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CN-121983399-A - Automatic rolling forming machine and forming method for ceramic insulator

CN121983399ACN 121983399 ACN121983399 ACN 121983399ACN-121983399-A

Abstract

The invention discloses an automatic rolling forming machine and a forming method of a ceramic insulator, and relates to the technical field of forming machines. According to the ceramic insulator automatic rolling forming machine, through setting the blank pretreatment unit and carrying out signal connection with the control unit of the self-adaptive leveling mechanism, blank state sensing is achieved, meanwhile, the follow-up forming process parameter dynamic adjustment is carried out, the blank pretreatment unit can detect the initial state of blanks on line and carry out targeted adjustment through the pretreatment executor, blanks entering a rolling station achieve ideal and uniform states, the blank pretreatment unit transmits the final state parameters of the processed blanks to the control unit, the rolling head and the die rotary disc parameters are adjusted in a linkage mode according to the final state parameters, the forming process can be self-adaptive to the characteristics of each blank, and product consistency and qualification rate are ensured.

Inventors

  • WANG LIANG
  • WANG YOU
  • Gan Jiao
  • HU LIU

Assignees

  • 江西亚拓电气集团有限公司

Dates

Publication Date
20260505
Application Date
20260325

Claims (10)

  1. 1. The utility model provides an automatic roll forming machine of ceramic insulator, includes frame (1), mould gyration dish (2) that set up on frame (1), rolling head (3) and drive feeding mechanism (4) that rolling head (3) fed, its characterized in that still includes: The self-adaptive leveling mechanism (5) is connected between the rolling head (3) and the feeding mechanism (4) and is used for dynamically maintaining the parallelism between the rolling head (3) and the surface of the die in the rolling process; The blank pretreatment unit (6) is arranged above the die rotary disc (2) and is positioned in front of the rolling station and is used for carrying out state adjustment on blanks before entering the rolling station; The blank preprocessing unit (6) is in signal connection with the control unit (53) of the self-adaptive leveling mechanism (5) so as to adjust rolling forming parameters in a linkage mode according to the preprocessed blank state parameters.
  2. 2. An automatic roll forming machine for ceramic insulators according to claim 1, characterized in that said self-adaptive levelling mechanism (5) comprises: The pressure sensing unit (51) is arranged between the rolling head (3) and the feeding mechanism (4) and is used for detecting the contact pressure distribution between the rolling head (3) and the ceramic blank in real time; the leveling execution unit (52) comprises at least three electric push rods (521) which are circumferentially arranged along the rolling head (3) and are independently driven, and the tail end of each electric push rod (521) is connected with the rolling head (3); And the control unit (53) is respectively connected with the pressure sensing unit (51) and the leveling execution unit (52) in a signal manner and is used for dynamically controlling the expansion and contraction amount of each electric push rod (521) according to the pressure distribution data.
  3. 3. An automatic roll forming machine for ceramic insulators according to claim 2, characterized in that the pressure sensing unit (51) is a plurality of pressure sensors (511) arranged in an annular array, and the plurality of pressure sensors (511) are uniformly distributed on the connecting interface at the back of the rolling head (3).
  4. 4. An automatic roll forming machine for ceramic insulators according to claim 3, characterized in that the electric push rod (521) of the leveling execution unit (52) is a servo electric cylinder, the end of which is connected with the rolling head (3) through a universal joint (522).
  5. 5. An automated roll forming machine for ceramic insulators according to claim 2, characterized in that said blank pretreatment unit (6) comprises: A sensor module (61) for detecting in real time at least moisture and temperature state parameters of the blank inside the mould; The pretreatment executor (62) is a multi-axis adjustable microwave or infrared heating humidity-adjusting module and is used for pretreating the blank; and the linkage control module (63) is respectively connected with the sensor module (61), the preprocessing executor (62) and the control unit (53) of the self-adaptive leveling mechanism (5) in a signal way.
  6. 6. An automated roll forming machine for ceramic insulators according to claim 5, characterized in that the sensor module (61) comprises a non-contact infrared moisture sensor (611) and a temperature sensor (612) integrated in the mold base of the mold turret (2), and an ambient temperature and humidity sensor (613) mounted on the frame (1).
  7. 7. The automatic rolling forming machine for ceramic insulators according to claim 6, wherein the linkage control module (63) is internally provided with a preprocessing algorithm and a parameter matching algorithm; the preprocessing algorithm is used for calculating and generating a heating power, action time and an action area adjusting instruction of the preprocessing executor (62) according to the initial state of the blank and the environmental parameters detected by the sensor module (61); The parameter matching algorithm is used for generating linkage adjustment instructions for the heating temperature of the rolling head (3), the reference pressure set value of the self-adaptive leveling mechanism (5) and the rotating speed of the die rotating disc (2) according to the final state parameters of the pretreated blank.
  8. 8. An automatic roll forming machine for ceramic insulators according to claim 1, characterized in that the inside of the rolling head (3) is provided with a heating device (31) in signal linkage with the control unit (53).
  9. 9. An automatic roll forming machine for ceramic insulators according to claim 1, characterized in that the mould rotating disc (2) is an indexing turntable structure, the rotation axis of which is vertically intersected with the feeding axis of the rolling head (3), and the control unit (53) is also connected with a man-machine interface (7) for displaying real-time process parameters and equipment states.
  10. 10. An automatic roll forming method for ceramic insulators, which adopts the automatic roll forming machine for ceramic insulators as claimed in any one of claims 1 to 9, and is characterized by comprising the following steps: step S1, when a die for bearing a blank rotates to a pretreatment station, non-contact scanning is carried out on the surface moisture and the temperature of the blank through a sensor module (61), and environmental temperature and humidity parameters are obtained; step S2, the coordinated control module (63) calculates a pretreatment scheme required for enabling the blank to reach an ideal pre-rolling state according to the data acquired in the step S1 and combining a target blank state model; step S3, driving a pretreatment executor (62) to perform local or whole heating and humidity adjustment on the blank according to the pretreatment scheme of the step S2; Step S4, transmitting the final state parameters of the blank processed in the step S3 to a control unit (53) of the self-adaptive leveling mechanism (5), and dynamically adjusting the heating temperature of the rolling head (3), the reference pressure set value of the self-adaptive leveling mechanism (5) and the rotating speed of the die rotary disc (2) by the control unit (53) according to the final state parameters; And S5, driving the feeding mechanism (4) to enable the rolling head (3) to contact the blank, monitoring pressure distribution in real time by the pressure sensing unit (51), and enabling the rolling head (3) to be parallel to the surface of the die in the forming process by dynamically adjusting each electric push rod (521) of the leveling execution unit (52) by the control unit (53) until the forming is completed.

Description

Automatic rolling forming machine and forming method for ceramic insulator Technical Field The invention relates to the technical field of forming machines, in particular to an automatic rolling forming machine for ceramic insulators and a forming method thereof. Background The ceramic insulator is a basic element in an electric power system, the performance and reliability of the ceramic insulator are greatly dependent on the quality of a blank forming stage, roll forming is one of the common processes for producing ceramic insulator blanks, the basic principle is that a plastic ceramic pug placed in a rotary die is rolled through a rotary rolling head, so that a required umbrella shape is formed, an existing automatic roll forming machine generally comprises a frame, a die rotary disc, the rolling head and a feeding mechanism for driving the rolling head to feed, the die rotary disc realizes the cyclic switching of stations, the feeding mechanism controls the pressing and lifting of the rolling head, and the structure realizes the continuity and automation of production. However, in the actual production process, the problem that the consistency and qualification rate of the molding quality are still affected still exists, firstly, the moisture and temperature distribution in the ceramic pug blank and on the surface of the ceramic pug blank may be uneven in the ageing, transporting and filling processes, the difference of the initial state directly affects the plasticity and deformation resistance of the blank, the blank is directly rolled, the rolling process parameters (such as pressure, temperature and rotating speed) can be generally set according to fixed values or experience, the actual state of each blank cannot be adapted, the defects of cracking, uneven density or over-size of the green body are easily caused, and in the rolling process, the defects of mounting errors of a die, the horizontal deviation of a die disc and the irregularities of the initial shape of the blank can cause the working face of the rolling head and the bearing face of the die to be not parallel, and although some devices adopt floating heads or simple spring buffer structures, the rolling process belongs to passive response, the leveling capability is limited, so that the pressure distribution of the blank is uneven, and the uniformity of the wall thickness and the internal structure are affected. Disclosure of Invention According to the automatic rolling forming machine and the forming method of the ceramic insulator, provided by the invention, the blank pretreatment unit is arranged and connected with the control unit of the self-adaptive leveling mechanism in a signal manner, so that the blank state sensing is realized, meanwhile, the forming process parameters are dynamically adjusted in the follow-up process, the blank pretreatment unit can detect the initial state of the blank on line and carry out targeted adjustment through the pretreatment executor of the blank, so that the blank entering a rolling station reaches an ideal and uniform state, the blank pretreatment unit transmits the final state parameters of the processed blank to the control unit, the rolling head and the mold rotating disc parameters are adjusted in a linkage manner according to the final state parameters, the forming process can be self-adaptive to the characteristics of each blank, the problem of unstable forming quality caused by the fluctuation of the initial state of the blank is solved, and the consistency and qualification rate of products are ensured. The automatic rolling forming machine for the ceramic insulator comprises a frame, a die rotating disc arranged on the frame, a rolling head, a feeding mechanism for driving the rolling head to feed, and further comprises: the self-adaptive leveling mechanism is connected between the rolling head and the feeding mechanism and is used for dynamically maintaining the parallelism between the rolling head and the surface of the die in the rolling process; The blank pretreatment unit is arranged above the die rotary disc and positioned in front of the rolling station and is used for carrying out state adjustment on blanks before entering the rolling station; The blank preprocessing unit is in signal connection with the control unit of the self-adaptive leveling mechanism, so that rolling forming parameters are adjusted in a linkage mode according to the preprocessed blank state parameters. Preferably, the adaptive leveling mechanism comprises: The pressure sensing unit is arranged between the rolling head and the feeding mechanism and is used for detecting the contact pressure distribution between the rolling head and the ceramic blank in real time; The leveling execution unit comprises at least three electric push rods which are arranged along the circumferential direction of the rolling head and are independently driven, and the tail end of each electric push rod is connected with the rolling