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Technical CommunicationPart1 automatic manipulator
A manipulator is an automatic operation device that can imitate some of the action functions of the human arm, and grasp and carry objects or operate tools in a fixed program.
The feature is that it can be programmed to complete a variety of expected operations, and the structure and performance have the advantages of both human and robotic machines.
1.1 Common equipment brands
1.2 Robot function
1.3 Composition of the manipulator
The crankshaft manipulator needs to realize the movement in three directions including the horizontal axis, the vertical axis and the rotating axis.
The vertical axis Z axis, the main function is to realize the loading and unloading of crankshaft parts.
The horizontal axis X axis is to realize the transfer of crankshaft parts between different equipment or processes.
The C-axis of the rotation axis is to take into account the different postures of the crankshaft in different stations, and the manipulator needs to rotate the workpiece according to the requirements of the station.
During the debugging process of the manipulator, in addition to cooperating with the parts of the machine tool (loading door, fixture, etc.) in terms of timing control, it is also necessary to increase the hard limit and anti-collision mechanism according to the movement stroke.
1.4 Expand the application of air blow cleaning
In the latest manipulator application, the air blowing function has been added: during transportation, cleaning the positions where the workpiece is prone to chip accumulation can not only clean up those positions (such as the center hole) that will be blocked after the parts are loaded, but also save money. Processing time.
Deburring applied
With the continuous improvement of the cleanliness requirements of powertrain products, a deburring process has been added to the machining process of crankshaft parts.
The realization of this function is usually that after the manipulator grabs the part, it contacts with the fixed position brush to complete the deburring function.
Common crankshaft locations that require burr cleaning are:
Joint surface class:
Keyway ①, pad surface ② (affects the phase accuracy of crankshaft rotation during processing), oil hole ③, outer circle of balance block + balance hole ④, the exit of the threaded hole of the signal plate ⑤.
Positioning base class:
Axial (two center holes) and angular (drive hole).
Part 2Machining Center
2.1 Common equipment brands
In crankshaft machining, use a machining center to machine both ends of the crankshaft (mandrel end and flange end).
Common machining center brands are ETXE-TAR and NTC.
2.2 Common tool types
Face mills, drills, reamers, taps, and hole feature deburring tools are commonly found in crankshaft machining centers.
It is worth mentioning that, in order to ensure the automatic processing requirements, the machining center needs to enable the tool breakage detection function.
Generally, the tool breakage detection function is for drills, reamers, taps, etc. with a diameter of <12mm, and tools with high risk of tool breakage.
2.3 Common tool holder types
There are 6 types of HSK high-speed tool holders according to the German standard, as shown in the following figure:
Adopt the double positioning method of tapered surface and end surface, A, C, E are common tool holders. And generally used in machining centers (with automatic tool change function) are A type, E type and F type.
Tool holder features, as shown in the following figure:
2.4 Processing content Crankshaft mandrel end/flange end
Processing content: milling both end faces and flange faces, drilling center holes, milling mandrels and flanges, milling PAD faces
Positioning reference: Axial: #1#8 balance weight; Angular: P1&P3; Radial: M1&M5.
The clamping and positioning method is shown in the following figure:
Tools used and their machining process:
Machining process: milling both end faces & flange faces → sleeve milling mandrel → drilling center holes at both ends → sleeve milling flange end → milling PAD face.
Crankshaft oil passage hole
Processing content: drilling straight oil holes, inclined oil holes and oil hole chamfering.
Positioning reference: front and rear center hole + PIN1
The clamping and positioning method is shown in the following figure:
Tools used and their machining processes:
Processing flow: pre-drilling oil holes → drilling through the oil holes → chamfering the oil holes → deburring the cross holes.
Center hole
Processing content: center hole processing at both ends
Positioning reference: Axial: Probe; Angular: P1; Radial: M1&M5.
The clamping and positioning method is shown in the following figure:
Processing flow: drilling the center hole of the mandrel → expanding the center hole of the mandrel → tapping the center hole of the mandrel → drilling the center hole of the flange → expanding the center hole of the flange → reaming the center hole of the flange
keyway etc.
Processing content: keyway, threaded hole of letter plate, threaded hole of flange, process
Positioning reference: Axial: Probe; Angular: P1; Radial: M1&M5.
The clamping and positioning method is shown in the following figure:
Machining process: milling keyway→sender threaded hole drilling+tapping→drilling process hole→flange threaded hole drilling+deburring→flange threaded hole tapping