

D

Cleaning system

After the pallet is processed from the CNC equipment, a large amount of cutting fluid and chips will remain. The cutting fluid must be left in the machine tool for recycling and recycling, and the cutting chips are processed in a centralized and clear manner to ensure that the conveyor line parts are cleaned and recycled;

In the CNC machine tool, a high-pressure air gun is designed on the manipulator fixture, which uses the space operability of the robot to set the motion trajectory to clean the processed pallet parts in all directions;

Before the pallet enters the double-speed chain conveying system for recycling, the pallet is cleaned and dried by moving up and down high-pressure air guns, and the residual cutting fluid and chips are sucked by low vacuum and negative pressure;

E

Inspection and measurement system

After the pallet is cleaned, it automatically recognizes the workpiece model through RFID, enters the inspection system, and uses laser to measure related processing data;

The detection data is communicated with the system to determine whether the processing size of the parts is qualified, and the data can be collected for traceability;

Analyze the detection data system and adjust the compensation amount of CNC machine tools;

F

CNC machining system and machine tool fixture

Integrating modern Yawei 400T CNC processing equipment, it has the characteristics of flexible processing, strong versatility, high precision, high production efficiency and high performance; it is especially suitable for the processing and production of small parts in the 3C home appliance industry consumer electronics shells and hardware parts.

It has the function of automatic tool exchange. By installing tools for different purposes in the tool magazine, the machining tools on the spindle can be changed by the automatic tool changer in one clamping, so as to achieve multiple channels such as drilling, boring, reaming, tapping, and grooving. Process processing function.

It can realize three-axis linkage control to ensure that the tool can process complex surfaces. In addition to linear interpolation and circular interpolation, the machining center also has various machining canned cycles, automatic tool radius compensation, automatic tool length compensation, processing graphics display, man-machine dialogue, automatic fault diagnosis, offline programming, etc. .

The professional pallet processing fixture of the machine tool uses hydraulic clamping and positioning pin positioning; it has strong clamping rigidity, accurate repeat positioning and reliable versatility.

G

GSK Manufacturing Execution System

The GSK intelligent manufacturing execution system has functions such as networked monitoring, control, and data collection. GSK-LING bus can be used to realize the high-speed connection of CNC machine tools, robot systems, pallet conveying systems, inspection and measurement systems and production auxiliary equipment to realize intelligent monitoring and management;

Processing task creation, processing task management, processing program management and upload;

Online detection, real-time display and tool compensation correction, as well as machine start and stop, initialization and management;

Equipped with intelligent kanban function: real-time monitoring of production equipment, production information and machine tool tool monitoring and other functional applications;

 

 

 

 

Robot and CNC equipment integrated intelligent machining process

 

 

 

 

 

 

 

Robot integrated application implementation effect

Adopt compatible flexible manipulator design, and solve the problem of multi-model and small-batch production on the same production line with less manufacturing cost;

Robots replace manual operations, realizing that one pair of three CNC numerically controlled machine tools can operate continuously for 24 hours and complete tasks stably;

The robot system is closely coordinated with CNC milling machines, inspection and measurement systems, and double-speed chain conveyors through the GSK manufacturing execution system to work stably, maximize production efficiency, and reduce production and operating costs.

CNC machining time averages 2 minutes/piece, manual production capacity: 300 pieces/hour; Production line integrated robot loading and unloading transformation production capacity: 350 pieces/hour, improving production efficiency by 16%;

 

 

 

 

 

 

 

 in conclusion 

Through actual application case demonstration, it is an inevitable trend to use robot-integrated CNC numerical control processing equipment to replace manual production in the production of parts and components in the home appliance industry. With the development of technology, the technology of robots has gradually matured, and its stability, reliability, work efficiency The machining accuracy has been greatly improved. At the same time, the scope of integrated applications is becoming wider and wider, and the popularity of technology has gradually reduced prices and costs. More and more manufacturers have begun to use robots for production. It will also promote the development of home appliance products to the trend of mass, professional, continuous and intelligent production.