The overall construction of the robotic bolting system This new assembly line was built primarily for the assembly of two series of 14 models of engines. The assembly structure of the 14 models of the engine assembled for the assembly line, in which the different models of the engine have the same general structure, and only some differences in some places, so decided to use the same assembly line to reduce costs and improve equipment utilization.
During assembly of the entire engine, the crankshaft, clutch platen, bearing cap and oil sump are assembled with multiple bolts to be tightened. When designing the bolt tightening system, it is considered that the bolts of the crankshaft and the clutch platen are on the side of the workpiece (engine), and the bolts of the bearing cap and the oil pan are on the top of the workpiece, so the crankshaft, the clutch platen, The bolting of the bearing cap and the oil pan is completed in four different stations, so that it is not necessary to flip the workpiece during the assembly process, avoiding the errors that may occur in turning the workpiece and the difficulty in fixing the fixture of the workpiece. After comprehensive consideration of various factors such as system cost, production cycle and workpiece structure, it is more reasonable to complete the bolt tightening of the crankshaft, clutch platen, bearing cap and oil pan by different stations.
Engine assembly structure diagram In the entire bolt tightening system, a tooling plate for fixing the workpiece is designed by using the matching hole at the bottom of the workpiece to ensure that the workpiece is always in a stable vertical position during the bolt tightening process. A certain auxiliary device is added to the tooling plate to match the working requirements of the conveyor belt, positioning device and other equipment. When the system is working, the workpiece fixed on the tooling plate is transported between the various stations by the conveyor belt, and the positioning device completes the positioning of the workpiece after the position is completed, and the robot completes the bolt tightening work.
The structure and working principle of the robot bolt tightening system work station Because the system is mainly to complete the tightening work of the bolt, so after considering a series of related factors such as the production cycle, bolt size, bolt position and robot installation position, according to the performance, For the convenience of maintenance and the principle of moderate price, use the ENRCZ series of bolts from ESTIC to tighten the robot to bear All the bolt tightening work in this system.
Before the engine is assembled, the crankshaft, bearing cap and other components have been assembled in place. The system only needs to complete the tightening work of the bolts that have not been tightened on the workpiece, thus dividing into 5 stations, assembly of each station. The process is as follows: (1) The purpose of station 1 is to complete the crank bolt tightening work. The position of the bolt of the crankshaft is on the side of the workpiece. The number of bolts is relatively small and the spacing is relatively small. In the current two series of engines, the positions of the bolts are the same. Therefore, the three bolt tightening robots are fixedly mounted on a bottom plate. If it is necessary to change the position of the robot due to the modification, it is only necessary to change the fixed position of the robot on the bottom plate.
After passing through the previous assembly process, the workpiece flows into the station 1 by the conveyor belt. When the workpiece is in position, the cylinder on the station 1 lifts the tooling plate together with the workpiece from the conveyor belt to the assembly position, and then the side cylinders push the robot to the working position for bolting. Tighten the work, after the completion of the cylinder reduction, the workpiece out of the station 1.
(2) The purpose of station 2 is to complete the clutch platen bolt tightening work. For the distribution diagram of the clutch platen bolt, the clutch platen bolt robot is tightened. The clutch platen bolt is positioned on the other side of the workpiece, as shown by the bolts being divided into inner and outer rings. Therefore, the mechanism as shown is designed. The two rings of the size and the six links connecting the two rings constitute the mechanism, and the six bolt tightening robots are mounted on the connecting rod, and pushing one of the rings allows the robot to be arranged. By making the circumferences with different radii, different distances can be obtained to obtain the circumferences of different radii, so that the clutch platen bolt tightening work of different types of engines can be completed. Clutch pressure plate bolt distribution diagram After the workpiece flows into the station 2, it is lifted to the assembly position by the cylinder top. Then the robot completes the bolt tightening work in two steps. After the completion of the cylinder reduction, the workpiece exits the station.
(3) The purpose of station 3 is to complete the tightening of the bearing cap bolts. The position of the cover bolt is at the top of the workpiece, and the bolt of the crankshaft is also relatively small, the spacing is relatively small, and the position is relatively fixed. Therefore, the required 8 bolt tightening robots are fixedly mounted on a bottom plate, and the bottom plate is suspended at the upper portion of the station. You only need to change the installation position of the robot when you change it.
After the clutch platen bolt robot tightening mechanism workpiece flows into the station 3, it is lifted from the cylinder top to the assembly position, then the robot is lowered from the other cylinders to the working position, the bolt tightening work is completed, the cylinder is restored after completion, and the workpiece is discharged from the station. 3.
(4) The purpose of station 4 is to complete the loading assembly of the oil pan. Due to the large size of the oil pan, but the quality is small, according to the cost performance and service considerations, YAMAHA's MR-20F series Cartesian robot is used with the appropriate fixture to complete the loading of the station.
(5) The purpose of station 5 is to complete the tightening of the oil pan bolts. The position distribution of the oil pan bolts is due to the relatively large number of bolts on the oil pan, the relatively large spacing, and the different positions of the oil pan bolts of different types of engines. Therefore, consider using four YAMAHA XY- The X series Cartesian robot is used for positioning, and the four bolt tightening robots are mounted on the Cartesian robot.
Oil sump bolt distribution diagram After the workpiece flows into the station 5 and is lifted to the assembly position by the cylinder top, the four robots complete the tightening of 19 bolts in 5 steps. In order to prevent each robot from interfering with each other during operation, the robot 1 follows the order of RSABC, the robot 2 follows the order of DEFGH, the robot 3 follows the order of IJKLM, and the robot 4 is positioned by the Cartesian coordinate robot according to the model of the engine according to the order of the NOPQ. When in place, the bolt tightens the robot to complete the tightening work. After all 5 steps are completed, the Cartesian robot returns to the waiting position, the cylinder is restored, and the workpiece is discharged from the station.
A schematic diagram of the control and control system of the robot bolt tightening system. It consists of five Mitsubishi MELSEC-Q series Q02H programmable controllers (PLCs), five robot controllers and five Mitsubishi A970GOT series touch screens. Station 1, station 2, station 3 are controlled by different PLCs; station 4 and station 5 jointly complete the assembly of the oil sump, so it is controlled by one PLC; the other PLC is used as the master PLC.
Each station PLC is responsible for the control of all operations of this station, including manual and automatic working mode, error alarm, working status display and so on. Through the interface signal, each station PLC communicates with the robot controller to complete the control of the robot. Each station can be regarded as an independent system for independent operation. Each station can only be connected with other connected stations through the interface signal before and after the action, and will not be affected by other stations during the action. Impact.
Control System Brief Conclusion This article mainly introduces the flexible robot bolt tightening system in engine assembly, including the structure, working principle and control of the system. The system works normally during the trial run and meets the customer's production requirements. After use, various types of engines can be assembled as needed. At present, it is mainly responsible for the assembly tasks of 14 models of the two series.
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