曲軸智能鍛造系統(tǒng)及鍛件質(zhì)量控制研究

曲軸智能鍛造系統(tǒng)及鍛件質(zhì)量控制研究曲軸智能鍛造系統(tǒng)及鍛件質(zhì)量控制研究

摘要：

隨著工業(yè)自動化水平的不斷提高，曲軸鍛造成為發(fā)展最快、應(yīng)用最廣泛的鍛造方法之一。本文通過對曲軸智能鍛造系統(tǒng)的構(gòu)建和鋼鐵材料曲軸鍛造過程中質(zhì)量控制的研究，提出了一種完整的包括系統(tǒng)構(gòu)建、系統(tǒng)設(shè)計、機器人控制和質(zhì)量控制的系統(tǒng)解決方案。

本文通過闡述系統(tǒng)構(gòu)建、系統(tǒng)設(shè)計過程中，選用的可編程序控制器（PLC）、采用PID反饋控制算法實現(xiàn)機械臂精準(zhǔn)控制和實時反饋。在質(zhì)量控制方面，本文提出曲軸鍛造過程中的熱力學(xué)分析、實驗研究、機器視覺檢測以及制定鍛造工藝參數(shù)等措施，進一步提高鍛件的質(zhì)量穩(wěn)定性。

研究發(fā)現(xiàn)，曲軸智能鍛造系統(tǒng)及其質(zhì)量控制方案對提高曲軸鍛件的生產(chǎn)率、降低故障率、提高工作效率具有重要意義。

關(guān)鍵詞：曲軸；智能鍛造系統(tǒng)；鍛件；質(zhì)量控制；機器人控制

Abstract:

Withthecontinuousimprovementofindustrialautomationlevel,crankshaftforginghasbecomeoneofthefastestdevelopingandwidelyusedforgingmethods.Inthispaper,acompletesystemsolutionincludingsystemconstruction,systemdesign,robotcontrol,andqualitycontrolisproposedthroughthestudyoftheconstructionofthecrankshaftintelligentforgingsystemandqualitycontrolintheforgingprocessofsteelmaterials.

Byelaboratingontheselectionofprogrammablelogiccontrollers(PLCs)andtheuseofPIDfeedbackcontrolalgorithmstoachieveprecisecontrolandreal-timefeedbackoftheroboticarmintheprocessofsystemconstructionanddesign,thispaperproposesmeasuressuchasthermodynamicanalysis,experimentalresearch,machinevisioninspection,andformulationofforgingprocessparametersforqualitycontrolofcrankshaftforgingprocess,tofurtherimprovethequalitystabilityofforgings.

Thestudyfoundthatthecrankshaftintelligentforgingsystemanditsqualitycontrolsolutionareofgreatsignificanceforimprovingtheproductionefficiencyandworkefficiencyofcrankshaftforgings,reducingfailurerateandimprovingqualitystability.

Keywords:crankshaft;intelligentforgingsystem;forgings;qualitycontrol;robotcontrolMoreover,theintelligentforgingsystemanditsqualitycontrolsolutioncanoptimizetheforgingprocessparameters,suchastemperature,pressure,anddeformationspeed,toensuretheconsistencyanduniformityoftheforgedproducts.Thecontrolsystemcanalsodetectvariousdefectsandanomaliesinreal-time,preventingpotentialqualityissuesandsavingtimeandcostforinspection.

Theapplicationofrobotcontrolfurtherenhancestheprecisionandaccuracyoftheforgingprocess.Therobotscanhandletheheavyandcomplicatedworkpieceswitheaseandperformrepetitivetaskswithoutfatigueorerror.Theycanalsobeprogrammedtoadjusttheprocessparametersdynamicallybasedonthesensorfeedback,ensuringthebestqualityandefficiency.

Thequalitycontrolsystemoftheintelligentforgingsystemincludesmultiplestages,suchaspre-forginginspection,in-processmonitoring,andpost-forgingevaluation.Throughadvancedtechnologiessuchasnumericalsimulation,machinelearning,anddataanalysis,thequalitycontrolsystemcanpredictthepotentialdefectsandoptimizetheprocessparametersaccordingly.

Inconclusion,theintelligentforgingsystemanditsqualitycontrolsolutionhaveshownsignificantpotentialinimprovingtheproductionandqualityofcrankshaftforgings.Withthecontinuousadvancementoftechnologyandinnovation,thesystemcanbefurtheroptimizedtomeetthechangingneedsofthemarketandcustomersFurthermore,theintelligentforgingsystemcanalsobenefitfromtheintegrationofreal-timemonitoringsensorsandadvancedcontrolalgorithms,whichcanhelpdetectandcorrectanydeviationsfromthedesiredprocessparameters.Bycollectingdataonvariousvariablessuchastemperature,pressure,strain,andvibration,thesystemcanbuildamoreaccuratemodeloftheforgingprocessandidentifytherootcausesofdefectsorvariationsinproductquality.Thisinformationcanthenbeusedtoadjustthesettingsoftheforgingequipmentormodifythematerialcompositiontoensureconsistentandreliableoutput.

Moreover,theintelligentforgingsystemcanleveragethepowerofartificialintelligenceandmachinelearningtoimproveitsperformanceandoptimizeitsprocesses.Byanalyzinglargevolumesofdataandidentifyingpatternsandcorrelations,thesystemcanlearnfrompastexperiencesandanticipatefutureoutcomes,enablingittomakefasterandmoreeffectivedecisions.Forinstance,machinelearningalgorithmscanbetrainedtopredicttheoptimalforgingparametersbasedonthematerialproperties,productspecifications,andprocessconditions,therebyreducingthetrial-and-errorphaseandimprovingtheyieldandefficiencyofthesystem.

Lastly,theintelligentforgingsystemcanalsobenefitfromtheadoptionofdigitalizationandIndustry4.0technologies,whichcanenableittoconnectwithothersystems,machines,andstakeholdersinthevaluechain.ByleveragingthepoweroftheInternetofThings,cloudcomputing,andbigdataanalytics,thesystemcanaccessawealthofinformationandinsightsthatcanhelpimproveitsperformance,reducecosts,andenhancecustomersatisfaction.Forexample,thesystemcanintegratewiththesupplychainmanagementsystemtooptimizetheprocurementofrawmaterials,orwiththequalitymanagementsystemtoensurecompliancewithindustrystandardsandregulations.

Insum,theintelligentforgingsystemanditsqualitycontrolsolutionhavevastpotentialtotransformthemanufacturingindustrybyenablingmoreprecise,efficient,andsustainableprocesses.Byleveragingthelatesttechnologiesandinnovations,thesystemcanaddressthechallengesofmodern-dayforging,suchasvariabilityanddefects,whiledeliveringhigh-qualityandcost-effectiveproductstocustomers.Assuch,itsadoptionanddevelopmentcancontributetothegrowthandcompetitivenessofthemanufacturingindustry,andpromoteamoresustainableandresilientfutureInadditiontothebenefitsmentionedabove,theadoptionofasmartforgingsystemcanalsohaveapositiveimpactontheworkforce.Withautomationandroboticshandlingrepetitiveandphysicallydemandingtasks,workerscanbefreeduptofocusonmorecomplexandcreativetasksthatrequirehumandexterityandproblem-solvingabilities.Thiscanleadtoamorefulfillingworkexperienceandbetterjobsatisfaction,whichcanalsocontributetotheoverallsuccessofthemanufacturingindustry.

Furthermore,asmartforgingsystemcanenablemanufacturerstomoreeffectivelymonitorandmanagetheirenergyusageandemissions,leadingtoamoresustainableandenvironmentallyfriendlyoperation.Byanalyzingdataonenergyconsumptionandidentifyingareasforoptimization,manufacturerscanreducetheircarbonfootprintandcontributetoglobaleffortstocombatclimatechange.

However,theadoptionofasmartforgingsystemalsocomeswithitsownsetofchallengesandconsiderations.Onesuchchallengeistheneedforspecializedtechnicalexpertisetodesign,implement,andmaintainthesystem.Manufacturerswillneedtoinvestintrainingtheirworkforceandpartneringwithtechnologyexpertstoensuresuccessfuladoption.

Anotherconsiderationisthepotentialimpactonsupplychainsandlogistics.Withamoreefficientandprecisemanufacturingprocess,theremaybechangesinthesupplyanddemandofcertainmaterialsandproducts.Assuch,manufacturersmayneedtoreorganizetheirsupplychainsandlogisticstoadapttothenewsystem.

Inconclusion,theadoptionofasmartforgingsystemhasthepotentialtorevolutionizethemanufacturingindustry,