The Design And Development Of The Automatic Assembly Line Of Wheel Brake Disc Based On IFix

This project comes from the actual demand of the enterprise,aiming to solve the disadvantages of low efficiency and high labor intensity existing in the current way of artificial assembly of train wheels and brake discs,based on sufficient analysis and research of assembling characteristics,technical conditions and process requirements,then designs a assembly production line of wheels and braking discs that can satisfy the production requirements and own high degree of automation.It can realize the feeding?assembling and discharging of wheels and brake discs automatically.First,we designed the hardware and communication system.The mechanical system is divided into five independent functional units which are responsible for the implementation of different assembly functions,and for the purpose of reducing system complexity and improving system stability,we use Toshib and KUKA manipulator sharing some process.Then designed the technological process for each functional unit,set up the detailed action and formulate the precise action time for every single step process.The communication between functional units and the integration with manipulator are realized by means of Ethernet,serial port and bus.Secondly,we designed the software system.Including the overall implementation of the control system,monitoring system based on the iFix,PLC system,servo system,detection system,and finished the iFix,PLC,robot programming.IFix is used as the host computer to carry on the centralized management,and the four module PLC is used as the lower computer to control the distributed field equipment.We developed the man-machine interface based on the software platform iFix,to display the running state collected by sensors of the detection system,realizing the real-time monitoring function of the control system,and meanwhile we developed the other auxiliary functions including bar code uploading and error handling.Thirdly,developed the key logic algorithm of the control system.Mainly including:wheel unbalance detection and assembly algorithm;parametric programming logic of the wheel selection process;bar code upload mode and combinational logic;the artificial correction method of Toshiba manipulator grabbing position.These are important technical supports for the development of automatic assembly line.Finally,do the commissioning test.On the basis of the installation and wiring of the field equipment,the electrical control cabinet,and the design of the software system.The no-load single step debugging,the load state single step debugging,and the load state automatic debugging are carried out in sequence.The results show that the software and hardware system design of the automatic production line has the characteristics of reasonable design,reliable scheme and high efficiency.It can meet the requirements of production tasks,and greatly improve the efficiency of wheel assembly.