CN113176030A

Movatterモバイル変換

Info

Publication number: CN113176030A
Application number: CN202110459409.XA
Authority: CN
Inventors: 柳丹; 刘杰安
Original assignee: Shanghai Ruiti Industrial Intelligent Technology Co ltd
Current assignee: Shanghai Ruiti Industrial Intelligent Technology Co ltd
Priority date: 2021-04-27
Filing date: 2021-04-27
Publication date: 2021-07-27

Abstract

The invention discloses a method for calibrating and comprehensively managing a tightening tool, which comprises the following steps: the device comprises a movable equipment body, a sensor, a test tool and a comprehensive management system, wherein the movable equipment body consists of a cabinet body, a movable pulley, a pushing handle, a track management tool cabinet and a UPS (uninterrupted power supply); the sensors comprise a dynamic torque sensor and a static torque sensor; the test tools are multiple sets and can be flexibly switched; the comprehensive management system integrates the functions of data recording, testing, point inspection, calibration, management and the like of the tightening tool.

Description

Calibration and comprehensive management method for tightening tool

Technical Field

The invention relates to the technical field of intelligent management of tightening tools.

Background

In the assembling process of bolt connection, all links such as station operation, system monitoring, quality control and the like are concerned, the tightening torque can be accurately controlled to a great extent by using a tightening tool, and the assembling reliability is ensured. With the driving of the recent intelligent manufacturing trend, manufacturers pay more attention to the quality of tightening assembly, and various tightening tools such as a tightening gun and a torque wrench are widely used.

At present, the use of a tightening tool is in an explosive growth situation, but the attention on the accuracy and precision of the torque of the tightening tool is insufficient, and links such as the recording and analysis of tightening data, the comprehensive management of the tightening tool and the like are weak, so that the following defects exist:

(1) the reasonable use range of the torque of the tightening tool is set within 80%, and the actual use often exceeds the torque range to tighten the fastener, so that the precision of the tightening tool is reduced, and even the tightening tool cannot work normally.

(2) The calibration of the tightening tool is inconvenient, the time interval is too long, and the precision exceeds the preset range and is still used.

(3) The software system for calibration is single in function and only provides a pass or fail determination.

Disclosure of Invention

The technical problem to be solved by the invention is to solve the defects of the prior art and provide a calibration and comprehensive management method for a tightening tool.

In order to solve the technical problems, the invention adopts the technical scheme that: a calibration and comprehensive management method for a tightening tool is characterized by comprising the following steps:

the intelligent cabinet comprises an equipment body and a comprehensive management system, wherein the equipment body comprises a cabinet body, and a conversion tool and a torque sensor are arranged on the cabinet body; the conversion tool is used for connecting to-be-detected tightening equipment, and the torque sensor is connected with the conversion tool and used for detecting torque and sending a detection signal to the comprehensive management system;

and (3) testing: the tightening tool is subjected to torsion testing through the conversion tool and the torque sensor, the comprehensive management system stores testing data, and when the torsion exceeds a set range, the comprehensive management system sends an alarm prompt;

checking: performing single-point single-time or single-point multiple-time tightening torque verification on a tightening tool, binding verification data with the tool, presetting a torque value of point inspection, a judgment standard and the number of point inspection, and judging whether the point inspection process is qualified or not in real time;

calibration: correspondingly calibrating the tightening tool, recording a measured value, and automatically judging whether the measurement requirement is met; after multiple times of calibration, the system automatically calculates the CPK (process capability index) of the front row measurement data until the measurement is completed, judges whether the tightening gun capability fluctuates or changes suddenly according to the change of the CPK, and gives an alarm when the fluctuation or changes suddenly, and prompts an operator to judge.

Further, torque sensor includes dynamic torque sensor and static torque sensor, the conversion frock includes dynamic torque test frock and static torque test frock, and static torque test frock and dynamic torque test frock are used for connecting the adapter of tightening tool respectively, and static torque sensor and dynamic torque sensor correspond with static torque test frock and dynamic torque test frock respectively.

Further, the selectable ranges of the static torque sensor are as follows: 10N.m, 50N.m, 100N.m, 200N.m and 500N.m, the precision is 0.1%, and the sampling frequency is not lower than 5 kHz; the static torque testing tool and the reserved interfaces of the static torque sensor are female end square heads, the selectable sizes comprise 1/2 ', 3/4 ' and 1 ', and the static torque testing tool and the reserved interfaces of the static torque sensor are respectively used for matching torque wrenches with different specifications; the selectable range of the dynamic torque sensor is as follows: 2N.m, 5N.m, 10N.m, 20N.m, 50N.m and 100N.m, accuracy 0.1%, and sampling frequency not lower than 5 kHz.

Further, still be provided with a tool drawer in the equipment body, be provided with the foam pad that is used for the trace management in the drawer, the foam pad is used for preventing conversion frock and torque sensor's use with.

Further, point inspection or calibration interval time and advance reminding time are set, the tool exceeds the next point inspection/calibration time, the module reminds that the tool is overdue, the point inspection/calibration is prompted, and the tool number is displayed on a calibration expiration interface.

Further, from the fifth calibration, the system automatically calculates the CPK of the measured data in the front row and displays the CPK on the interface until the measurement is finished, the change of the CPK is dynamically displayed to guide a measurer to judge whether the capacity of the tightening gun fluctuates or suddenly changes, and when abnormal data occurs, the measurement gives an alarm and prompts the operator to judge.

The technical scheme shows that the invention has the following advantages:

(1) the equipment body can be compatible with various tightening tools such as a tightening gun, a torque wrench and the like, and is convenient for factory management of tightening assembly.

(2) The mode of conversion frock is adopted in the change of multiple tightening tool, the simple operation.

(3) The device can be provided with dynamic and static torque sensors with various measuring ranges, so that the calibration of tightening tools with different measuring ranges is facilitated, and the occurrence of mixed use of the tools can be effectively prevented.

(4) The high-precision and high-resolution torque sensor is adopted, so that the use precision of a screwing tool can be improved, and the quality of screwing assembly is improved.

(5) Adopt the integrated management system of multiple functions, can carry out multi-level management to screwing up the instrument, carry out diversified analysis, it is more high-efficient, intelligent to relevant data.

(6) The comprehensive management system has a real-time monitoring function of test data, and when the torque display exceeds a set limit range, the alarm is triggered, so that the fastening piece can be effectively prevented from being screwed up by exceeding the torque range, and the damage of a screwing tool is avoided.

(7) The integrated management system has the functions of calibration reminding and limiting: when a certain tightening tool approaches the calibration date, a prompt is sent; the calibration is not carried out when the tool is expired, the use of the tool and other tools can be limited, and the condition that the tool is used out of date is avoided.

(8) Compared with single-point analysis, the CPK analysis of the tightening data is introduced, so that the use trend of the tool can be reflected, the state of the tool is pre-judged, and the use of unqualified tools is avoided in advance.

Drawings

FIG. 1 is a schematic structural view of an apparatus body according to the present invention;

Detailed Description

The following detailed description of embodiments of the invention refers to the accompanying drawings.

The device body structure adopted by the invention is shown in figure 1, and comprises: the equipment cabinet comprises a cabinet body 1, amovable pulley 2, apushing handle 3, a track management tool cabinet 4, a UPS (uninterrupted power supply)standby power supply 5, astatic torque sensor 6, adynamic torque sensor 7, a static torque testing tool 8, a dynamictorque testing tool 9 and anindustrial control computer 10, wherein the industrial control computer comprises a comprehensive management system.

The table top is provided with a dynamic torque test tool fixing position for calibrating a tightening gun; and setting an embedded fixed position of the static torque sensor for calibrating the wrench. The switching joint for the test tool is made of SKS93 material and is wear-resistant.

The dynamic torque sensor is a continuously rotatable dynamic torque sensor. The strain bridge is formed on the elastic shaft by adopting a strain gauge electrical measurement technology, and the electric signal of the elastic shaft which is twisted can be measured by providing a power supply for the strain bridge. After the strain signal is amplified, the signal is converted into a frequency signal which is in direct proportion to the strain through voltage/frequency conversion, and then the signal is converted into an analog quantity signal.

The simulation bolt is arranged below the dynamic torque test tool, the self-rebounding device is arranged in the dynamic torque test tool, the continuous measurement requirement can be met, namely, after the tightening gun is calibrated and fastened once, reverse rotation is not needed, measurement is continued after automatic unloading, and the tool is convenient and fast.

The selectable range of the static torque sensor is as follows: 10N.m, 50N.m, 100N.m, 200N.m and 500N.m, the precision is 0.1%, the sampling frequency is not lower than 5kHz, and the component range test and calibration can reduce the system error and is more accurate. The reserved interface of the static torque sensor is a female end square head, the selectable sizes comprise 1/2 ', 3/4 ' and 1 ', and the reserved interface is respectively used for matching torque wrenches with different specifications. In addition, various testing tools are also arranged at the female end of the sensor, so that size switching can be conveniently carried out.

Likewise, the selectable ranges of the dynamic torque sensor are: 2N.m, 5N.m, 10N.m, 20N.m, 50N.m and 100N.m, accuracy 0.1%, and sampling frequency not lower than 5 kHz. The conventional rotating speed of the tightening gun is about 1200rpm, so that the rotating speed of the dynamic torque sensor is not lower than 1500rpm, and various testing tools are configured for conversion and are matched with the tightening gun.

The test tool and the torque sensor which is not installed on the table top are placed in the tool drawer with the track management foam pad, and the using conditions of the tool and the sensor are clear at a glance.

The UPS uninterrupted power supply is arranged in the cabinet, the sensor and the industrial control computer are powered when the power is off, and the power supply duration can be longer than 4 hours.

The industrial control computer is arranged on the table top of the cabinet and is inclined at a certain angle, so that the operation of personnel is facilitated. In order to meet the requirements of data processing and storage, the memory of the industrial control computer is not lower than 4G, and the hard disk is not lower than 128G.

The data collected by the torque sensor is transmitted to a comprehensive management system installed in an industrial control computer in real time through transmission (or direct communication). The integrated management system stores and analyzes the data.

The industrial control computer is pre-loaded with a WIN10 system and is internally provided with a comprehensive management system.

The comprehensive management system is provided with a database management system for carrying out authority management on operators, managers and the like, carrying out state management on the tightening tools and storing and binding tightening data. And a software module is compiled based on a database, so that the functions of testing, point inspection and calibration of the tightening tool are realized.

(1) Testing

And carrying out real-time data communication on the tightening tool and the comprehensive management system, and visualizing the tightening process. When the torsion value exceeds the preset range in the tightening process, the testing module software gives an alarm to remind an operator of the occurrence of abnormal conditions.

The tightening data can be bound with the tightened workpiece and the tightening tool and then stored, so that misuse is prevented, and follow-up tracing is facilitated.

(2) Point inspection

And in the point inspection process, the upper and lower limits of the collected torque data are judged, and the maximum value, the minimum value and the average value are analyzed.

(a) After the screwing tool selects the point inspection module, the system automatically calls out corresponding tool information and prompts to start measurement;

(b) when the point inspection is finished once, automatically recording a point inspection value, and displaying through a line graph;

(c) each time of point inspection, the system automatically judges whether the measurement requirements are met, and the measurement points are distinguished by different colors and are judged according to the single measurement result;

(d) after the set measurement times are finished, a point inspection result is automatically output, and the method comprises the following contents: the method comprises the following steps of post, number of tightening guns, calibration torque, calibration precision, calibration result, current calibration time, next calibration time, early reminding time, upper calibration torque limit, lower calibration torque limit, maximum sample value, minimum sample value and average sample value;

(e) the point inspection interval time and the advance reminding time can be set, and corresponding administrator permission is set.

(3) Calibration

And in the calibration process, the torque data acquired for many times are subjected to statistical analysis, and judgment is carried out according to specific requirements.

(a) After the fastening tool selects the calibration module, the system automatically calls out corresponding tool information and prompts the start;

(b) when the calibration is completed once, the system automatically records the measured value and displays the measured value through a line graph;

(c) each time of calibration, the system automatically judges whether the measurement requirements are met, and the measurement points are distinguished by different colors and are judged according to the single measurement result;

(d) and starting from the fifth calibration, the system automatically calculates the CPK of the measured data in the front row and displays the CPK on the interface until the measurement is finished, dynamically displays the change of the CPK to guide a measurer to judge whether the gun tightening capacity fluctuates or suddenly changes, and when abnormal data (such as LCL/UCL exceeding LSL/USL or bias exceeding a set value) occur, the measurement gives an alarm and prompts the operator to judge.

(e) After the set calibration times are finished, a calibration result is automatically output, including but not limited to the following contents: the method comprises the following steps of station, tightening gun number, calibration torque, calibration precision, CPK, calibration result, calibration time this time, next calibration time, early reminding time, calibration torque upper limit, calibration torque lower limit, sample maximum value, sample minimum value, sample average value bias, sample unbiased estimation quantity standard deviation and sample +/-4 sigma control interval.

(f) After the calibration is finished, a calibration report is exported, and a parallel process visual graph is obtained: Xbar-S mean standard deviation graph, normal distribution graph, etc.

(4) Database management

(a) The database can add/delete/update/modify the fastening tool information and set different levels of authority;

(b) different application moments may exist in the same tool, and the corresponding application moments can be added/deleted/modified/deactivated;

(c) when the software identifies the bar code of the tool, all the existing torques which should be checked/calibrated currently by the tool are called out, and an operator is prompted to finish all the checking/calibration work.

(d) Before each point inspection/calibration work is started, the system should remind an operator to adjust the gear to the gear or the program of the corresponding torque and confirm the start; after each point inspection/calibration operation is finished, the system should remind an operator to input a gear or a program for the stress moment and confirm the gear or the program.

(e) The gear corresponding to each point detection/calibration may have a slight difference, the system needs to record faithfully, and a historical data fluctuation graph (embodied in a line graph) of the gear corresponding to the same torque can be obtained.

(f) When the tool is close to the next point inspection/calibration time, the module has the function of reminding in advance, the number of days in advance can be set, and the corresponding administrator permission is set.

(g) The tool does not reach the next time of point inspection/calibration, the module defaults that the tool is available and does not remind.

(h) When the tool exceeds the next time of point inspection/calibration, the module reminds the tool of being out of date, prompts point inspection/calibration, and displays the tool number on a calibration expiration interface.

(i) The tool with the overdue period does not complete the point inspection/calibration, and the point inspection/calibration of other tools can not be activated.

(j) The system can filter all tool numbers that expire before a certain date according to the time point and display them through a list.

Claims

1. A calibration and comprehensive management method for a tightening tool is characterized by comprising the following steps:

calibration: correspondingly calibrating the tightening tool, recording a measured value, and automatically judging whether the measurement requirement is met; after multiple times of calibration, the system automatically calculates the CPK of the front row measurement data until the measurement is completed, judges whether the capacity state of the tightening gun fluctuates or changes suddenly according to the change of the CPK, and sends out an alarm when the capacity state fluctuates or changes suddenly and prompts an operator to judge.

2. The method for calibration and integrated management of a tightening tool according to claim 1, characterized in that: the torque sensor comprises a dynamic torque sensor and a static torque sensor, the conversion tool comprises a dynamic torque test tool and a static torque test tool, the static torque test tool and the dynamic torque test tool are respectively used for connecting an adapter of a tightening tool, and the static torque sensor and the dynamic torque sensor respectively correspond to the static torque test tool and the dynamic torque test tool.

3. The method for calibrating and comprehensively managing the tightening tool according to claim 2, wherein: the selectable measuring range of the static torque sensor is as follows: 10N.m, 50N.m, 100N.m, 200N.m and 500N.m, the precision is 0.1%, and the sampling frequency is not lower than 5 kHz; the static torque testing tool and the reserved interfaces of the static torque sensor are female end square heads, the selectable sizes comprise 1/2 ', 3/4 ' and 1 ', and the static torque testing tool and the reserved interfaces of the static torque sensor are respectively used for matching torque wrenches with different specifications; the selectable range of the dynamic torque sensor is as follows: 2N.m, 5N.m, 10N.m, 20N.m, 50N.m and 100N.m, accuracy 0.1%, and sampling frequency not lower than 5 kHz.

4. The method for calibrating and comprehensively managing the tightening tool according to claim 2, wherein: still be provided with a tool drawer in the equipment body, be provided with the foam pad that is used for the trace management in the drawer, the foam pad is used for preventing conversion frock and torque sensor from using mixedly.

5. The method for calibration and integrated management of a tightening tool according to claim 1, characterized in that: setting point inspection or calibration interval time and advance reminding time, wherein the tool exceeds the next point inspection/calibration time, the module reminds the tool of being overdue, prompts point inspection/calibration, and displays the tool number on a calibration expiration interface.

6. The method for calibration and integrated management of a tightening tool according to claim 1, characterized in that: and starting from the fifth calibration, the system automatically calculates the CPK of the measurement data in the front row and displays the CPK on the interface until the measurement is finished, the change of the CPK is dynamically displayed so as to guide a measurer to judge whether the gun tightening capacity fluctuates or suddenly changes, and when abnormal data occurs, the measurement gives an alarm and prompts an operator to judge.