The present invention relates to an air servo cylinder apparatus used for pressurizing work, and a controlling method therefor. More specifically, the present invention pertains to an air servo cylinder apparatus and a controlling method therefor capable of reducing the shock at a time when a pressurizing member contacts work, and applying a required pressurizing force to the work in a short time after the contact.
For example, in a welding gun used for welding work, a common air cylinder is generally used. The welding gun is configured to perform welding operation while applying a required pressurizing force to work after having clamped the work by a clamping mechanism. However, when work is to be clamped, a welding tip may collide against the work and deforms it. This results in poor welding. With this being the situation, the welding gun is formed by an air servo cylinder, and in order to reduce the shock at a time when work is clamped and to shorten the welding time by decreasing pressurization time after the clamping, an air cushion mechanism is attached to the cylinder, as well as a changeover valve or a quick exhaust valve is provided in a drive circuit for the cylinder, whereby the air cylinder is allowed to perform proper operations.
However, the air cushion mechanism attached to the air cylinder can exert a cushioning action only at a specified position such as a stroke end. When work is clamped at a plurality of positions, that is, when the thickness of work varies and target positions are not invariant, a shock reduction by the air cushion cannot be achieved. Also, provision of an air cushion, a changeover valve, and a quick exhaust valve besides servo valves can raise problems of incurring a large size, heavy weight, high cost, short lifetime, low-reliability and the like.
The present inventors have attempted to drive the air cylinder by 5-port servo valves. However, controlling the pressurizing force by the 5-port servo valves separately requires pressure control valves. This has undesirably brought about upsizing and difficulty in cost-reduction.
The object of the present invention is to provide an air servo cylinder apparatus and a controlling method therefor capable of reducing shock at a time when a pressurizing member contacts work, as well as applying a required pressurizing force to the work in a short time after the contact.
To achieve the above-described object, the present invention provides an air servo cylinder apparatus that includes a cylinder having a piston for driving a pressurizing member for work; servo valves individually connected to respective pressure chambers on the head side and the rod side of the cylinder; pressure sensors for detecting the pressures in the respective pressure chambers; a position sensor for detecting operational positions of the cylinder; and a controller outputting control signals to the two servo valves based on detected signals from the pressure sensors and the position sensor.
In the control by the above-described controller, an advancing process of advancing the piston up to a target position where the pressurizing member is to contact work, and a pressuring process of subsequently applying a required pressurizing force to the work, are performed. In the advancing process, in a state where the servo valve on the head side is opened to the air intake side while the servo valve on the rod side is opened to the exhaust side, the piston starts to be driven. Thereafter, in a state where the servo valve on the rod side is left opened to the exhaust side, the valve opening degree thereof is adjusted to become a valve opening degree in accordance with a deviation of the current position from the target position, whereby the piston is smoothly decelerated as it approaches the target position.
The controlling method according to the present invention further includes an intermediate stop process of holding the piston at an intermediate stop position. In the intermediate stop process, the pressure in each of the pressure chambers on the two sides in the pressurizing cylinder is kept lower than the pressure in the pressure chamber on the head side at the time when work is in a clamped state, and the pressures in the pressure chambers on the two sides are kept at values close to each other.
In the above-described advancing process, it is preferable that the opening degree of the servo valve on the head side be controlled in accordance with the aforementioned deviation, or that the servo valve on the head side be controlled in accordance with a deviation of a measured pressure by the corresponding pressure sensor, from a set pressure.
In the present invention, in the advancing process, at the point in time when the speed of the piston has been sufficiently decelerated and the piston has reached a set position that is sufficiently close to the target position, the opening degree of the servo valve on the rod side may be fixed to a minute and constant value, whereby the pressurizing member is brought into contact with work at a constant and low speed.
In the above-described pressurizing process, the pressures in the two pressure chambers in the cylinder may be compared based on signals from the pressure sensors, and at the point in time when the pressure in the pressure chamber on the head side has become higher than the pressure in the pressure chamber on the rod side, the servo valve on the rod side may be fully opened toward the exhaust side, whereby compressed air in the pressure chamber on the rod side may be rapidly discharged.
Furthermore, it is preferable that, after the piston has reached the target position, until the compressed air in the pressure chamber on the rod side is discharged, control be performed so that, by raising the pressure in the pressure chamber on the head side, the difference in the pressure between the pressure chamber on the head side and the pressure chamber on the rod side becomes a desired cylinder thrust. This allows the time before the cylinder thrust reaches the desired cylinder thrust to be reduced.
Thus, the present invention provides advantages in its capability of reducing the shock at a time when a pressurizing member contacts work, and applying a required pressurizing force to the work in a short time after the contact.
The welding gun G shown in
The cylinder 10 includes a cylinder tube 13, a piston 14 slidably inserted therethrough, and a piston rod 15 connected to the piston 14. The cylinder 10 is for clamping work using the piston rod 15. The cylinder tube 13 is a sealed cylindrical member, and includes a pressure chamber 11 on the head side of the piston 14 and a pressure chamber 12 on the rod side thereof, with the piston 14 interposed therebetween. The piston rod 15 hermetically passes through the cylinder tube 13 and extend toward the outside. To the end of the piston rod 15, extending to the outside, one electrode member out of a pair of electrode members of the welding gun is mounted as a pressurizing member 15a for pressurizing work while maintaining contact with it.
The head-side pressure chamber 11 is for driving the piston 14 by compressed air that is supplied and discharged from the head-side servo valve 20 through a flow path 22. The head-side pressure chamber 11 includes a head-side pressure sensor 23 for detecting the pressure in this chamber, and a probe 26 of a position detecting sensor 25 for detecting the drive position of the piston 14, the probe 26 being inserted through the piston 14 from the head cover side. Each of the outputs of the head-side pressure sensor 23 and the position detecting sensor 25 is outputted to the controller 40.
On the other hand, the rod-side pressure chamber 12 is for driving the piston 14 by compressed air that is supplied and discharged from the rod-side servo valve 30 through a flow path 32. The rod-side pressure chamber 12 has a rod-side pressure sensor 33 for detecting the pressure in this chamber. The output of the rod-side pressure sensor 33 is also outputted to the controller 40.
Each of the head-side servo valve 20 and the rod-side servo valve 30 is a three-port valve including an intake port for introducing compressed air from a supply source 41 of compressed air, an output port for outputting this compressed air, and an output port for discharging it. This three-port servo valve is for causing the above-described ports to communicate with one another as appropriate in accordance with output signals from the controller 40, and thereby allowing controlled compressed air to flow. The servo valves 20 and 30 have substantially the same construction.
The controller 40 incorporates a microprocessor, and detected values by the head-side and rod-side pressure sensors 23 and 33, and the position detecting sensor 25 are inputted to the microprocessor. Also, information such as operational positions and intermediate stop positions of the piston 14 is inputted to and stored in the controller 40. Such information may be inputted either as digital values or as analog values such as voltages and currents. Based on command signals inputted from the external controller 50 and instructing for the execution of welding, such as “intermediate stop”, “clamping”, and “application of pressurizing force”, the aforementioned detected values and set values are compared, and drive signals are outputted to the head-side servo valve 20 and the rod-side servo valve 30 so that the cylinder 10 performs a predetermined operation.
In
Next, the functions of the controller 40 and the controlling method of the welding gun G by the controller 40 will be described.
In the control of the welding gun, basically, by controlling the piston 10, an advancing process of moving the electrode member 15a up to a clamping position (target position) where the electrode member 15a is to contact work, a pressurizing process of subsequently applying a required clamping force (pressurizing force) to the work by the electrode member 15a, and an intermediate stop process of retreating the electrode member 15a after welding and stopping it at an intermediate position, are performed. Herein, the pressures in the pressure chambers 11 and 12 in the cylinder 10 are detected by the pressure sensors 23 and 33, respectively; the position of the piston 14 is detected by the position detecting sensor 25; and the servo valves 20 and 30, respectively, are controlled to properly adjust the pressures in the pressure chambers 11 and 12. Thereby, the pressurizing force (clamping force) of the welding gun is correctly controlled, resulting in an improved welding quality. Here, detecting both of the head-side pressure Ph and the rod-side pressure Pr makes it possible to detect the cylinder thrust based on these pressures Ph and Pr, thereby the cylinder 10 is controlled, as described later in detail.
In the control of the cylinder, an air servo cushion is adopted. Specifically, the position and the speed of the piston 14 in the cylinder 10 are detected by the position detecting sensor 25, while the pressures in the pressure chamber 11 and 12 are detected by the pressure sensor 23 and 33, respectively, and these detected values are inputted to the controller 40. The controller 40 outputs signals to the servo valves 20 and 30 for driving thereof so as to control the position of the piston 14 and the pressures in the pressure chambers 11 and 12, and to prevent the welding tip from colliding against work and giving a shock to work. In this case, because the servo valves 20 and 30 are used to exert a cushioning function, no special mechanism for reducing the shock is needed, thereby allowing the reduction of the installation space and the weight of the cylinder 10 and surrounding equipment for providing cushioning functionality.
With reference to time charts shown in
Basic operations of the welding gun are now described with reference to
As a result, as shown in
As shown in
After having started the driving of the piston 14 as described above, the head-side servo valve 20 is pressure-controlled along the curves illustrated in
In this case, it is desirable that the opening degree of the head-side servo valve 20 be reduced in accordance with the aforementioned deviation ΔX, or that the opening degree be adjusted in accordance with the deviation of a measured pressure in the head-side pressure chamber 11 by the head-side pressure sensor 23 from the pressure therein at the time when work is in a clamped state (i.e., a set pressure) so that the measured pressure and the set pressure become equal to each other.
In the illustrated example, with the start of the driving of the piston 14, the opening degree of the rod-side servo valve 30 is smoothly varied, while that of the head-side servo valve 20 starts to be varied at a time a little later than the start of the driving of the piston 14.
In the above-described advancing process, it is preferable that the piston be sufficiently decelerated, and that, at the point in time when the piston has reached a set position (Xc) by sufficiently approaching the target position, the servo valve opening degree (ΔV) of the rod-side servo valve 30 be fixed to a minute constant value. This enables the electrode member 15a to contact work at a constant and low speed.
After the piston 14 has reached the clamping position, and the piston rod 15 has contacted the work as described above, the above-described pressurizing process are subsequently performed, and the work is welded in a pressurized state. During this pressurizing process, in the controller 40, signals indicating pressures in the two pressure chambers 11 and 12 in the cylinder 10 and being issued from the pressure sensors 23 and 33 are monitored. As shown in
Also, as shown in
After the above-described pressurizing process and welding have been performed, the intermediate stop process is performed in which the electrode member 15a, and consequently, the piston 14 is retreated and stopped at an arbitrary position. As shown in
Thereby, when attempting to start the clamping operation, it is possible to reduce the delay time before the piston 14 starts to move, as well as to save the amount of air pressure used. Specifically, a trial calculation has clarified that making the pressure in each of the two pressure chambers 11 and 12 to Pt/2, reduces the amount of air usage to about one half. In addition, when the cylinder 10 is at the intermediate stop position, the air leakage from the servo valves can also be saved.
The above-described embodiment is an implementation in which the present invention is applied to a welding gun. Besides such a welding gun, the present invention can also be applied to general machining techniques to machine work in a chucked state.
Number | Date | Country | Kind |
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2004-100815 | Mar 2004 | JP | national |