Stamping robotic arm is an important foundation of intelligent manufacturing.
Automatic stamping dies are very important in stamping. Without qualified dies, it is difficult to carry out mass stamping production; Without advanced die, advanced stamping technology cannot be realized.
Stamping process and die, stamping equipment and stamping materials constitute the three elements of stamping processing. Only when they are combined with each other can stamping parts be obtained. The cost of stamping robot is low and can return to the cost in half a year.
A robotic arm is about 60000-100000 Yuan. Different axle numbers and brands will affect the price.
The cost will be a lot of money in the early stage, but if calculated by time and month, it is equivalent to the salary of the staff and workers for half a year.
Moreover, the operation efficiency is very high, and the error rate is much lower than that of manual operation.
The development of robot industry will bring new opportunities for China’s high-end intelligent manufacturing industry.
Due to high production efficiency, low processing cost and stable quality, stamping production plays an important role in automobile, household appliances, electronics and other industries.
Stamping robotic arm is a kind of control object often encountered in the field of industrial automatic control.
Modern stamping workshops are usually equipped with stamping robotic arms to improve production efficiency and complete difficult or dangerous work for workers.
Stamping robotic arm can do a lot of work, such as moving objects, assembly, cutting, spraying and so on.
What is a stamping robotic arm?
Stamping robotic arm is a kind of precision production auxiliary equipment that replaces manual operation with intelligent device.
The stamping robotic arm adopts man-machine interface and PLC control system.
It is convenient to set the feeding speed and step distance.
It can set the stamping target output and display the current stamping quantity.
With the abnormal prompt function, the maintenance is more simplified.
It integrates robotic arm, feeding, receiving and stacking rack.
The fully automatic feeding device, combined with the auxiliary feeding mechanism, can realize fully automatic stamping, taking and feeding, completely replacing manual operation.
Double servo feeding can be adopted, with high precision, high efficiency, and convenient adjustment of feeding speed and step distance.
It is widely used in all kinds of large sheet metal stamping parts, stretching parts, single station operation and automatic production line.
Characteristics of stamping robotic arm
1. The whole press robotic arm is designed and manufactured according to CE standard, with high transfer efficiency.
The main drive is realized by imported servo motor, which is controlled by microcomputer, operated and set by man-machine interface;
2. The feeding mode of the stamping robotic arm is that the coil material can be matched with the air feeder and NC roller feeder, and the sheet material can be matched with the double stack stacking rack.
The number of punch table, turnover table and peripheral equipment requiring continuous action can be easily selected;
3. According to the characteristics of the parts (material, structural characteristics, etc.), different ways can be selected for the stamping robotic arm to grasp the parts: vacuum suction cup, electromagnetic iron suction and pneumatic fixture to adapt to different workpieces.
4. The stamping robotic arm adopts functional modular design, and carries out professional design of functional modules according to the different characteristics of stamping process in different industries, so as to make the system stable and convenient combination;
5. The stamping robotic arm adopts the combination of mature German technology and local professional design, and carries out the applicability design according to the needs of customers, so as to make the stamping system of customers reach the optimal state;
6. The key components of the stamping robotic arm, control computer and other components are all European brands, with stable and reliable quality, which can effectively reduce the maintenance cost of customers;
7. The punch robotic arm, stamping equipment and die are integrated into a professional and automatic stamping system, which can carry out automatic production;
8. The stamping robotic arm can effectively reduce the cost of manpower and material resources and save the floor space;
9. The press robotic arm adopts computer control system, which can set parameters, feed speed, step setting, stamping target output, display current stamping quantity, fault prompt function and simplify maintenance.
Types of punch robotic arm
The use of robotic arm for tool exchange is the most widely used, because the robotic arm has great flexibility in tool change and can reduce the tool change time.
Forms and types of robotic arm in automatic tool changing CNC machine tools, the forms of robotic arm are also diverse.
There are six common types of punch robotic arm:
1. Single arm single claw rotary robotic arm
The arm of this robotic arm can rotate at different angles for automatic tool change.
There is only one clamping claw on the arm.
Whether on the tool magazine or on the spindle, it depends on this clamping claw to load and unload the tool, so the tool change time is long.
2. Single arm double claw swing robotic arm
The arm of this kind of robotic arm has two clamping claws.
The two clamping claws have a division of labor.
One clamping claw only performs the task of removing the “old knife” from the spindle and returning it to the tool magazine, and the other J clamping claw I performs the task of taking out the “new knife” from the tool magazine and sending it to the spindle.
The tool change time is less than that of the above single claw rotary robotic arm.
3. Single arm double claw rotary robotic arm
There is a clamping claw at both ends of the arm of this robotic arm.
The two clamping claws can grasp the tools on the tool magazine and the spindle at the same time.
After rotating 180 °, the NC punch tools are put back into the tool magazine and installed into the spindle at the same time.
The tool change time is shorter than the above two single arm robotic arms, which is the most commonly used form.
4. Double robotic arm
This CNC turret punch robotic arm is equivalent to two single arm and single claw robotic arms, which cooperate with each other for automatic tool change.
One robotic arm takes down the “old knife” from the spindle and returns it to the tool magazine; The other robotic arm is taken out from the magazine
Install the “new tool” into the machine spindle.
5. The two arms of this carding machine can move back and forth and cross into a certain angle.
One arm removes the “old knife” from the spindle and returns it to the tool magazine.
The other arm takes out the “new knife” from the tool magazine and installs it on the spindle. The whole robotic arm can move in a straight line along a guide rail or rotate around a rotating shaft to realize the tool transportation movement between the tool magazine and the spindle.
6. Double arm end face clamping robotic arm
This kind of robotic arm is only different from the previous ones in the clamping part.
The first few God robotic arms grasp the tool by clamping the outer circular surface of the tool handle, and this kind of robotic arm clamps the two end faces of the tool handle.
Three key components of punch robotic arm
The key basic components of punch robotic arm refer to the component units that constitute the transmission system, control system and human-computer interaction system of robotic arm, play a key role in the chiral energy of punch machinery, and have universality and modularization.
It is mainly divided into the following three parts: high-precision reducer, high-performance AC / DC servo motor and driver, and high-performance robot controller.
Reducer is the key component of punch robotic arm.
At present, two types of reducer are mainly used: harmonic gear reducer and RV Reducer.
It is applied to the base and arm joints of punch robotic arm.
The harmonic drive method was invented by American inventor C. Walt Musser in the mid-1950s.
Harmonic gear reducer is mainly composed of three basic components: wave generator, flexible gear and rigid gear.
Relying on the wave generator, the flexible gear produces controllable elastic deformation and meshes with the rigid gear to transmit motion and power.
The single-stage transmission speed ratio can reach 70 ~ 1000.
With the help of flexible gear deformation, reverse meshing without backlash can be achieved.
Compared with the general reducer, when the output torque is the same, the volume and weight of the harmonic gear reducer can be reduced by 2 / 3 and 1 / 2.
The flexible wheel bears large alternating load, so its material has high requirements for fatigue strength, processing and heat treatment, and the manufacturing process is complex.
The performance of the flexible wheel is the key of high-quality harmonic gear reducer.
2. Servo motor and driver
In terms of servo motor and drive, the current European brands mainly include Lenz, lust, Bosch Rexroth, etc.
These European motors and drive components have good overload capacity and dynamic response, strong driver openness and bus interface, but the price is expensive.
Japanese brands mainly include Yaskawa, Panasonic, Mitsubishi, etc.
Their prices are relatively low, but their dynamic response ability and openness are poor, and most of them only have analog quantity and pulse control mode.
In terms of punch robotic arm controller, the current general multi axis controller platform is mainly divided into motion control card with embedded processor (DSP, PowerPC) as the core and PLC system with industrial computer and real-time system as the core.
Its representatives are PMAC card of DeltaTau and TwinCAT system of Beckhoff respectively.
Main working forms of punch robotic arm
The stamping forming of parts is mainly composed of upper and lower material mechanism and punch, but the upper and lower processes of punch realize the requirements of automatic operation and production conditions of punch according to the requirements of production process.
The punch robotic arm plays an important role in the stamping production line.
According to the stamping process, it controls the movement coordination between the robotic arm and the feed turntable, completes the work of loading and unloading materials, has stable maintenance, low response, reliability and cost control.
In this process, the punch robotic arm automatically completes several specified actions according to the preselected program, so as to realize the automatic clamping and transportation of objects.
The distance of the material fed by the automatic feeding robot for each stamping is called the feed step, which can be determined according to the shape and size of the stamping part and the needs of the stamping process.
The cycle is synchronous with the punch, continuous production, simple and compact overall structure, stable transmission, reliable performance, safe use, convenient operation, convenient processing, disassembly, adjustment, maintenance and manufacturing economy.
It has broad application prospects in cold extrusion industry, especially in bearing stamping process.
Driving forms of punch robotic arm
1. Hydraulically driven
The hydraulic driven robotic arm of punch robotic arm is usually composed of hydraulic motor (various oil cylinders, oil motors), servo valve, oil pump, oil tank, etc. the driving system is operated by the actuator of the driving robotic arm.
Generally, it has a large lifting capacity (up to hundreds of kilograms).
It is characterized by compact structure, stable action, impact resistance, vibration resistance and good explosion-proof performance. However, the hydraulic components are required to have high manufacturing accuracy and sealing performance, otherwise oil leakage will pollute the environment.
2. Pneumatic driven
Its drive system is usually composed of cylinder, air valve, air tank and air compressor.
It is characterized by convenient air source, rapid action, simple structure, low cost and convenient maintenance.
However, it is difficult to control the speed and the air pressure should not be too high, so the snatch ability is low.
3. Electrically driven
The electric drive of punch robotic arm is the most widely used driving mode of robotic arm.
It is characterized by convenient power supply, fast response, large driving force (the holding weight of joint type has reached 400kg), convenient signal detection, transmission and processing, and can adopt a variety of flexible control schemes.
The driving motor generally adopts stepping motor, and DC servo motor (AC) is the main driving mode.
Due to the high speed of the motor, the reduction mechanism (such as harmonic drive, RV cycloid pinwheel drive, gear drive, screw drive and multi rod mechanism) must be adopted.
Therefore, the robotic arm has begun to use the high torque and low speed motor without deceleration mechanism for direct drive (DD), which can not only simplify the mechanism, but also improve the control accuracy.
4. Mechanically driven
The mechanical drive of punch robotic arm is only used in the occasion of fixed action.
Generally, cam linkage mechanism is used to realize the specified action.
It is characterized by reliable action, high working speed and low cost, but it is not easy to adjust.
How to deal with the failure of punch robotic arm?
Although the stamping robotic arm is a high-tech and high-tech product, it may also have problems.
Then, what should we do when the stamping robotic arm has problems?
In fact, under normal circumstances, the punch robotic arm has few problems.
If there is a problem, don’t worry.
First deal with it according to the following methods.
If not, you can contact the punch robotic arm manufacturer directly.
Basically, all punch robotic arms are guaranteed for one year and provide permanent after-sales service.
If there is a problem, it’s right to find the manufacturer.
1. Check whether there are disturbance sources near the control elements of the stamping robotic arm
If the analog signal of stamping robotic arm is unstable, after eliminating the problem of signal source, we should consider whether there is signal disturbance.
Find out the type and intensity of disturbance source, which can be handled by installing isolator, using double glue shielded wire, adding equipment grounding point, etc.
2. Check all power, air and hydraulic sources of the stamping robotic arm
The problems of power supply, air source and hydraulic source of stamping robotic arm often lead to the problems of automation equipment.
Check whether the power supply voltage of the main circuit and control circuit is normal and whether there is phase loss;
According to the air source demand, check whether the system pressure is normal, whether the compressed air quality is qualified, and whether there is pipeline leakage and blockage;
The hydraulic system needs to check whether the system pressure and temperature are normal, whether there is leakage and blockage of pipeline, whether the system impurities are overspent, etc.
3. Check the control components of the stamping robotic arm
Check whether there are problems in the motor and valve of the stamping robotic arm and the equipment causing problems.
Such problems are relatively simple to find and deal with;
After admitting that it is correct, check the control components. Such defects are usually difficult to find.
It is necessary to carefully measure and test according to the schematic diagram to check whether the operation condition of components is normal.
If some components of the controller cannot be measured and judged, such as frequency converter, they can be judged by exchanging components or replacing new components.
4. Check whether the orientation of the sensor or tested component of the stamping robotic arm is offset
Due to the neglect of equipment protection personnel, the orientation of some sensors may be wrong, such as not in place, sensor problems, sensitivity problems, etc.
Always check the sensing orientation and sensitivity of the sensor of the stamping robotic arm, and adjust the error in time. If the sensor is broken, replace it immediately.
In addition, due to the sensation of automation equipment, most sensors and detected blocks will show loose orientation after long-term use.
Therefore, during daily protection, we should often check whether the orientation of the sensor of the stamping robotic arm is correct and whether it is fixed reliably.
Maintenance of stamping robotic arm
1. Each set of punch robotic arm shall be inspected and maintained regularly, and a special person shall be assigned to take charge of it.
2. Before going to work every day, be sure to check whether the punch robotic arm is turned on, and the machine tool can be officially operated only after it is confirmed to be normal.
3. Do the habit of regularly cleaning the robotic arm of the punch, especially the cleaning of the filter plate, and try to avoid oil and dust.
If possible, it is best to make a protective cover for the punch robotic arm.
4. If the machine tool needs to replace or debug the die, adjust the height and safety distance of the punch robotic arm to the appropriate position after completion.
5. Try not to stack things next to the installation of punch robotic arm.
In this way, it is not easy to damage the robotic arm.
6. The stamping robotic arm shall be inspected or maintained by professionals once a year as far as possible.
If the robotic arm fails, do not handle the maintenance without permission, but ask a professional master for maintenance.
Press robotic arm review
From the first mock exam mode (mode 1 and continuous mode), safety is one way to travel.
Number of slave punches (single multi station and multi connection)
PS: here refers to a single unit and multiple units. Of course, multiple single units can also form a production line, which is not in the scope of this description.
Four quadrants can be obtained:
1. Single installation
2. Multiple installation
3. Single continuous
4. Multiple continuous
From easy to difficult, one by one.
1. Single installation
1) Many people should think of six joint robot immediately
Well, the four families of six joint robots, KUKA, YASKAWA, ABB and FANUC, are relatively reliable at present
It should be noted that the six joint robot used in the welding field is very mature, but it should be used for stamping.
Take YASKAWA (YASKAWA) as an example, it is divided into general type and special type for stamping, so we must choose this special type for stamping.
Although the price is much more expensive, the configuration of reducer and motor varies a lot.
Application field: flexible design, the most widely used field
Efficiency: Generally speaking, 6-8 times per minute.
It is said that there are good ones that can do 10 times.
2) Simple robotic arm
It became very popular for a while. It is said that there must be hundreds of manufacturers in Guangdong.
It is indeed simple in structure and low in cost. It can be done by two people.
However, I would like to say that this thing is not available in Europe, America, Japan and South Korea, but in China, which shows that we have realized the replacement of six joint robot in the stamping field in the most economical and lowest cost way.
In fact? I also want to say that it reminds me of the gravitational wave event.
To get down to business, this thing can actually be used, but it is limited to the situation that your product is single and large in batch.
There is no need to change the mold and debug the robotic arm frequently.
If not, you must not buy a decoration at a cheap price.
Application field: known as flexible design, it replaces all classical robotic arms and unifies the Jianghu
Efficiency: hard to say.
Price: as cheap as you want (someone marked the public price of 30000)
3) In mold robotic arm (classic inheritance)
In the above we make comlaints about the “new star”, next let’s discuss the mature design.
Generally speaking, this kind of equipment can be used for handling between multiple processes of a single equipment.
It should be noted that the mechanical claw is hidden in the interval of the die station when the press is pressed down, so a good space should be reserved in the design.
Application: in mold handling
Efficiency: 8-10 times per minute
2. Multiple installation
1) Link robotic arm
One connecting rod runs through a row of punches, which is suitable for connecting multiple sets of small tonnage punches.
An intermediate station is set in the middle of the press, which can supplement the turnover process.
Application: in mold handling
Efficiency: 8-10 times per minute
2) Independent robotic arm
For small sheet metal handling, the punch spacing does not exceed 1500
Application fields: small sheet metal, connection of multiple presses,
Efficiency: 8-12 times per minute
3. Single continuous
1) NC 3D two bar robotic arm
70% of stamping parts in developed countries are processed in this way, which is simple and efficient.
At present, one hand that domestic robotic arm manufacturers can do well can be counted, which is the high section of domestic stamping robotic arm.
Pay attention to the design of equipment interference curve at the beginning of planning.
Application: very wide range, suitable for large tonnage punch and multi station stamping
Efficiency: greatly affected by the stroke, generally 15 ~ 40 times / min.
Price: the most cost-effective
2) NC 2D two bar robotic arm
There is one less lifting shaft than the three-dimensional robotic arm.
It is required to keep the same horizontal height of process parts after demoulding during mold design.
Application: small parts, such as battery case, motor case, etc
Efficiency: greatly affected by the process, the speed of 18650 battery case can reach 150 times / min, and it is normal to punch parts 20-40 times / min.
4. Multiple continuous
1) OEM customized production line
Hundreds of billions of production lines can only look up at… Everything is pale.
2) Homologous punch connection