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CN-121976012-A - Online heat treatment and forming continuous production method and system for coil springs

CN121976012ACN 121976012 ACN121976012 ACN 121976012ACN-121976012-A

Abstract

The invention discloses an online heat treatment and molding continuous production method and system for coil springs, and belongs to the technical field of machine manufacturing. The system comprises an intelligent feeding device, an online gradient heat treatment device, an integrated forming device, an automatic discharging and sorting device and a central control system which are sequentially arranged along a production line. The method comprises the steps of carrying out gradient heat treatment on raw materials sequentially through a quenching section, a heat preservation transition section and a tempering section after cleaning and precise feeding, immediately carrying out winding forming under a thermal state, and automatically detecting and sorting. The invention realizes continuous and automatic production of the whole process by seamlessly integrating the heat treatment and the forming process, effectively solves the problems of intermittent process, low temperature control precision and high energy consumption of the traditional sectional type processing, remarkably improves the production efficiency, the product performance consistency and the dimensional precision, greatly reduces the energy consumption and the labor cost, and is suitable for manufacturing large-scale, high-precision and green coil springs.

Inventors

  • SHAO XUEFEI
  • YU DINGFENG

Assignees

  • 浙江衢州双通工贸有限公司

Dates

Publication Date
20260505
Application Date
20251215

Claims (10)

  1. 1. An on-line heat treatment and molding continuous production system for coil springs, which is characterized by comprising the following components sequentially connected along the direction of a production line: The intelligent feeding device is used for cleaning and accurately conveying raw materials; The online gradient heat treatment device is used for carrying out continuous quenching, heat preservation transition and tempering treatment on the raw materials; the integrated forming device is used for winding and forming the raw materials after heat treatment into coil springs; The automatic blanking and sorting device is used for grabbing and sorting the formed coil springs; And the central control system is used for carrying out real-time monitoring and cooperative control on the operation parameters of the whole system.
  2. 2. The online heat treatment and molding continuous production system of the coil spring according to claim 1, wherein the intelligent feeding device comprises a servo driving roller group, a positioning sensor and a high-pressure airflow dust removal module, the feeding speed is adjustable within the range of 0.5-2m/min, and the positioning accuracy is +/-0.1 mm.
  3. 3. The on-line heat treatment and molding continuous production system of a coil spring according to claim 1, wherein the on-line gradient heat treatment device comprises a quenching section, a heat preservation transition section and a tempering section which are sequentially and continuously arranged; The quenching section adopts an intermediate frequency induction heating mode and is provided with an infrared thermometer; The heat preservation transition section is a heat insulation cavity; the tempering section adopts a resistance heating mode and is provided with a hot air circulation system; And a high-temperature-resistant conveying belt is arranged below each section, and the running speed of the high-temperature-resistant conveying belt is synchronous with that of the intelligent feeding device.
  4. 4. An on-line heat treatment and molding continuous production system for coil springs according to claim 3, wherein the heating temperature of the quenching section is 860-880 ℃, and the temperature control precision is + -5 ℃; the temperature of the heat preservation transition section is maintained at 800-820 ℃; the heating temperature of the tempering section is 420-440 ℃, and the temperature control precision is +/-3 ℃.
  5. 5. The on-line heat treatment and molding continuous production system of a coil spring according to claim 1, wherein the integrated molding device comprises a servo winding mechanism, a molding die and a size detection sensor; the winding speed of the servo winding mechanism is adjustable within the range of 0.3-1 m/min; The forming die is adapted to a coil spring with the diameter of 10-50mm and has a die temperature compensation function of 150-200 ℃; the accuracy of the size detection sensor was + -0.05 mm.
  6. 6. The online heat treatment and molding continuous production system of coil springs according to claim 1, wherein the automatic blanking and sorting device comprises a mechanical gripper with positioning accuracy of +/-0.2 mm and an automatic sorting module for sorting based on detection results; the sorting module automatically sorts the coil springs into qualified products and unqualified products according to the result of the size detection sensor in the integrated forming device.
  7. 7. The online heat treatment and molding continuous production system of coil springs according to claim 1, wherein the central control system takes a PLC as a core, integrates a touch screen man-machine interface, can collect feeding speed, heat treatment temperature and molding size parameters at a frequency of at least 1 time/second, supports one-key setting of parameters, and automatically adjusts the running state of equipment or gives an alarm when abnormal parameters are detected.
  8. 8. An on-line heat treatment and molding continuous production method for coil springs using the system as claimed in any one of claims 1 to 7, comprising the steps of: s1, raw material feeding, namely cleaning the raw material through an intelligent feeding device and accurately conveying the raw material to an online gradient heat treatment device; s2, gradient heat treatment, namely sequentially carrying out quenching treatment on raw materials through a quenching section of an online gradient heat treatment device, preserving heat for 2-3 minutes, then entering a heat preservation transition section for 1-1.5 minutes, and finally entering a tempering section for tempering treatment and preserving heat for 3-4 minutes; s3, integrally forming, namely immediately feeding the raw materials which are subjected to heat treatment and are in an easy-to-form state at 400-420 ℃ into an integral forming device, winding the raw materials into coil springs according to preset parameters by a servo winding mechanism, and synchronously detecting the sizes; S4, blanking and sorting, namely grabbing a formed coil spring by a mechanical gripper of an automatic blanking and sorting device, and automatically sorting into qualified products and unqualified products according to a size detection result; S5, whole-process monitoring, namely, monitoring operation parameters of each step in real time by a central control system, and automatically adjusting or alarming when abnormality occurs.
  9. 9. The on-line heat treatment and formation continuous production method for coil springs according to claim 8, wherein in step S2, the temperature control accuracy of the quenching section is ±5 ℃, and the temperature control accuracy of the tempering section is ±3 ℃.
  10. 10. The on-line heat treatment and molding continuous production method of a coil spring according to claim 8, wherein in step S3, the molding die of the integrated molding apparatus is maintained at a temperature of 150-200 ℃.

Description

Online heat treatment and forming continuous production method and system for coil springs Technical Field The invention relates to the technical field of mechanical manufacturing, in particular to an online heat treatment and forming continuous production method and system for coil springs. Background The coil spring is used as a core elastic element in the equipment manufacturing industry, the performance of the coil spring is directly related to the reliability, stability and service life of a host product, the manufacturing of the coil spring is a complex process, and generally comprises key links such as raw material pretreatment, heat treatment (quenching and tempering), winding forming, subsequent strong pressure treatment, surface treatment and the like, wherein the heat treatment link aims to optimize the internal tissue structure of a material (such as obtaining high-strength tempered troostite) through precise heating and cooling control, so that the excellent elastic limit, fatigue resistance and other core mechanical properties of the coil spring are given, and the forming link is to process the treated raw material into a required spiral shape. At present, a sectional processing mode is commonly adopted in coil spring manufacturing industry, specifically, raw materials (such as spring steel bars) are transported to an independent heat treatment furnace offline for quenching (heat preservation at 850-900 ℃) and tempering (heat preservation at 400-450 ℃) after being subjected to pretreatment such as flattening, and then transported to another winding machine for forming processing by manual or simple mechanical mode after being cooled to room temperature, and the mode has the following obvious inherent defects: ① The continuous process is poor in continuity and low in production efficiency, and the heat treatment and the forming are used as two independent processes, and physical intervals and transfer time exist between the two independent processes, so that the production beat is interrupted, and continuous flow cannot be formed, so that the single-day productivity is limited (generally lower than 500 pieces), and the modern large-scale and high-efficiency production requirements are difficult to adapt. ② The heat treatment precision and effect are poor, because of the transfer between the working procedures, the temperature of the raw materials can be rapidly reduced (can reach 50-80 ℃) after leaving the heat treatment furnace, so that the raw materials are not in the optimal plastic forming temperature interval when entering the forming working procedure, and in order to compensate the temperature loss, secondary heating is sometimes even needed, so that the energy consumption is increased, the continuity of the heat treatment process is seriously damaged, the ideal tissue transformation of the materials cannot be realized, and finally the mechanical property (such as fatigue life) of the coil spring is unstable, and even is reduced by 15-20%. ③ The energy consumption and the cost are high, namely, the heat loss caused by offline transfer and possibly secondary heating measures are adopted, so that the energy consumption in the whole production process is obviously increased, the additional energy consumption accounts for 25% -35%, meanwhile, the labor cost is increased by manual transfer, the damage risks of scratch, collision and the like of the surface of the raw material are brought, and the qualification rate of the finished product is generally only 88% -92%. ④ The automation degree is low, the quality consistency is difficult to ensure, the prior art scheme, even a semi-continuous system, also often depends on manual experience and operation in key links (such as temperature regulation and control and feeding speed matching), human errors are easy to introduce, the rejection rate of products is higher (8% -10%), and high-precision and high-quality consistent large-scale production is difficult to realize. Based on the above-mentioned defects, in the prior art, although an improved scheme is tried, for example, a semi-continuous system is adopted for connecting a heat treatment furnace and a winding machine by using a conveyor belt, but generally, only a quenching process is integrated, tempering is still required to be carried out independently after forming, the conveyor belt lacks effective heat preservation, the problem of temperature loss still exists, and a simple scheme of manual auxiliary on-line heating is adopted, but the temperature control is extremely inaccurate (the fluctuation can reach +/-20 ℃), a complete and qualified heat treatment process cannot be realized, and the method is only suitable for small-batch production with extremely low requirements. Therefore, there is a strong need in the art for a method and system for integrated, continuous and automated production of coil springs in a "heat treatment-forming" process, which essentially overcomes the above-mention