超声磨削装置设计【含CAD高清图纸和文档】【GC系列】
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1 绪论机械手,英文名mechanical hand,是指模仿人手和臂的某些动作和功能,用以按固定程序抓取、搬运物件或操作工具的自动操作装置。工业机械手即在工业生产中所使用的机械手,是一种可编程序的自动机械手。它是在五十年代末出现,近年来迅速发展起来的重要的自动化装置,是实现冬夜自动化的重要手段。目前,在各个生产领域,为了提高生产效率和产品质量,实现安全生产,都采用了各种不同形式,不同功能的机械手。由于机械手的出现,在许多生产工艺中都代替了人工,使工业自动化有了较大的发展,这不仅大大的提高了劳动生产率,改善了劳动条件,减轻了工人劳动强度,而且使成批生产有了质量技术的保证,就因为如此,机械手的设计开发成了目前工业技术的重要课题。1.1 研究背景及发展现状机械手在工业生产中广泛的应用于机加工,锻压,铸造,冲压,焊接,装配,喷漆,热处理等各个行业,特别是在笨重,高温有毒,放射性,多粉尘等恶劣危险的劳动环境中,机械手由于有显著的优点而备受重视。以下是机械手在工业中的几种典型应用: 1.在实现单机自动化方面 1) 各类半自动车床,有自动加紧、进刀,切削、退刀和松开的功能,但仍需人工上下料。装上机械手,可实现全自动生产,一人看管多台机床。目前,机械手在这方面应用最多,如上海柴油机厂的曲拐自动车床和座圈自动车床机械手,大连第二机床厂的自动循环机械手,沈阳仿形车床机械手,沈阳第三机床厂的Y38滚齿机械手,青海第二机床厂的滚铣花键机床机械手等。由于这方面使用已有成熟的经验,国内一些机床厂已在这类机床产品出厂时旧附上机械手,或为用户自行安装机械手提供条件。2)注塑机有加料、合模、成型、分模等自动工作循环,装上机械手自动装卸工件,可实现全自动生产。3)冲床有自动上下料冲压循环,装上机械手上下料,可实现冲压生产自动化。目前机械手在冲床上应用有两个方面:一是160t以上的冲床用机械手的较多。如沈阳低压开关厂200t冲床磁力起动机壳体下料机械手;一是用于多工位冲床用作冲压件工位间步进。如上海第二汽车配件厂的灯壳冲压生产线机械手等。2.在铸、锻、焊等如处理方面在锻造方面,机械手一般用作加热炉,锻压加床或冲床的上下料和工件的传送,其中包括多工位冲床的中间传送。如天津第二锻造厂研究了JS01通用机械手用于精锻机上下料。在铸造方面,机械手应用较多的是在熔模铸造中,也用于浇铸,造型,制芯及清理工作。美国Dochlcn-jarvis工厂是使用工业机械手最多的,约12万台,主要用于从压型中取出铸件,然后用喷气法清洗铸件表面,该厂使用机械手后铸件质量得到了很大提高,稳定性增强。在焊接方面,这种机械手可分为点焊接机械手和弧焊接机械手。对于点焊接机械手,其手臂能伸缩,俯仰,回转,手腕能摆动,回转,俯仰。至于弧焊接机械手,它的焊炬能作复杂三维曲线运动以调节焊接范围。3.选装体零件生产流水线自动化方面采用机械手在旋转体零件(如轴类、盘类、环类等)生产流水线上的机床之间传送工件能够提高生产线的自动化。国内已建成的这类自动线很多,如沈阳泵厂的深井泵轴承体加工自动线(环类),大连电机厂的4号和5号电动机轴加工自动线(轴类),上海拖拉机齿轮厂的齿坯加工自动线(盘类)等。加工箱体类零件的组合机床自动线,一般采用随行夹具传送工件,也有采用机械手的,如上海动力机厂的汽缸盖加工自动线转为机械手。4. 在装配方面工业机械手在装配中的应用,是近几年国内外研究和发展的一个重要方面,特别是在汽车制造业的汽车装配自动化和弹药装配等危险作业上有很大的使用价值。目前装配机械手正由串联结构向并联结构转换。1.2 本课题的研究目的及意义工业机械手具有许多人类无法比拟的特点,满足了社会化大生产的需要,其主要优点如下:1. 能代替人从事危险、有害的操作。只要根据工作环境进行合理设置,选择适当的材料和结构。机械手就可以在异常高温或低温、异常压力和有害气体、粉尘、放射线作用下,以及冲压、灭火等危险环境中胜任工作。工伤事故多的工种,如冲压、压铸、热处理、锻造、喷漆以及有强烈紫外线照射的电弧焊等作业中,应推广工业机械手或机器人。2. 能长时间工作,不怕疲劳,可以把人从繁重单调的劳动中解放出来,并能扩大和延伸认的功能。人在连续工作几小时后,总会感到疲倦和劳累,而机械手只要注意维护、检修,即能胜任长时间的单调重复劳动。3. 动作准确,因此可以稳定和提高产品的质量,同时又可避免人为的操作失误。4. 机械手特别是通用工业机械手的通用性、灵活性好,能较好的适应产品品种的不断变化,以满足柔性生产的需要。5. 机械手能明显的提高劳动生产率和降低成本。由于机械手在工业自动化和信息化中发挥了以上巨大的作用,世界各国都很重视工业机械手的应用及发展,机械手的应用在我国还处于起步阶段,就显示了许多无法替代的优点,展现了广阔的应用前景。近十几年来,机械手的开发不仅越来越优化,而且涵盖了许多领域,应用的范畴十分广阔。成品电动机机体形状很复杂,从毛坯到成品需要很多道加工工序,各道工序及工序之间都要实现机体的移位及定位,这些工序如果全靠人工完成将大大增加工人的劳动强度,不仅使加工质量难以得到保证还增加了劳动的危险性。本课题的研究是为了设计出一种电动机机体加工自动线上用的辅助机械手,该机械手在机体加工自动线能完成下料,转位和翻转等多种功能,提高生产效率,降低劳动强度。1.3 本课题的研究内容本次设计的多功能机械手用于电动机座加工自动线上,主要由手爪、小臂、大臂等组成,具备上料、翻转和转位等多种功能,并按该自动线的统一生产节拍和生产纲领完成以上动作。本机械手为圆柱坐标式机械手,自动线围绕机体布置,具有大手臂旋转、小手臂伸缩、手指伸缩共2个自由度。其中大手臂旋转是为了将工件从自动线转移到卸料工位上,小臂升降手指伸缩是重复自由度,目的是扩大升降范围,避免小手臂频繁升降;驱动方式为液压驱动,且选用双联叶片泵,系统压力为2.5MPa,电机功率为3KW,共有推动大臂旋转油缸、小臂升降油缸、手爪夹紧油缸共3个液压缸;定位采用机械挡块定位,定位精度为0.51mm,采用行程控制系统实现点位控制。 本机械手装置应具备如下功能; 1. 具有友好的人机界面,以保证人机通讯、人机互助和人机协同工作。 2.能够自动完成系统所要求的动作,具有连续工作、单周期工作、单步工作、自动返回原点、手动返回原点、手动操作等功能。 3.在保证精度的前提下,有一定的容错性。 4.能够依次对电动机座完成上料、转位、翻转等辅助加工功能。 5.在保证完成以上功能的前提下具有一定的通用性,使该机械手在整个电动机座加工自动线都具有一定的适应性。2 机械手的总体设计2.1 总体方案的比较与选定2.1.1 各种坐标形式机械手的比较按坐标形式分,机械手主要有以下四种不同的类型: 1. 直角坐标式 2. 圆柱坐标式 3. 球坐标式 4. 平面多关节式 根据设计要求,本课题设计的机械手需要在电动机座加工自动线卸料,包括上料,升降,转位,等多种功能。结合设计要求对各种坐标形式的机械手的优缺点作出评析。如下:1. 直角坐标式机械手(如图2.1)。这种机械手所有的送放运动均为直线运动,结构简单,直观性好,便于实现一定的精度要求,但本机械手需要在多个工位上完成辅助加工功能,故在相同的动作范围内其所需要的空间位置大,灵活性差,同时由于手爪部分移动,不利于电液集中配置。 图2.1 直线坐标式机械手2. 圆柱坐标式机械手(如图2.2)。这是一种回转型机械手,其手臂除了可以伸缩,可以升降外,还可以绕立柱回转。这种机械手与直角坐标式机械手相比,占地面积小而活动范围大,结构亦比较简单,并能达到较高的定位精度。但是,它的手臂的升降受到机械手结构的限制,距离地面总有一定的距离,不能从地面抓取物件,因此不能完成上料的工序。 图2-2 圆柱坐标式机械手 1手部 2腕部 3臂部3.球坐标式机械手(如图2.3)。这种机械手与圆柱坐标式机械手相比,在占有同样大小的空间情况下,可以扩大工作范围,能将手臂伸向地面抓取物件。其缺点是运动的直观性差,结构较复杂,且臂部有两个回转运动,位置精度误差较大。图2.3 球坐标式机械手 4.多关节坐标式机械手(如图2.4)。这种机械手可以在以臂部最大伸展长度为半径的球体空间范围内任意抓取物件,灵活性大。它与其他坐标形式的机械手相比,所占空间最小。但其运动直观性差,臂部前端的位置由多个回转运动决定,要达到较高的运动精度比较困难,为此必须提高制造精度,因而使设计和制造均较为复杂。图2.4 多关节坐标式机械手2.1.2选定的两个机械手方案的概述及比较 根据本课题的设计要求,该机械手能够完成上料、升降、转位工件等多种功能,所以,在这里设计了四个机械手将要到达并完成辅助加工的工位,依次是:上料工位、升降工位、转位工位、再次转位工位(见图2.6和2.7)。机械手在一个周期内的动作过程如下: 一上料。机械手在运动开始前面向第一工位。开始工作后,机械手的小手臂的升降缸将手部5下降到取料位置,手部上的定位压盘正卡在工件已加工完的上端止口及其端面上,同时,手指伸缩油缸1的活塞杆下端连接着带圆锥面得推动杆6,使内撑式手部的三个手指伸入到工件内的空槽中。 二完成以上动作后,机械手转向第二工位,将工件升起,小手臂2的油缸上升,将工件提起到预定的高度。 三接下来,大手臂回转90度(当前输送带前进到终点发信)。 四然后小手臂下降到工件准确地放到转载装置前输送带的适当位置上。 完成一个周期的动作后,机械手转向第一工位,处于“回到原点”状态。这时,第一工位的专机已经完成加工处于“等候上料”状态,机械手在第一工位再次完成上料后转向第二工位,这时,在第一工位加工完毕的机体已经顺着自动线传至第二工位,机械手将其转位使其完成第二工位的加工。在连续工作状态中机械手的动作过程如上所述依次循环。 总结上述各种形式的机械手,在满足设计要求的前提下设计出以下两种方案。方案一:外形图及运动简图如下: 图2.5 方案一外形图 图2.6 方案一运动简图这是一种屈伸型机械手,该机械手具有与人体上肢相类似的结构。臂部由大臂和小臂两个部分组成。除了大臂本身具有回转和俯仰运动外,小臂相对于大臂也可以俯仰,通过大臂和小臂的俯仰来实现手臂的伸缩,通过机身的回转来实现使手臂面向不同的工位。该机械手有E1-E5(见图2.6)共5个自由度,其中: E1:机身绕机座回转 E2:大臂的俯仰 E3:小臂的俯仰 E4:手腕的俯仰 E5:手腕的回转 这种机械手采用直线式流水线,待加工的电动机座从流水线上依次流A,B,C,D四个工位,机械手通过机身的回转依次停在四个工位,分别完成下料、转位、翻转、再次转位四个辅助加工动作。通过大臂、小臂和手腕的俯仰使机械手到达四个工位点,通过手腕的俯仰和翻转使手爪能够有正确的夹持姿态。方案二:外形图及运动简图如下,见下图图2.8 方案二外形图图2.9 方案二运动简图这是一种圆柱坐标坐标式机械手。该机械手由机座、机身(即立柱)、大臂、小臂、手腕和手爪组成。有E1-E3共2自由度(立柱升降自由度E2和小臂升降自由度E3是重复自由度),其中: E1:大手臂回转 E2:手指伸缩E3:小手臂升降本机械手为圆柱坐标式机械手,自动线围绕机体布置,具有大手臂旋转、小手臂伸缩、手指伸缩共2个自由度。其中大手臂旋转是为了将工件从自动线转移到卸料工位上,小臂升降手指伸缩是重复自由度,目的是扩大升降范围,避免小手臂频繁升降;驱动方式为液压驱动,且选用双联叶片泵,系统压力为2.5MPa,电机功率为3KW,共有推动大臂旋转油缸、小臂升降油缸、手爪夹紧油缸共3个液压缸;定位采用机械挡块定位,定位精度为0.51mm,采用行程控制系统实现点位控制。该机械手的工作流程图如下: 图2.10 方案二的工作流程图该机械手由电动机驱动回转缸里的小齿轮,小齿轮通过与大齿轮啮合来驱动大手臂回转;由直动式液压缸推动小臂升降;由直动式液压缸推动手指夹紧与放松。在工作中,自动流水线环绕机座两旁布置,机械手在一个工位完成辅助加工后,缩回手臂,大手臂依次回转到下一工位,伸出手臂完成相应的功能。两种方案通过流水线的不同布置都能使手爪到达指定的工位并且都能够实现所要求的功能,手爪都具有足够的自由度,能从正确的方位夹持电动机座体。两种方案都具有电液集中,占地面积小,可以从地面上抓取工件的优点。所不同的是:方案一通过腰部的回转、大臂的俯仰及小臂的俯仰来使手爪到达正确的工位,而方案二是通过大手臂回转、小手臂的升降和手指伸缩来使手爪到达正确的工位。 但是,方案一运动直观性差,结构复杂。首先,臂部位置由多个回转运动决定,手臂在俯仰时底部回转角度的误差容易在手臂端部造成误差扩大,通过大臂、小臂、手腕的回转误差累积,最终容易使手爪位置与指定位置有较大偏差。其次,越靠近机身的俯仰运动所需要的驱动力越大,使整个系统各液压缸工作压力相差很大,不易配置液压驱动系统且回转缸出力不大。再次,方案一的手臂有多种屈伸状态,则需要很多的定位装置,而回转液压缸内空间狭小,不宜布置过多的机械挡块。如果改采用连续轨迹控制的机械手,成本太高。所以在第二种方案中回转缸里大小齿轮的啮合来促使手臂回转,通过行程挡铁与形成开关来实现对回转的控制。 综上所述,本课题采用第二种方案。1 Introduction Manipulator, the English name of mechanical hand, is the manpower and arms to imitate certain actions and functions of a fixed procedure for the capture, handling objects or tools of the automatic operation device operation. Industrial robot that is used in industrial production robot is a programmable robot hand. It is in the late fifties, developed rapidly in recent years the importance of automation equipment, automation is an important means to achieve winter. At present, in all areas of production, in order to improve production efficiency and product quality, to achieve safe production, have used a variety of different forms, different functions of the robot. The emergence of the robot, in many production processes have replaced the manual, the industrial automation has made significant development, which not only greatly improve labor productivity, improved working conditions, reduce labor intensity, but also mass production With the guarantee of quality and technology, because of this, the robot design and development of industrial technology has become an important issue at present. 1.1 Background and Development of Manipulator in industrial production are widely used in machining, forging, casting, stamping, welding, assembly, painting, heat treatment and other industries, especially in the heavy, high temperature toxic, radioactive, and more dust and other harsh dangerous work environment, the robot Because of significant advantages has been taken seriously. The following is a robot in the typical industrial applications: 1. In the realization of single automation 1) various types of semi-automatic lathes, automatic step, into the knife, cutting knife and release the function back, but still needs manual loading. Fitted with mechanical hand can be realized fully automatic production, one person in more than one machine. Currently, the mechanical hand in this respect the most widely used, such as Shanghai Diesel Engine Plant crank automatic lathes and seat automatic lathe robot, Dalian Second Machine Tool Plant of automatic loop manipulator, Shenyang copying lathe robot, Shenyang Third Machine Tool Plant of Y38 hobbing mechanical hand, the second machine tool plant in Qinghai spline roller milling machine robots. Since this has proven experience in the use of some domestic machine tool plant has been in such an old machine attached to the factory robots, or users themselves provide the conditions for installation of mechanical hand. 2) injection molding machine with feeding, clamping, forming, parting, such as automatic work cycle, fitted with automatic loading and unloading the workpiece manipulator can realize automatic production. 3) Punch press with automatic loading and unloading cycles, fitted with mechanical hand cutting, stamping automation can be realized. The current robot applications in the red bed has two aspects: First, more than 160t mechanical hand with more punch. Such as low-voltage switchgear plant in Shenyang 200t cutting punch shell magnetic starter manipulator; first multi-station presses used for stamping station between the steps. Such as auto parts plant in Shanghai Second lamp shell punch line robots. 2. In casting, forging, welding, etc., such as processing In forging, the mechanical hand normally used for heating, forging an extra bed or press the up and down the transmission of material and artifacts, including the middle of multi-station transfer presses. Such as Tianjin, the second of the JS01 Forge General manipulator forging machine for loading and unloading. In casting, the mechanical hand is used more often in the investment casting, also used for casting, molding, core making and clean-up work. U.S. Dochlcn-jarvis plant is the largest use of industrial robots, about 12 million units, mainly used to remove from the pressure-type casting, and then clean the casting surface jet method, the plant after the use of mechanical hand has been greatly improved casting quality, stability enhanced. In welding terms, this robot can be divided into point arc welding robot and welding robot. For spot welding robot, the arm can stretch, pitch, rotating the wrist to swing, swing, pitch. As for the arc welding robot, and its complex three-dimensional welding torch can be curved to adjust the welding range. 3. Optional Parts production line automation Hand in the rotating body by mechanical parts (such as axle, disc type, ring type, etc.) on the production line is transferred between parts of machine tools can improve the production line automation. China has built many of these auto lines, such as the deep well pump plant in Shenyang, automatic production line for bearing body (ring type), motor plant in Dalian 4 and 5, automatic production line for the motor shaft (shaft), the Shanghai factory gear blank Tractor Gear automatic production line (disk type) and so on. Processing machine tool box part of the automatic line, commonly used to send the workpiece pallet, there is also the manipulator, such as the Shanghai Power Machinery Factory automatic production line for the cylinder head into the robot. 4. In the assembly area Industrial machinery in the assembly of hand, is the research and development at home and abroad in recent years, an important aspect, especially in the automotive industry vehicle assembly automation and ammunition assembly is very dangerous to use operationally value. Present assembly structure of the robot by the serial to parallel conversion structure. 1.2 The purpose and significance of the research project Industrial robots have many human beings can not match the characteristics of large-scale production to meet the needs of society, its main advantages are as follows: 1. Can replace people in dangerous and harmful operations. As long as a reasonable working environment based on set, select the appropriate materials and structures. Robot can in abnormal high or low temperatures, abnormal pressure and harmful gases, dust, radiation, under, and stamping, fire and other dangerous environments the task. Many types of accidents, such as stamping, casting, heat treatment, forging, painting, and a strong ultraviolet radiation of the electric arc welding and other operations, should be the promotion of industrial machinery or robots. 2. Can work long hours, fear of fatigue, can be from the heavy monotonous work of liberation, and to expand and extend the function of recognition. After several hours of continuous work people always feel tired and fatigue, and mechanical hand as long as the attention to maintenance, overhaul, that is, capable of performing repetitive work a long time. 3. Action is accurate, it can stabilize and improve product quality, while avoiding the human operational errors. 4. In particular, general industrial robot manipulator versatility, flexibility, can better adapt to changing product variety to meet the needs of flexible production. 5. Manipulator can significantly improve productivity and reduce costs. The robot in industrial automation and information technology has played a more significant role in the world attach great importance to industrial robot application and development of robotic applications in China is still in its infancy, it shows a lot of irreplaceable advantages, showing a broad application prospects. Over the last decade, the development of the robot is not only more and more optimized, and it covers many areas, the application scope is very broad. Product motor body shape is very complex, from rough to finished product requires a lot of channel processing procedures, of the procedures and processes must be achieved between the movement and position of the body, these processes will be done manually if the greatly increased thanks to the labor intensity of workers, not only difficult to ensure the machining quality of labor also increased the risk. Research of this subject is to design a motor body processing aid used in automated robotic line, the robot can automatic production line in the body to complete the next, turn the bit and flip, and other functions, improve productivity and reduce labor intensity. 1.3 The research topic The multi-functional manipulator designed for automatic processing of the motor seat online, mainly by the gripper, the arm, the arm and other components, with feeding, turning and translocation of other functions, according to the unity of the automatic line takt and production program to complete the above action. The robot is a cylindrical coordinate manipulator, automatic line around the body layout, with a large arm rotation, small arms stretching, fingers stretching a total of 2 degrees of freedom. Rotate the arm of which is to be transferred to the workpiece from the automatic line on the discharge station, the arm movements are repeated finger stretching degrees of freedom, the purpose is to expand the range of movements to avoid frequent movements of small arms; drive for the hydraulic drive, and the selection of double pump, system pressure 2.5MPa, motor power 3KW, there to promote the rotating cylinder arm, arm lift cylinder, a total of three gripper cylinder clamping hydraulic cylinder; positioning mechanical stop position, positioning accuracy is 0.5 1mm, stroke control system using control points. The robotic device should have the following functions; 1. Has a friendly interface, in order to guarantee machine communication, human solidarity and human work together. 2. Can automatically complete the requested action system, with continuous work, single-cycle work, the work of a single-step, automatic return to origin, manual return to origin, manual operation and other functions. 3. In the given accuracy, there is some fault tolerance. 4. To complete the turn on the motor seat, turn the bit, flip and other auxiliary processing functions. 5. In ensuring the completion of the above function under the premise has a certain generality, so that the robot in automatic production line for the seat motor has a certain flexibility. 2 the overall design of the robot 2.1 Comparison of the overall program with the selected Coordinates in the form of various robotic 2.1.1 Comparison The form of points by coordinates, the robot has the following four different types: 1. Cartesian Coordinate 2. Cylindrical Coordinate 3. Spherical coordinate type 4. Planar multi-joint type According to design requirements, the issue needs to design the robot automatic production line for motor discharge seat, including feeding, lifting, transfer, and other features. Coordinate with the design requirements of various forms of mechanical hand to Review the advantages and disadvantages. As follows: 1. Cartesian coordinate manipulator (Figure 2.1). This mechanical hand movements are all put give linear motion, the structure is simple, intuitive, and easy to achieve a certain degree of accuracy, but the robots need to be completed in a number of station auxiliary processing functions, it is within the same range of motion of its spatial location required for a large, inflexible, and because the gripper part of the move, is not conducive to concentration of electro-hydraulic configuration.Figure 2.1 Linear coordinate manipulator2. cylindrical coordinate manipulator (Figure 2.2). This is a transition back to the robot, in addition to its retractable arm that can lift, you can also turn around the column. The Cartesian robot manipulator with compared to the scope of activities covers an area of small and large, the structure is also relatively simple and can achieve high positioning accuracy. However, its movements by the robot arm structural limitations, there is always a certain distance from the ground and can not grab the object from the ground, it can not be completed on the material processes. Figure 2-2 cylindrical coordinate manipulator 1 - Hand 2 - wrist 3 arm3. spherical coordinate manipulator (Figure 2.3). The cylindrical coordinate robot manipulator and compared occupy the same space in the case, you can expand the scope of work, the arm extending toward the ground can grab objects. The disadvantage is the poor visual movement, more complex structure, and the arm has two rotary movement, position accuracy errors.Figure 2.3 The spherical coordinate manipulator4. multi-joint coordinate manipulator (Figure 2.4). The robot can be extended to the maximum length of arm radius sphere crawl space any objects within, flexibility. It coordinates with other forms of mechanical hand than for the smallest. Intuitive, but its movement is poor, the location of the front arm rotary movement by a number of decisions, the movement to achieve a higher precision is difficult, for the need to improve manufacturing precision, and thus make the design and manufacturing are more complex.Figure 2.4 Coordinate multi-joint manipulator2.1.2 The two selected overview of the robot program and comparison According to the project design requirements, the robot can do the feeding, lifting, transfer jobs and other functions, so here the design of the four mechanical hand to reach and complete auxiliary processing station, in order: feeding station , lift station, transfer station, once again shifted station (see Figure 2.6 and 2.7). Robot moves in a cycle as follows: One. Feeding. In the beginning of the campaign in front of the robot to the first station. Started work, a small robot arm lifting cylinder 5 will hand down to get material position, hand position on the pressure plate is stuck in the workpiece has been processed and completed the Mouth of the top end surface at the same time, fingers stretching cylinder 1, the lower end of piston rod was connected to the push rod with a conical surface 6, so that the support-type hand three fingers into the empt
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