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In the field of metal casting, handling robots have a wide range of applications and requirements. The following is a handling robot developed on the basis of customer requirements to work on the aluminum ingot casting production line. Its characteristics are a large load range, ranging from a few kilograms to several tons; fast operation speed and adjustable speed; flexible operation, Can complete complex tasks; high reliability, easy maintenance
First, the task requirements:
By work category: The exercise space is three-dimensional and four-degrees of freedom.
Stroke: 2200mm in X direction, 1500mm in Y direction, 1200mm in Z direction, horizontal rotation: +-900
Can integrate with the production line and have good communication functions.
The maximum load weight is 150Kg and the rated load is 125Kg. The layers are crossed at a 90-degree angle between the layers.
Each time there are nine floors with a floor height of 1000mm.
The fastest speed is 1000mm/s and the average speed is 500mm/s.
Accuracy: 1mm
Second, the robot composition:
The robot consists of a mounting frame, a robot positioning system, a servo drive system, a glue supply system and a glue gun, a control system, an electronically controlled power distribution system, and a safety protection device.
1, the robot mounting bracket
Because the robot looks for fast movements, the start-stop condition has a great impact on the mounting bracket. The mounting bracket must have very good rigidity to ensure the stability of the robot's operation. Therefore, we use the welded steel frame structure as a support frame.
2, robot positioning system
The robot positioning system is the core of the entire equipment and is the product of Japan OTC. Because the speed of the movement is high, the repeat accuracy is not high. The X, Y, and Z coordinates are all selected as the synchronized toothed belt transmission. The single-coordinate repeat positioning accuracy is 0.1mm, the fastest linear motion speed: 1000mm/s. The X coordinate axis is two positioning systems ELZ100 with a length of 3000mm and a span of 2200mm. The synchronization transmitter ensures the synchronization of the two positioning systems and is driven by a 3000W servo motor. For the matching of the driving torque and inertia, a speed reducer is required.
The Y-axis uses a double positioning system. The reason why such a large-section positioning unit is selected is mainly because the Y-axis is a double-end support with a mid-air suspension. If the selected cross-section is not enough, the stability of the robot motion cannot be guaranteed and the robot is at high speed. Shaking will occur during exercise. One is the main drive structure and one is the auxiliary structure. Two positioning units are used side by side, sandwiching the Z-axis, which balances the load very well. This type of mounting has very good stability. The two positioning systems are driven by a 2500W servo motor. For the matching of the drive torque and inertia, a planetary reducer is required. The Z-axis uses a double-sliding, fast, and fully-enveloped positioning system that is robust and stable
The rotary axis and the Z axis are integrated by adding a penetrating long axis at the center of the Z axis positioning body. The uppermost end of the long axis serves as a drive end and is mounted together with the servo motor. The lower end of the long axis serves as the load end and is used for mounting objects. Due to the heavier objects and the larger rotational inertia, they cannot be mounted directly on the drive shaft. A disc reducer must be added to match. The power of the servo motor is first transmitted from the long axis to the speed reducer and then transmitted to the load, thereby realizing the function of the rotary load.
3, servo drive system
The Profibus-equipped servo motor is used for this handling robot. Each movement axis is equipped with a servo motor and a speed reducer, four movement axes, a total of four sets of servo motors and four speed reducers, among which the vertical movement axis is equipped with a brake servo motor.
4, the machine grippers
The robot uses Japanese OTC robot grippers with adjustable pressure. It is equipped with a pressure-reducing valve, which allows the gripping motion to be smooth. A sensing mechanism is installed on the hand to automatically sense the object and inform the control center to pick up the object.
5, control system
The control system consists of a large PLC and a touch screen. The system has a powerful Profibus communication function. The data can be transmitted to Ethernet in real time, and the control commands can be sent to the servo system as a bus so that the entire movement is quite smooth. This system can preset a variety of workpiece programs. When replacing a product, the corresponding program can be called on the touch screen.
6, security devices
The machine has fault prompting and alarm functions, and it can accurately reflect the specific location of the fault each time a fault occurs. It is easy to quickly eliminate faults, mainly including: robot collision protection function; workpiece mounting in place detection; light curtain security protection.
Industrial robots in the metallurgical industry
With the development of robotics, the use of handling robots is increasing. On the basis of years of robot technology application, numerical control technology and product R&D, Suzhou Verdi Mechatronics Co., Ltd. has developed a series of cost-effective NC handling, assembly robots and welding robots based on the linear positioning system and robotic arm of Japan OTC Corporation. Widely used in metallurgy, automotive manufacturing, food processing, electronics and other industries, is an important equipment for aviation, automotive and other industries.