上下料机器人辅助柔性生产

发布日期:2012-04-06    兰生客服中心    浏览:11281

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  ISA公司采用机器人进行辅助加工,当进行磨削时,它可以以5.5kW的驱动功率传递到接触轮,进行抛光时,驱动功率甚至可达到11kW。然而,人们用手动方式以这样的力和速度进行加工是不可能实现的。ISA公司采用了ABB公司的工业机器人来装备其设备,这些机器人的型号为IRB2400,IRB4400和改进型的IRB6400。由于其紧凑的结构,可以用来构成作业空间十分精简的机器人单元。企业可以用它来改装用户现有的主要设备。例如在对家具部件进行精整加工时,甚至可在5台加工机床的中央设置一台机器人,机器人抓取待加工的工件并将其送到每一台设备上(图1)。对于加工几何形状复杂的扶手进一步开发了机器人系统。为了实现加工机床所需的不同定向,ISA公司是将每台机床安装在机床自己的一台回转工作台上。而回转工作台就起到机器人的第7个坐标轴的作用。这样,ISA公司在一台加工单元上,以包括三台磨床和二台抛光机在内的十台机床的配置,通过工业机器人完成扶手的综合加工-从毛坯件直到具有光泽表面的成品件,最后又自动将成品件进行堆垛。

在精加工钢管时,机器人抓取待加工工件
并将其送到径向布置的磨床和抛光机上

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  机器人单元的核心设备是ABB公司一种刚性特别好的铸造结构的IRB2400型工业机器人。三班制运行的机器人必须要具有很高的刚性,以便能承受在去毛刺时产生的加工力和获得始终如一的成果。刚性决定了所能达到的进给速度和有待获得的表面质量,链式传送带把从加工中心上卸下来的轴瓦(总是8个为上部和8个是下部)输送到机器人单元,机器人首先从传送带上抓取工件,并将工件平放在测量装置上,在这里,以最大为5μm的偏差测量今后要安装曲轴主轴颈的上部和下部的已加工表面。PC对测量数据进行分析处理,并提供给机器人,然后由机器人从各相配零件中选定一对配合件。把超差的零件从生产流程中剔除出去。在下一工步中,机器人针对不同型号的零件采用不同的工具(如铣刀,锉刀和刷子)去除毛刺。接着,机器人以0.2mm的重复精度把工件存放到堆垛装置上。在这里,加工并包括测量和堆垛,整个节拍时间约为45秒。后面的传送带把已去除毛刺的经过测量和清洗过的工件(不经手动的中间操作)输送到自动装配机上。这个系统的主要优点是具有稳定和高的去毛刺质量。此外,连续的测量同时又立即把测量数据反馈给加工中心,这对保证质量和避免废品损失作出了重要贡献。
 
IRB6400在进行铸件的精整加工

  丹麦DISA集团是以其顶尖的喷丸清理设备和自动化去毛刺设备而著称,算得上是全球领先的机械设备制造厂。DISA集团的成套设备包括有采用机器人作业的去泥芯,去型砂,去铸造氧化皮,捣碎,切割,锯切和机械精整加工等设备。铸件精整系统的核心部件是ABB公司的IRB6400型工业机器人,在这种应用情况中,机器人抓取已预先定位的工件,接着自动完成锯切,磨削,如需要也可完成其它的工序。对此,机器人操纵着工件将其靠到固定的抛光轮、砂轮和其它工具上进行相应的加工,加工完后,把工件存放到传送带上进行进一步的输送(图2和图3)。
 
  在铸件经锯切、磨削和精整之后,机器人
把已加工好的工件放置在传送带上以继续进行传送

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