耳机插头注塑自动化设备的开发

华中科技大学硕士学位论文耳机插头注塑自动化设备的开发姓名：黄漩申请学位级别：硕士专业：机械工程指导教师：张海鸥2011-05-23摘要许多电子产品需要通过注塑来进行定位与封装成型，且产品品种繁多，因而注塑生产设备市场巨大。

但由于电子注塑产品更新换代频率快，注塑企业要在剧烈的市场竞争中保持领先，迫切需要通过注塑生产自动化改造来提高生产效率和产品质量、降低成本。

注塑生产线效率不仅取决于注塑机的自动化水平，而且与其配套的辅助机械自动化水平及模具设计水平密切相关。

目前我国注塑辅助工作几乎全靠人工，辅助机械自动化程度显著落后于注塑机的自动化水平，成为制约注塑生产线效率的瓶颈。

本文针对现有耳机插头产品注塑生产工艺中出现的生产效率低、成品率不高、工人劳动强度大等问题，选取了一种常见的耳机插头产品注塑生产过程作为研究对象，进行了自动化生产设备的开发。

其难点在于耳机插头注塑过程中既有铜针等金属刚性镶件，也有线材等柔性镶件，这两种镶件的摆放与固定是进行自动化改造必须解决的问题。

通过对注塑加工企业现有耳机插头注塑生产现状的调查与分析，本文提出了适应自动化改造的生产方案，本自动化设备的开发主要分为机械结构的设计和控制系统的设计两部分。

对于机械结构设计部分，提出了多功能复合注塑模具设计方案，设计了分体式模具和铜针自动定位与线梳理线自动化装置，通过增设模条结构部分和压紧与理线自动化机构来代替手工压紧与理线以适应自动化生产的需要，以压缩空气作为动力源来驱动执行机构，使模条准确定位，最后应用Pro/ENGINEER三维造型软件进行了机械结构部分的参数化建模并进行了机构的运动学仿真与模拟。

控制系统采用基于STC89C58RD型单片机的直接控制结构，完成了硬件电路和控制软件设计，控制硬件包括信号输入输出、串口下载、数码管显示、按键等模块；控制软件包括机构位置状态显示、故障报警、故障代码提示、急停与恢复等相关功能。

设备试运行结果表明，使用本套自动化设备，将插拔模具和理线等准备时间由7s缩短到2s，而且由单工位一模两件作业拓展到双工位一模六件同时作业，由此能在保证成品率不低于98%的条件下，显著提高该耳机插头注塑生产效率达216%，同时降低工人劳动强度，完全达到了厂家规定的设计要求。

此外本套设备还具有结构紧凑，操作方便，运行稳定，成本低等特点。

本研究室发明的多功能复合模具注塑自动化机构，不仅适用于插头类带线产品高效率优质的自动化注塑生产，而且适用于带刚性金属镶嵌件与软质线材的复合材料产品的注塑成型，具有广阔的应用前景。

关键词：注塑自动化; 耳机插头; 多功能复合模具结构; 自动定位与理线;AbstractMany electronic products need to locate and packaging through the injection molding,and the product is variety of types,therefore,the injection molding equipment has a huge marketing potential. However,the update cycle of the electronic injection product is short .If the Injection enterprise wants to keep the outstanding position,they must improve the efficiency of production and the quality of products,and reduce the cost,which can be solved by increasing the automation level of the injection molding.The efficiency of the injection molding production line depends not only on the level of automation of injection molding machine, but also its auxiliary machinery automation level and the level of mold design.At present,the injection auxiliary work almost be done by men,and the auxiliary machinery automation level fall behind the automation of the injection molding machines significantly,which became a bottlenecks to constraint the efficiency of the production line.In this paper,the injection production process of a common headphone plug products was selected as the research object,which the automated production equipment was developed,in order to solve the problem such as low productivity, low yield and high labor intensity,etc.The difficulty lies in the both kind of inserts,which included metal rigid inserts such as copper needle and flexible inserts such as wire rod existing at the same time,and the placement and fixation of the both inserts must be solved in the automated transformation.Through the survey and analysis of the existing earphone plug plastic injection enterprises, an automation production plan is proposed. The development process is divided into two parts: mechanical structure and control system. For the mechanical structure designing part, a multi-functional compound injection mold plan is proposed. The split type mold is designed and the automatic positioning and cable sorting installment is developed. The installment can make automatic production by using the automated compression and cable sorting parts which can take place of manual labor. Theactuator uses the compressed air as power source to make accurate position of the mold bar. Finally, the Pro/ENGINEER software is used to build the 3D model and simulate the movement of the mechanical structure.The Control system consists of hardware and software,and is directly controlled by a SCM of STC89C58RD. The design of the hardware involves I/O, serial ports,LED,buttons and so on. The software module of the system has the following functions:reflecting the positions of the mechanism,failure alarming, error code hinting, emergency stop, status resumption and so on.The test run results of the equipment shows that by using this set of automation equipment,the preparation time of the plug mold and carding line reduced to 2s from 7s, and the working style extended from a single work station with duplex operation to double work station with six simultaneous operation, Which can ensure that under the condition that the production yield is no less than 98%, it significantly improved the efficiency of the earphone plug injection up to 216% and at the same time reduced labor intensity, and that it fully meets the design requirements those the manufacturers specified. In addition, this set of equipment also has a series of advantages, compact structure, easy operation, stable operation and low cost. The complex multi-functional compound injection mold machine has a broad application prospects ,for it not only fits the automated injection molding production with high efficiency and quality of plug products with line, but also fits the automated injection molding production of metal inserted parts and soft wires with composite materials.Keywords: Injection molding automation, Earphone plug, Multifunctional composite mold structure, Automatic positioning and cable management agencies独创性声明本人声明所呈交的学位论文是我个人在导师指导下进行的研究工作及取得的研究成果。