Automatic unloading cylinder manipulator in the winding area of narrow space

Advantages of this proposal：

1、The installation and construction of the sky rail system is simple and convenient: the hanging support legs are made of stainless steel welded, bolt connect to steel beams in the factory building.The height error of the support legs is within 20mm, which does not affect their use; The left and right double tracks are made of stainless steel rectangular tubes, connected by connecting plates, with a joint gap of less than 1mm.

2、Convenient track adjustment: Use a lightweight track adjustment fixture and level to adjust the adjustment bolts. Can quickly adjust track height, track spacing, and track levelness.

3、Swinging wheel type X-axis walking platform with good adaptability: four sets of swinging type rubber wheel frames, walking on rectangular track beams. Smooth and silent operation, low precision requirement for track installation, and easy construction. Within ± 5mm of track spacing error and ± 10mm of track horizontal error, it does not affect the positioning accuracy of the robotic arm.

4、Good synchronization of X-axis walking drive: One speed reduction motor dual output shaft drives both the left and right gear rack mechanisms simultaneously, ensuring synchronous walking and drive without any jamming phenomenon.

5、Reinforced Y-axis and R-axis load-bearing frames: Made of thickened stainless steel plates welded and processed as a whole, with high dimensional accuracy, strong rigidity, and the ability to withstand larger overturning moments and bending moments. The dimensional deformation is small and does not affect positioning accuracy.

6、High strength, high safety, and high protection Z-axis structure: The Z-axis frame adopts a modular structure, with thickened stainless steel plates welded and processed as a whole. It has high dimensional accuracy, strong rigidity, and can withstand larger overturning moments and bending moments. The dimensional deformation is small and does not affect positioning accuracy. Select heavy-duty linear guide rails and install protective organ covers, and install mechanical fall prevention mechanisms, ensuring high safety and good protection.

7、Closed type silent rotary unit: using worm gear and worm fully sealed rotary support, achieving 360 ° rotation, large overturning torque, and strong bearing capacity.

8、High positioning accuracy and stable transmission of each axis system: using high-precision gear rack transmission and linear guide rail to ensure repeated positioning accuracy of ± 0.1mm.

9、High success rate of yarn retrieval: using heavy-duty linear guide rails, increasing the size of the guide rail fastening bolts to M8 and M6, and using large-diameter linear bearings. After fully extending, the deformation under a load of 150kg is less than 5mm, and the deformation under a load of 60kg is less than 2mm.

10、Real time automatic calibration of positioning benchmarks for each axis system to reduce cumulative positioning errors: Each axis system is equipped with a benchmark zero point proximity switch. After the equipment runs for a period of time, it can automatically perform zero point benchmark calibration to avoid increasing cumulative errors and reducing positioning accuracy.

11、The dual measures of limit sensors and mechanical limits improve safety: limit proximity switches and mechanical limit devices are installed on each shaft system to enhance safety.

12、Install gear racks and linear guide rail protective devices to avoid accumulation of filaments and water mist effects: Install L-shaped shields above all racks and linear guide rails to prevent accumulation of filaments and water mist from falling onto the racks and linear guide rails. On both sides of the rectangular track beam, protective covers are installed to prevent pollutants such as filaments that accumulate on the track from falling onto the cake.

13、The centralized automatic lubrication system makes maintenance more convenient: the gears and racks are lubricated with felt gear to add grease, and all lubrication points are connected through distribution blocks and lubrication hoses. The electric automatic lubrication device can regularly and quantitatively add lubricating grease to each lubrication point, reducing the labor intensity of lubrication and maintenance, providing sufficient lubrication and extending the service life.

14、Install a grease drip collection tank to prevent grease from falling onto the ground and causing personal injury: Install an L-shaped grease collection tank under all racks and linear guides to completely collect spilled grease and prevent grease from falling onto the ground and causing personal injury.

15、Innovative torque and displacement control methods greatly improve the success rate of yarn retrieval: the retraction stroke of the expanding disc is 3-5mm, and the travel of lifting the yarn cake away from the drawing machine head is theoretically only 6-10mm. The torque and displacement control methods can accurately control the lifting stroke, ensuring successful yarn retrieval. Otherwise, it is easy to cause damage to the yarn cake.

16、The selection of high-power and long stroke electric cylinders greatly improves the reliability and service life of the electric cylinders by improving their protective measures. The imported high-power and long stroke electric cylinders are selected, and each electric cylinder is equipped with two sets of large diameter linear bearings, which enhances the bearing capacity. The electric cylinder shaft and linear bearing optical shaft are equipped with shaft seals, and rectangular corrugated seals are added to the periphery, greatly improving the anti pollution ability and improving the reliability and service life of the electric cylinder operation.

17、The F-axis and A-axis yarn retrieval mechanisms can be replaced as a whole, which is easy to maintain and improves the equipment startup rate. Adhering to the design concept of modular structure and overall replacement, the lubrication and power control communication cables of the F-axis and A-axis yarn retrieval mechanisms are all equipped with quick insertion and extraction connectors. By using a quick disassembly and assembly cart, the yarn retrieval mechanism can be completely replaced within 10 minutes, allowing for quick recovery of the equipment.

18、security protection solution greatly improves security: front and rear solid-state LiDAR, three side safety touch sensors, safety grating, six sets of diffuse reflection sensors, emergency stop button, control program selects different security control strategies according to the equipment in different working areas, forming a multi-sensor spatiotemporal coupling security protection measure.

19、By using sliding contact wire power supply and wireless communication, without drag chain device, cross area operation scheduling of the yarn unloading device can be achieved. The power supply system adopts high protection sliding contact wire power supply and 5.8GHz wireless communication, and the power and control cables do not require drag chain sliding, providing space for cross area operation scheduling of the automatic yarn unloading device.

20、Innovative visual secondary positioning method and anti-collision yarn safety protection measures.

21、Simple and fast touch and click operation can achieve quick product replacement of winding machines: each winding machine can produce products of different specifications,. When changing the product variety of the winding machine, such as one cake winding, two cakes winding, three cakes winding, and four cakes winding, simply find the corresponding machine ID through HMI, click on the corresponding position of the yarn cake on the machine head, and the yarn balls on each winding machine can be flexibly removed without additional mechanical adjustment.

22、The yarn cake forming quality management system can adjust the bushing process in real time: the weight data of each machine position and batch of yarn cakes are transmitted in real time to the DCS control system, and the corresponding flow rate changes of the bushing are analyzed. The temperature of the bushing is precisely controlled to achieve product optimization and improve the stability of the winding operation. It can achieve statistics on shift production and yield, and automatically complete the classification and processing of qualified and degraded products.

23、Innovative queue management and scheduling algorithms greatly improve yarn unloading efficiency: with manual, semi-automatic, and fully automatic yarn unloading modes, the innovative one is called fleet management. Based on the set queue priority and cutting principles, as well as the principle of nearest operation and shortest distance, it assists in cross regional operations strategy and comprehensive scheduling greatly improve work efficiency.

24、Real time display of yarn cake weight: The unloading device is equipped with a large screen to directly display the weight of yarn cakes, making it convenient for workers to understand the quality of yarn cake forming in real time.

25、Equipment intelligent operation and maintenance management system, achieving intelligent maintenance management: maintenance personnel operate through a mobile app, and data is synchronized in real-time to the database; Preventive maintenance: Count the operating time of each component of the equipment, estimate the estimated service life, remind maintenance personnel to prepare accessories and maintenance materials and tools in advance for preventive maintenance; Support reporting of fault situations in the form of images, text, and videos to improve troubleshooting efficiency; According to the established maintenance plan, automatically remind maintenance personnel and push maintenance content.

26、The centralized management platform for the yarn unloading device adopts a B/S architecture, which can achieve web and mobile queries, centralized data management, and integration with ERP. It can also set parameters in bulk online. Configure the database to complete functions such as data storage, display, upload, reporting, and statistical analysis.