Development And Application Of Automatic Production Line For Diesel Engine Piston Machining

Piston is the "heart" of engine.It bears the alternating load brought by high-speed reciprocating motion in high temperature and high pressure environment.Its quality has an important impact on the reliability,service life,exhaust emission and fuel economy of engine.With the continuous improvement of engine emission standards and reliability requirements,users have higher and higher requirements for piston parts manufacturing accuracy,delivery cycle and production management.In order to achieve high quality,high efficiency and low cost production of diesel engine piston,based on the needs of intelligent transformation of the piston production process of the author’s unit,the development of diesel engine piston machining automatic production line is carried out,aiming to build an automatic production line of diesel engine piston,which integrates numerical control processing,industrial robot,automatic material transportation and process monitoring.The specific research contents are as follows(1)Automatic production line design.According to the typical machining process of diesel engine piston,IE technology is used to analyze the demand of automatic production line and optimize the process;The composition scheme and layout design of the diesel piston automatic production line with unified management and monitoring function,which is composed of automatic loading and unloading system,automatic conveying system and machining center,are completed.(2)Automatic production line system selection and design.According to the overall design of automatic production line,complete the selection of automatic processing equipment such as machining center;Based on the characteristics of diesel engine piston and the requirement of material transportation,the equipment selection of automatic loading and unloading system is completed;The automatic conveying system is analyzed and designed.Each station is connected according to the technological process to realize the automatic conveying of workpieces between stations;And completed the structure design of the automatic cleaning machine,which can realize all-round cleaning and drying of the piston.(3)Automatic production line key tooling design.In order to ensure the processing quality of the piston in the key process of automatic production,the fixture for rough boring pin hole,vehicle fixture and fine boring pin hole fixture are designed;Aiming at the problem of piston position error in the production process,the error proofing device is designed by using visual recognition and piston orientation method to ensure the correct orientation of piston in the process of automatic feeding.(4)Production line management and monitoring.Based on the requirements of automatic operation of piston production line,the system management architecture and network communication architecture of automatic operation of production line are designed,and the system monitoring structure and specific monitoring scheme are designed for the monitoring objectives of production progress,process quality,equipment operation status and tool life,so as to ensure the orderly operation of automatic production line according to the process flow and feed back the processing information in real time.(5)Automatic production line debugging and operation.The on-line debugging of each system of diesel engine piston machining automatic production line is completed,and the operation capacity of the automatic production line and the process capacity of key processes are evaluated.The results show that the balance rate of the production line is 99.31%,and the process capacity index CPK of key processes is ≥ 1.67.The expected goal of automatic processing and real-time digital management of diesel engine piston stability is realized.