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1. Design principles

1.1 User requirements

This project is designed to meet the needs of online fully automatic Rockwell Hardness Testing of aluminum gas cylinders, focusing on its small batch and multi-variety product types, and solving the hardness measurement problems of aluminum cylinders with diameters of Ø80mm to Ø300mm and different lengths. The system design takes economy, safety, reliability, flexibility, applicability and good human-machine interface interaction as design criteria to ensure the successful delivery of the project and quality management throughout the life cycle.

1.2 Design ideas

This solution is mainly suitable for online Rockwell hardness fully automatic Testing of gas cylinders. This solution complies with GB/T230.1-2018 "Metallic Materials Rockwell Hardness Test Method" and ASTM E18 American Standard.

The test line adopts a modular design. The system consists of a gantry frame, a crossbeam hydraulic lifting mechanism (including a hydraulic station), a hardness loading and clamping mechanism, a V-shaped aluminum bottle conveyor line, a PLC control system, and a large module of a Rockwell hardness measurement system. High installation efficiency, convenient maintenance, and strong interchangeability of spare parts.

Rockwell hardness measurement system. The workpiece ID number is established by group, the upper and lower limits are set, and the workpiece is automatically judged whether it is qualified. The qualified ones are displayed in green, and the unqualified ones are displayed in red. There is also an audible and visual alarm device. It can also achieve real-time communication with the equipment; the test results can be set with functions such as input, export, and sharing according to different permissions.

2. Design plan

2.1 Plan layout

Layout of the overall plan:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 1. Plan schematic

2.2 Plan description

According to the project requirements, the inspection line consists of a gantry frame, a crossbeam hydraulic lifting mechanism (including a hydraulic station), a hardness loading and clamping mechanism, a V-shaped aluminum bottle conveyor line, and a PLC control system. The system is based on the loading spindle and forms a fully automatic inspection line.

2.3 Standard specifications

(1) GB/T230.1-2018 "Metallic Materials Rockwell Hardness Test Method"

(2) 4.1, 4.2, 4.3, 4.5 in GB/T230.2-2012 standard; the repeatability and relative error of the Hardness Tester are in accordance with Table 2.

(3) ISO6508-2015 Metallic materials — Rockwell hardnesstest —Part 1: Test method Table2

(4) ASTM E18-2017 Standard Test Method for Rockwell Hardness of Metallic Materials Table3

(6) JJG China National Metrology Verification Procedure JJG112-2006.

2.4 Workpiece parameters

According to the user description, a test line was planned, mainly for testing aluminum bottles.

2.4.1 Workpiece type: aluminum bottles

2.4.2 Basic functions

Automatic loading in the previous process, position sensor determines the test position, hydraulic jacking rises, automatic clamping, automatic pressure, automatic measurement, hydraulic cylinder falls, and data is automatically connected to the MES system.

2.4.3 Gas cylinder diameter

Specification range: diameter Ø80~Ø300mm, straight body length 320mm~1500mm;

2.4.5 Gas cylinder weight

Approximately?.

2.4.6 Inspection requirements

The inspection position is 1 to 3 points on the upper surface of the aluminum cylinder busbar. Inspection of more than 1 point must be based on the straight body length not less than 600mm.

2.5 Main functions

2.5.1 Test process: automatic loading of the previous process, position sensor determines the first detection position, hydraulic lifting, automatic pressing, automatic pressure, automatic measurement, automatic recording, automatic lowering of the hydraulic lifting device, the line body sends the gas cylinder out of the roller, and the data is automatically connected to the MES system.

Note: The definition of data evaluation needs to be negotiated by both parties or delivered in writing.

2.5.2 Automatic transmission of the line body and automatic position judgment.

2.5.3 Hydraulic automatic lifting of aluminum bottles.

2.5.4 Loading method: servo motor automatically loads, holds and unloads.

2.5.5 Pressure head: Φ1.5875 is installed separately.

2.5.6 Software functions:

Main interface: system settings, test results, report output.

Measurement function: can realize single measurement, batch measurement, continue a batch measurement, view a batch measurement, automatically save single data, and automatically save batch measurement data.

Test method: can be set, with the functions of storing, setting and loading test parameters.

Auxiliary functions: upper and lower limit settings, over-limit sound and interface color alarm.

Protection function: force overload protection, test process protection.

Divided authority management: operators of different levels have different operating permissions, and the operable menus and other contents are also different. The operation of ordinary operators is simple, convenient and fast; the operation of managers adds professional operation content, which effectively protects the system.

Data statistics: average value, maximum value, minimum value, repeatability and mean square error; indentation range, OK/NG data statistics.

Test parameter storage: automatic storage and save path.

★TCP/IP address and port: Enter the TCP/IP address and port number of the receiving data server.

Test environment: It can work stably at an operating temperature of 10℃~35℃, and the surrounding environment should be clean, vibration-free, and free of corrosive gases.

2.6 Main indicators

(1) Test load (kgf): 98.07N/10kgf, 588.4N/60 kgf, 980.7N/100 kgf, 1471N/150 kgf

(2) Force accuracy: ±1%

(3) Measuring range: HRBW in accordance with the standard

(4) F1 loading time (s): ≤5

(5) Hardness value repeatability and indication error: in accordance with the standard.

(6) Maximum allowable sample diameter (mm): ≤300

(7) Y-axis aluminum bottle conveyor line length (m): 3.2

(8) Y-axis aluminum bottle conveyor line moving speed (mm/min): up to 2000

(9) Spindle loading servo motor power (KW): 0.75

(10) Hydraulic lifting clamping force (T): ≤2

(11) Hydraulic system is equipped with a set of 2.2KW 380V solenoid valves plus pressure holding valves, throttle valves, pressure sensors, temperature sensors, 80 liters of oil tank and cooling

(12) Y-axis aluminum bottle conveyor line servo motor power (KW): 0.75

(13) Overall dimensions (L×W×H) about m: 2.65×3.16×2.35

(14) Basic weight of the main machine about (T): 5

(15) Power supply voltage: AC 380V; total power: 3.7KW

2.7 Floor space (L×W×H) m

This project is an independent operation system, with a total floor area of about 2.65 (L) x 3.16 (W) x 2.35 (H) meters. The actual floor area is subject to the final design. The oil source floor area is about: 0.63×0.5×0.7; the electrical control cabinet (ready-made) floor area is about: 0.75×0.75×1.4. The actual floor area is subject to the final design.

2.8 Beat Analysis

2.8.1 Inspection Process

Take the inspection of Φ300×10.6×1500 as an example. The entire workflow is as follows:

(1) The PLC system automatically receives the batch number of the MES system (or scans the QR code to obtain it).

(2) Manually input the cylinder diameter, length, number of measurement points, and number of inspections (3 inspections in 1 or 5 inspections in 1) on the touch screen. The system automatically calculates the path planning operation parameters.

(3) The aluminum bottle enters the inspection line and reaches the specified position to trigger the position sensor, and the line stops.

(4) The hydraulic lifting mechanism automatically lifts the workpiece to the clamping position.

(5) The hardness loading mechanism automatically detects the first point.

(6) Repeat steps (3) to (5) to complete the 3-point inspection.

(7) The hydraulic lifting mechanism automatically resets, the aluminum bottle falls to the conveyor line, and the line automatically sends the sample away.

(8) The system makes a numerical judgment of OK/NG based on the judgment conditions, and the signal light flashes to indicate.

2.8.2 Capacity Analysis

According to the inspection process in 2.8.1, each aluminum bottle is inspected at one point on the upper surface of the busbar, and the beat simulation is as follows:

(1) The conveyor body transports the aluminum bottle to the designated position for about: 8s (auxiliary cycle T);

(2) Hydraulic jacking is about: 3s (inspection cycle T);

(5) Loading head movement time is about: 5s (inspection cycle T);

(6) Scheme 1 loading and measurement: 20s (inspection cycle T, calculated as 1 point).

Note: Scheme 2 uses a spring pressure head, loading and measuring for 10s (inspection cycle T, calculated as 1 point)

(7) Hydraulic jacking reset is about: 3s (inspection cycle T);

Scheme 1: Calculation of the total time of the servo motor loading structure test:

Assuming that one cylinder inspects one point as one cycle, it takes about: 40s. The working time of one device in one shift is calculated as 8 hours, and the output is about 720 pieces.

Scheme 2: Calculation of total time for spring loading mechanism test:

Assume that one cylinder circle detects one point as one cycle, which takes about 30 seconds. The working time of one device in one shift is calculated as 8 hours, and the output is about 960 pieces.

Note: The above time estimate is only for reference, and the specific implementation is subject to actual conditions.

The above time calculation is 100% detection.

2.8.3 Information Flowchart

Note: The information flow needs to be confirmed with the customer in detail about the data input and output content.

(1) Input part:

a. Manually input the test parameters or the system provides the test parameters;

b. Or obtain the test product serial number through a barcode scanner.

(2) Output part:

a. If the existing functions are used, the software can provide a link to the saved data file, which the company's data management department can retrieve.

2.9 User Notice

2.9.1 Reserve enough space to install the online Rockwell hardness test line based on the overall floor area and layout.

2.9.2 Meet the power, air source, lighting, temperature, humidity and other conditions required by the test line.

 

3. Key Function Description

3.1 Gantry frame

The frame system is mainly composed of a base, a gantry and accessories, which are welded and assembled from high-strength structural steel. After welding, it has undergone heat aging treatment to eliminate welding stress and ensure structural stability. The key assembly surfaces of the gantry are all precisely machined by machine tools to ensure assembly accuracy.

3.2 Hydraulic lifting mechanism

The lifting system is mainly composed of a cylinder, a linear bearing, a clamping structure, a linear guide rail, etc. After the gas cylinder reaches the specified position, the cylinder rises and lifts the gas cylinder to the bottom surface of the gantry to achieve three-sided positioning of the gas cylinder, ensuring that the gas cylinder is clamped accurately and firmly.

3.3 Hardness loading mechanism

The hardness measurement unit includes a digital displacement measurement system with a resolution of up to 0.1 μm; a force sensor, the force sensor and the pressure head are coaxial, and the load acts directly on the main axis of the pressure head, without causing deviation, friction, or overload.

Grating linear measurement technology is used to obtain the highest accuracy and resolution currently available. The floating contact seat can eliminate the influence of the hardness Tester's own deformation on the measurement results to the greatest extent. The measurement results are highly accurate and repeatable. The pressure head can be replaced conveniently and quickly, and the hardness test method can be changed. The entire test process adopts closed-loop control to automatically realize the loading and unloading and holding functions of the test force.

3.4 Servo motion system

The servo motion system is mainly composed of servo motor, ball screw, slide rail, etc. The servo motor is controlled by PLC to drive the screw to rotate, and the screw drives the slide to move horizontally, which can realize high-precision motion control and positioning of the system.

3.5 Aluminum bottle conveyor line

The aluminum bottle conveyor line is mainly composed of the conveyor line frame, motor, V-shaped double sprocket aluminum bottle, transmission chain, etc. The motor drives the aluminum bottle to rotate to realize the conveying of the gas cylinder. The conveyor line is equipped with multiple sets of photoelectric detection switches for detecting gas cylinders of different specifications to ensure that gas cylinders of different specifications can stop accurately at the measuring station.

3.6 General control system

PLC is the control platform of the automatic inspection line. Through the control of various modules, it completes the collection, measurement, feedback and control of various test index parameters such as gantry mechanism hardness spindle loading control, hydraulic cylinder lifting and reset, line speed control, path planning, etc., and realizes multi-point automatic inspection of ring parts. The operation interface adopts authority management, and the user interface is user-oriented. On the basis of meeting functional requirements, various personalized designs are carried out according to the actual needs of users.

3.6.1 Introduction to PLC control system

(1) Manually input the cylinder diameter, length, and number of measurement points on the touch screen. In the inspection mode (3 inspections in 1 or 5 inspections in 1), the system automatically calculates the path planning operation parameters.

(2) After setting the system parameters, the system will automatically plan the measurement point path and automatically load according to the specified test process and test method. During the test, the loading speed will be automatically calculated according to the force value range, so as to perform closed-loop loading to the set force for load maintenance;

(3) Force value load holding time setting. When the force value reaches the set indication value, the countdown begins. When the time count reaches zero, the hardness loading system will automatically return to the initial zero point;

(4) Speed setting of each measuring platform. The speed of the beam movement of each platform can be flexibly set according to the situation;

(5) Calibration of analog quantity parameters. This interface can calibrate displacement, force value and other analog quantities according to the corresponding relationship of the standard value;

(6) Each limit and fault indicator light clearly displays the status of each state, such as green light when there is no limit and red light when there is a limit, and there are corresponding text prompts.

The above programs are interconnected. After filling in the information, click to start the test, and it will automatically enter the program control state, automatic grinding, automatic pressing, automatic return, automatic measurement, data storage, data transmission, etc.

3.6.2 PLC human-machine interface

 

Figure 4.1Main operation interface, for reference

 

 

Figure 4.2 Motion control interface, for reference

 

Figure 4.3 Alarm interface

3.6.3 Fault monitoring and abnormal protection control module

This control module is embedded in the control system. It consists of an external proximity sensor, an I/O communication card and an internal judgment module. It mainly has functions such as system self-checking, position monitoring, and fault alarm. If an abnormality occurs, the control system issues an I/O control command, closes or pauses the corresponding execution unit, and issues a fault message. After the fault is eliminated, it will continue the original production rhythm or restart a new workflow according to user requirements.