Intelligent precise blanking process for new energy bus floor and full-automatic production system

Abstract

The invention discloses an intelligent precise blanking process and a full-automatic production system for a new energy bus floor. The intelligent precise blanking process comprises the following steps: importing a floor design drawing into an intelligent control system to automatically optimize a blanking scheme; through cooperation of the intelligent control system, the intelligent plate hoisting switching feeding system, the sinking type automatic lifting feeding platform and the vacuum suction cup feeding mechanism, intelligent and accurate feeding of various plates according to needs is achieved; the plate cutting position is determined through the 3D visual recognition system and the laser positioning technology, the multi-tool-bit cutting system intelligently recognizes the plate type, tool bits are automatically switched, and cutting is completed through the numerical control cutting machine. The high-precision quality detection module detects the size precision and the surface quality of the blanking part and feeds back a detection result to the intelligent control system; the mechanical arm sorting and stacking system automatically sorts qualified plate components and stacks the qualified plate components to the transfer trolley according to a preset sequence; and after the qualified plates are sorted, unqualified plates and waste materials are automatically conveyed into the waste material collecting device through the conveying belt discharging mechanism.

Description

Technical Field:

[0001] The present invention relates to an intelligent and precise blanking process and a full-automatic production system for the floor of new energy buses, belonging to the technical field of new energy bus manufacturing. Background Art:

[0002] With the continuous improvement of market requirements for vehicle economy, comfort, etc., the requirements for the installation quality, blanking accuracy, and blanking efficiency of various interior boards of new energy buses (bamboo plywood floors with a thickness of 10 - 18 mm, PVC floors, PP honeycomb floors, PVC roof panels with a thickness of 3 - 5 mm, perforated aluminum-plastic roof panels, PVC side panels with a thickness of 3 - 5 mm, and aluminum-plastic side panels) are getting higher and higher. Due to the high degree of customization of new energy buses, the board specifications and materials required for various length models are also increasing. Therefore, it is very important to continuously improve the installation quality, blanking accuracy, and blanking efficiency of various interior boards of new energy buses, which is directly related to the production efficiency of the whole new energy bus, the product market competitiveness, and the customer vehicle use experience.

[0003] For the existing blanking of new energy buses, manual measurement and blanking are adopted. After the vehicle skeleton welding is completed, the floor blanking size data is obtained by on-site actual measurement. The operator needs to carry the board to a simple blanking wooden frame, then manually measure and layout the lines according to the measured board size, and then use a hand-held woodworking saw for cutting and blanking. At the same time, the waste is manually carried to the waste recycling bin, and finally the blanked board is manually collected and carried to the transfer trolley and transported to the production line for the next installation step.

[0004] The traditional blanking process has the following problems:

[0005] 1. Low efficiency: Traditional blanking relies on manual operation or semi-automatic equipment, which takes a long time. The blanking time for a single vehicle is 30 - 40 minutes.

[0006] 2. Poor accuracy: Manual operation is prone to cause blanking size deviation (cutting accuracy ±3 mm), affecting the floor assembly quality.

[0007] 3. More material waste: It is difficult to optimize the material utilization rate (the utilization rate is only 85%) in the traditional blanking process, resulting in waste.

[0008] 4. Poor adaptability: Traditional equipment is difficult to adapt to the size and shape differences of floors of different models and cannot support the cutting of various materials such as lightweight composite materials and aluminum alloys.

[0009] 5. Lack of quality inspection: The surface defects of the board after blanking are not detected, and the appearance quality of the blanked board cannot be monitored in real time.

[0010] Therefore, it is necessary to improve the existing technology to solve the deficiencies of the existing technology. Summary of the Invention:

[0011] The present invention provides an intelligent and precise blanking process and a full-automatic production system for the floor of a new energy bus to solve the problems existing in the above-mentioned prior art, so as to solve the problems of low efficiency, poor accuracy, and much material waste in the traditional floor blanking process, and realize the efficient, precise, and intelligent blanking of the floor.

[0012] The present invention adopts the following technical solutions: An intelligent and precise blanking process for the floor of a new energy bus, comprising the following steps:

[0013] Step S1, data import and optimization. Import the floor design drawing into the intelligent control system, and the intelligent control system automatically optimizes the blanking scheme.

[0014] Step S2, intelligent loading. Through the cooperation of the intelligent control system, the intelligent sheet hoisting and switching feeding system, the sunken automatic lifting loading platform, and the vacuum chuck loading mechanism, intelligent and precise on-demand loading of various sheets is realized.

[0015] Step S3, automatic positioning and cutting. Through the 3D vision recognition system and the laser positioning technology, determine the cutting position of the sheet. At the same time, the equipped multi-tool head cutting system intelligently identifies the type of the sheet, automatically switches the adapted tool head, and the numerical control cutting machine completes the precise cutting.

[0016] Step S4, quality inspection and feedback. The high-precision quality inspection module automatically inspects the dimensional accuracy and surface quality of the blanking parts, and feeds the inspection results back to the intelligent control system.

[0017] Step S5, automatic sorting and stacking. After the quality inspection is completed, the robotic arm in the robotic arm sorting and stacking system automatically sorts the qualified sheet parts and stacks them on the transfer trolley in a preset order for subsequent online assembly.

[0018] Step S6, automatic waste collection. After the qualified sheets are sorted, the conveyor belt blanking mechanism automatically conveys the unqualified sheets and waste to the waste collection device for centralized treatment.

[0019] Furthermore, a deep learning algorithm and an AI algorithm are introduced into the intelligent control system.

[0020] Furthermore, the cutting accuracy in Step S3 reaches within ±0.1 mm.

[0021] The present invention also adopts the following technical solutions: A full-automatic production system, based on the aforementioned intelligent and precise blanking process for the floor of new energy buses, the full-automatic production system includes an intelligent control system, a numerical control cutting machine, a gantry slide rail, a 3D vision recognition system, a robotic arm sorting and stacking system, and a high-precision quality inspection module. One end of the gantry slide rail is connected to a sunken automatic lifting and loading platform, and the other end of the gantry slide rail is connected to a conveyor belt blanking mechanism. The gantry slide rail is integrated with a vacuum suction cup loading mechanism, a blanking main machine, a vacuum blanking platform, a multi-tool head cutting system, and a 3D vision recognition system. The conveyor belt blanking mechanism is connected to a waste collection device together.

[0022] Further, the numerical control cutting machine is equipped with a high-precision cutting head and a multi-tool head cutting system.

[0023] Further, the 3D vision recognition system is integrated with a high-precision camera.

[0024] Further, the robotic arm sorting and stacking system is equipped with a multi-degree-of-freedom robotic arm.

[0025] Further, the high-precision quality inspection module is integrated with a laser scanner and sensors.

[0026] Further, it also includes a centralized sheet storage area where sheets are stored.

[0027] Further, it also includes an intelligent sheet hoisting and switching feeding system, and the operation range of the intelligent sheet hoisting and switching feeding system can cover the centralized sheet storage area.

[0028] The present invention has the following beneficial effects: The present invention can achieve intelligent and precise blanking of sheets with various different thicknesses and materials, effectively improve the blanking efficiency, blanking accuracy, and sheet installation quality of vehicle sheets, reduce production costs, and enhance the market competitiveness of products. Description of the Drawings:

[0029] Figure 1 It is a schematic diagram of the full-automatic production system of the present invention. Detailed Embodiments:

[0030] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in this application will be clearly and completely described below in conjunction with the drawings in this application. Apparently, the described embodiments are some, but not all, of the embodiments of this application. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in this application without making creative efforts shall fall within the scope of protection of this application.

[0031] In the description, claims and the above drawings of this application, terms such as "first", "second", "third", "fourth", etc. (if any) are used to distinguish similar objects and do not necessarily describe a specific order or sequence. It should be understood that the data used in this way can be interchanged under appropriate circumstances so that the embodiments of this application described herein can be implemented in an order other than those illustrated or described herein. In the embodiments of this application, words such as "exemplary" or "for example" are used to represent examples, illustrations or explanations. Any embodiment or design solution described as "exemplary" or "for example" in this application should not be construed as being more preferred or having more advantages than other embodiments or design solutions. Rather, the use of words such as "exemplary" or "for example" is intended to present relevant concepts in a specific manner

[0032] The following will describe in detail some embodiments of this application with reference to the drawings. The intelligent precise blanking process for the floor of a new energy bus of the present invention includes the following steps:

[0033] Step S1, data import and optimization. Import the floor design drawings into the intelligent control system 8, and the intelligent control system 8 automatically optimizes the blanking plan to maximize the material utilization rate.

[0034] Introduce a deep learning algorithm into the intelligent control system 8. According to historical blanking data and real-time production requirements, dynamically optimize the blanking plan to further improve the material utilization rate. Optimize the blanking plan through the AI algorithm to maximize the material utilization rate. The material utilization rate is increased to more than 98%, reducing waste.

[0035] Step S2, intelligent loading. Through the cooperation of the intelligent control system 8, the intelligent sheet hoisting and switching feeding system 13, the sunken automatic lifting loading platform 2, and the vacuum sucker loading mechanism 3, realize intelligent and precise on-demand loading of various sheets, improving production efficiency.

[0036] Among them, the sheets are stored in the sheet centralized storage area 1, and the operation range of the intelligent sheet hoisting and switching feeding system 13 only needs to cover the sheet centralized storage area 1.

[0037] The sunken automatic lifting loading platform 2 is connected to one end of a gantry slide rail (not shown). The gantry slide rail is integrated with a vacuum sucker loading mechanism 3, a cutting host 4, a vacuum cutting platform 5, a multi-tool head cutting system 11, and a 3D vision recognition system 16. The other end of the gantry slide rail (not shown) is connected to a conveyor belt blanking mechanism 6. The conveyor belt blanking mechanism 6 is connected to a waste collection device 15.

[0038] Step S3: Automatic positioning and cutting. Through the 3D vision recognition system 16 and laser positioning technology, the cutting position of the board is determined. Meanwhile, the equipped multi-tool head cutting system 11 can intelligently identify the type of the board, automatically switch the adapted tool head, and the numerical control cutting machine completes the precise cutting.

[0039] In step S3, the numerical control cutting machine and the 3D vision recognition system 16 are added to ensure that the cutting accuracy reaches within ±0.1 mm.

[0040] The multi-tool head cutting system 11 is added to the numerical control cutting machine to realize the cutting of various boards (bamboo plywood floors, PVC floors, and PP honeycomb floors with a thickness of 10 - 18 mm, PVC roof panels and perforated aluminum-plastic composite roof panels with a thickness of 3 - 5 mm, PVC side panels and aluminum-plastic composite side panels with a thickness of 3 - 5 mm); meanwhile, it can intelligently identify the current board type, load and stack multiple small-sized boards for synchronous cutting, greatly improving the production efficiency by more than 60%.

[0041] Step S4: Quality inspection and feedback. The high-precision quality inspection module 12 automatically inspects the dimensional accuracy and surface quality of the blanking parts and feeds back the inspection results to the intelligent control system 8.

[0042] Step S5: Automatic sorting and palletizing. After the quality inspection is completed, the robotic arm in the robotic arm sorting and palletizing system 14 automatically sorts the qualified board parts and palletizes them onto the transfer trolley in a preset order (by set), facilitating subsequent on-line assembly.

[0043] Step S6: Automatic waste collection. After the qualified boards are sorted, the conveyor blanking mechanism 6 automatically conveys the unqualified boards and waste to the waste collection device 15 for centralized treatment.

[0044] The fully automatic production system of the present invention includes an intelligent control system 8, a numerical control cutting machine, a gantry slide rail, a 3D vision recognition system 16, a robotic arm sorting and palletizing system 14, and a high-precision quality inspection module 12. One end of the gantry slide rail is connected to a sunken automatic lifting loading platform 2, and the other end is connected to a conveyor blanking mechanism 6. The vacuum suction cup loading mechanism 3, the blanking host 4, the vacuum blanking platform 5, the multi-tool head cutting system 11, and the 3D vision recognition system 16 are integrated on the gantry slide rail. The conveyor blanking mechanism 6 is connected to the waste collection device 15.

[0045] The intelligent control system 8 is based on an industrial computer and AI algorithms to realize the optimization of the blanking plan and the full-process automatic control.

[0046] The numerical control cutting machine is equipped with a high-precision cutting head. Meanwhile, the equipped multi-tool head cutting system 11 can automatically switch the adapted tool head according to the current board type to achieve the precise cutting of floor boards.

[0047] The 3D vision recognition system 16 realizes the automatic positioning of the sheet material and the cutting path planning through a high-precision camera and an image processing algorithm.

[0048] The robotic arm sorting and stacking system 14 is equipped with a multi-degree-of-freedom robotic arm, which realizes the automatic sorting and stacking of floor components, and can cooperate with the conveyor blanking mechanism 6 to automatically convey unqualified sheet materials and waste to the waste collection device 15 for centralized treatment.

[0049] The high-precision quality inspection module 12 is integrated with a laser scanner and sensors to detect the dimensional accuracy and surface quality of the blanking components in real time, and feedback the inspection results to the intelligent control system 8.

[0050] The intelligent and precise blanking process for the new energy bus floor of the present invention solves the problems of low material utilization rate, poor cutting accuracy, insufficient adaptability, low production efficiency, and great dust hazard in manual operation in the prior art through technical means such as deep learning algorithms, 3D vision recognition system 16, multi-tool cutting system 11, and high-precision quality inspection module 12, and can realize full-process automated production.

[0051] The above are only the preferred embodiments of the present invention. It should be noted that for those of ordinary skill in the art, several improvements can be made without departing from the principle of the present invention, and these improvements should also be regarded as the protection scope of the present invention.

Claims

1. An intelligent and precise blanking process for the floor of a new energy bus, characterized in that: It includes the following steps: Step S1, data import and optimization: Import the floor design drawings into the intelligent control system (8), and the intelligent control system (8) automatically optimizes the cutting plan. Step S2, intelligent loading: Through the cooperation of the intelligent control system (8), the intelligent sheet hoisting and switching feeding system (13), the sunken automatic lifting loading platform (2), and the vacuum suction cup loading mechanism (3), realize intelligent and accurate on-demand loading of various sheets. Step S3, automatic positioning and cutting: Determine the cutting position of the sheet through the 3D vision recognition system (16) and laser positioning technology. At the same time, the equipped multi-tool head cutting system (11) intelligently identifies the type of the sheet, automatically switches the adapted tool head, and the numerical control cutting machine completes accurate cutting. Step S4, quality inspection and feedback: The high-precision quality inspection module (12) automatically inspects the dimensional accuracy and surface quality of the cut parts and feeds back the inspection results to the intelligent control system (8). Step S5, automatic sorting and stacking: After quality inspection, the robotic arm in the robotic arm sorting and stacking system (14) automatically sorts the qualified sheet parts and stacks them on the transfer trolley in a preset order for subsequent online assembly. Step S6, automatic waste collection: After the qualified sheets are sorted, the conveyor belt blanking mechanism (6) automatically conveys the unqualified sheets and waste to the waste collection device (15) for centralized processing.

2. The intelligent and precise blanking process for the floor of a new energy bus according to claim 1, wherein: The deep learning algorithm and AI algorithm are introduced into the intelligent control system (8).

3. The intelligent and precise blanking process for the floor of a new energy bus according to claim 2, characterized in that: The cutting accuracy in Step S3 reaches within ±0.1 mm.

4. A fully automatic production system, based on the intelligent precise blanking process for the floor of a new energy bus according to any one of claims 1-3, characterized in that: The full-automatic production system includes an intelligent control system (8), a numerical control cutting machine, a gantry slide rail, a 3D vision recognition system (16), a robotic arm sorting and stacking system (14), and a high-precision quality inspection module (12). One end of the gantry slide rail is connected to a sunken automatic lifting loading platform (2), and the other end is connected to a conveyor belt blanking mechanism (6). The gantry slide rail is integrated with a vacuum suction cup loading mechanism (3), a blanking host (4), a vacuum blanking platform (5), a multi-tool head cutting system (11), and a 3D vision recognition system (16). The conveyor belt blanking mechanism (6) is connected to the waste collection device (15).

5. The fully automatic production system according to claim 4, characterized in that: The numerical control cutting machine is equipped with a high-precision cutting head and a multi-tool head cutting system (11).

6. The full-automatic production system according to claim 5, wherein: The 3D vision recognition system (16) is integrated with a high-precision camera.

7. The fully automatic production system according to claim 6, characterized in that: The robotic arm sorting and stacking system (14) is equipped with a multi-degree-of-freedom robotic arm.

8. The fully automatic production system according to claim 7, wherein: The high-precision quality inspection module (12) is integrated with a laser scanner and a sensor.

9. The fully automatic production system according to claim 8, wherein: It also includes a sheet centralized storage area (1) where sheets are stored.

10. The fully automatic production system according to claim 9, characterized in that: It also includes an intelligent sheet hoisting and switching feeding system (13), and the operation range of the intelligent sheet hoisting and switching feeding system (13) can cover the sheet centralized storage area (1).

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