High-precision automatic installation equipment for vehicle door impact beam

Abstract

The utility model discloses a kind of high-precision automatic installation equipment of vehicle door crash beam, including first six-axis mechanical arm, first six-axis mechanical arm is installed with gripper frame, handling gripper is installed on the gripper frame, 3D vision camera, pneumatic clamping unit, high-precision adjustable positioning pin are installed on the gripper frame, the right side of first six-axis mechanical arm is equipped with crash beam clamp, the utility model relates to vehicle door crash beam technical field.Integrating 3D vision camera and high-precision adjustable positioning pin, system can real-time perceive the relative position of crash beam and vehicle door, and carry out self-adapting fine adjustment, ensure that the positioning accuracy of every installation is far more than artificial level, fundamentally eliminates installation deviation, guarantees the safety performance of product.

Description

Technical Field

[0001] This utility model relates to the field of vehicle door anti-collision beam technology, specifically a high-precision automatic installation device for vehicle door anti-collision beams. Background Technology

[0002] Traditional processes employ a combination of manual and semi-automatic tooling: the operator moves the crash beam (weighing 8-15kg) to the inner door panel, visually aligns it with pre-drilled holes, uses pneumatic clamps for initial fixing, and then tightens 4-6 bolts in stages (torque 20-25N·m). Auxiliary tools include a laser positioning pen and mechanical limit blocks. The installation cycle is approximately 120 seconds per piece, and the angle and force are adjusted based on the operator's experience.

[0003] Defects and problems

[0004] Precision defects: Manual positioning error > ±1.5mm, resulting in uneven gap between the anti-collision beam and the curved surface of the door (measured 0.5-3mm), causing wind noise at high speeds (increased by 8-15dB(A) at 120km / h);

[0005] Efficiency bottleneck: The installation time for a single part is ≥120 seconds, which becomes the bottleneck of the cycle time of the automated production line (accounting for 35% of the total assembly time of the door).

[0006] Quality risks: The bolt tightening pass rate is only 85% (due to human fatigue leading to missed tightening or overloading), and the bolt preload dispersion coefficient (CV value) is greater than 20%, which reduces collision safety;

[0007] Safety hazards: Handling heavy anti-collision beams can cause lumbar muscle strain in workers; the average annual work injury rate in automobile factories is 3.2%. Utility Model Content

[0008] To address the shortcomings of existing technologies, this utility model provides a high-precision automatic installation device for car door anti-collision beams. This solves the problems of traditional processes that combine manual labor with semi-automatic tooling: the operator moves the anti-collision beam (weighing 8-15 kg) to the inner door panel, visually aligns it with pre-set holes, uses pneumatic clamps for initial fixing, and then tightens 4-6 bolts in stages (torque 20-25 N·m). Auxiliary tools include a laser positioning pen and mechanical limit blocks. The installation cycle is approximately 120 seconds per piece, and the process relies on the operator's experience to adjust the angle and force.

[0009] To achieve the above objectives, this utility model is implemented through the following technical solution: It includes a first six-axis robotic arm, on which a gripper frame is mounted, a handling gripper is mounted on the gripper frame, and a 3D vision camera, a pneumatic clamping unit, and a high-precision adjustable positioning pin are mounted on the gripper frame. A collision-resistant beam clamp is provided on the right side of the first six-axis robotic arm, and a second six-axis robotic arm is provided on the right side of the collision-resistant beam clamp. A frame is mounted on the second six-axis robotic arm, and a tightening gun adjustable connecting block, a tightening gripper, an electric valve island, a servo electric screwdriver, and a photoelectric sensor are mounted on the frame.

[0010] Preferably, the anti-collision beam clamp is equipped with a clamp main frame, a clamping cylinder unit, and a swing cylinder unit. The swing cylinder unit is equipped with a floating mechanism, and the floating mechanism is provided with positioning pins and contour blocks on both sides.

[0011] This utility model provides a high-precision automatic installation device for vehicle door anti-collision beams. It has the following beneficial effects:

[0012] It achieves fully automated and high-precision operation: By integrating a 3D vision camera and high-precision adjustable positioning pins, the system can perceive the relative position of the anti-collision beam and the door in real time and make adaptive fine adjustments to ensure that the positioning accuracy of each installation far exceeds the level of manual installation, fundamentally eliminating installation deviation and ensuring the safety performance of the product.

[0013] Significantly improves production efficiency and stability: The use of dual six-axis robotic arms enables seamless integration of the entire process of automatic gripping, handling, precise positioning, and automatic tightening of the crash beams. The entire process is stable and reliable, significantly reducing the installation time of individual parts, greatly improving production cycle time, and overcoming quality fluctuations caused by factors such as human fatigue.

[0014] It possesses excellent flexibility and adaptability: the key high-precision adjustable positioning pins, adjustable connecting blocks for tightening guns, and floating mechanisms on the anti-collision beam clamps enable the equipment to be quickly adjusted through the program, easily adapting to the installation tasks of anti-collision beams of different models and specifications, greatly enhancing the flexibility of the production line and reducing the modification costs and time when switching models.

[0015] High degree of integration and intelligence: The equipment integrates intelligent components such as photoelectric sensors, electric valve islands and servo electric screwdrivers, realizing precise control and real-time quality monitoring of the tightening process (such as torque and angle monitoring), ensuring that every tightening point meets the process requirements, and improving the traceability and consistency of the overall assembly quality. Attached Figure Description

[0016] Figure 1 This is a structural schematic diagram of a high-precision automatic installation device for a car door anti-collision beam as described in this utility model.

[0017] Figure 2 This is a top view of the high-precision automatic installation device for a car door anti-collision beam described in this utility model.

[0018] In the diagram: 1-First six-axis robotic arm; 2-Gripper frame; 3-Transfer gripper; 4-3D vision camera; 5-Pneumatic clamping unit; 6-High-precision adjustable positioning pin; 7-Anti-collision beam fixture; 8-Second six-axis robotic arm; 9-Frame; 10-Adjustable connecting block for tightening gun; 11-Tightening gripper; 12-Electric valve island; 13-Servo electric screwdriver; 14-Photoelectric sensor; 15-Main frame of fixture; 16-Clamping cylinder unit; 17-Swing cylinder unit; 18-Floating mechanism; 19-Positioning pin; 20-Pattern block. Detailed Implementation

[0019] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0020] Please see Figure 1-2 This utility model provides a technical solution: a high-precision automatic installation device for a car door anti-collision beam, including a first six-axis robotic arm 1, a gripper frame 2 mounted on the first six-axis robotic arm 1, a handling gripper 3 mounted on the gripper frame 2, a 3D vision camera 4, a pneumatic clamping unit 5, and a high-precision adjustable positioning pin 6 mounted on the gripper frame 2, an anti-collision beam clamp 7 provided on the right side of the first six-axis robotic arm 1, a second six-axis robotic arm 8 provided on the right side of the anti-collision beam clamp 7, a frame 9 mounted on the second six-axis robotic arm 8, and a tightening gun adjustable connecting block 10, a tightening gripper 11, an electric valve island 12, a servo electric screwdriver 13, and a photoelectric sensor 14 mounted on the frame 9.

[0021] As a preferred technical solution, the anti-collision beam clamp 7 is further equipped with a clamp main frame 15, a clamping cylinder unit 16, and a swing cylinder unit 17. The swing cylinder unit 17 is equipped with a floating mechanism 18, and the floating mechanism 18 is provided with positioning pins 19 and contour blocks 20 on both sides.

[0022] It should be noted that:

[0023] The handling gripper uses a 3D camera to identify and grasp the frame workpiece, placing it onto the fixture with a placement accuracy of 0.02mm.

[0024] The handling gripper uses a 3D camera to identify and grasp the anti-collision beam, placing the workpiece onto the fixture with a placement accuracy of 0.02mm.

[0025] The tightening and handling gripper uses a 3D camera to identify and tighten the workpiece.

[0026] 1. The 3D vision system uses a 3D stereo camera (2448×2048 resolution) combined with a laser scanner (accuracy ±0.02mm) to capture real-time point cloud data of the curved surface of the car door inner panel. It dynamically calculates the normal vector deviation of the anti-collision beam mounting point and automatically generates pose compensation commands, achieving an assembly accuracy of ±0.1mm.

[0027] The 3D stereo camera (resolution 2448×2048) is fixed to the aluminum alloy camera bracket with 4×M6 hex screws. The back of the bracket is designed with a Φ12mm through hole for wiring. The camera signal line is connected to the control cabinet through an M12-8 shielded connector.

[0028] The laser scanner (accuracy ±0.02mm) is connected to the camera bracket via an L-shaped mounting plate. The mounting plate is 8mm thick and has a U-shaped groove for adjusting the scanner's tilt angle (±15°). M5 wing nuts are used for locking for quick fine-tuning.

[0029] The point cloud data processing unit (Intel i7 processor) is connected to the industrial PC motherboard via a PCIe×4 slot. Power is supplied by a 24V DC power module, and the power cable uses shielded twisted pair cable to reduce electromagnetic interference.

[0030] 2. High-precision adaptive fixtures and grippers

[0031] The modular design, with a pneumatic clamping unit and stepped positioning pins (H7 / g6 tolerance), enables high-precision workpiece positioning (with repeatability up to ±0.05mm).

[0032] The pneumatic clamping unit (cylinder diameter Φ32mm) is mounted on the clamping base plate (material 6061-T6) via 4×M8 flange nuts. The piston rod end is threaded to the cylinder. The positioning block surface is laser-coated with a tungsten carbide coating (thickness 0.3mm) to enhance wear resistance.

[0033] The stepped locating pin (tolerance H7 / g6) is connected to the fixture base plate through the locating block and support. The locating pin can be adjusted in three directions (XYZ). The top of the pin is designed with a tapered guide section (15° cone angle) to assist in the coarse positioning of the workpiece. The locating pin can be adjusted in terms of accuracy, ensuring that the adjustment accuracy is within 0.2mm.

[0034] II. Multi-axis tightening module

[0035] 1. Six-degree-of-freedom robotic arm

[0036] Repeat positioning accuracy ±0.02mm, end effector integrates four servo electric screwdrivers (torque range 2-40N·m, control accuracy ±3%). 2. The servo electric screwdrivers (torque range 2-40N·m) are fixed to the linear slide by V-shaped clamps. The slide is connected to the end effector platform by M6 screws. The power screwdriver power cable and encoder cable pass through the cable chain (inner height 25mm) and are connected to the robot body junction box.

[0037] 3. Torque Feedback System

[0038] The electric screwdriver has a built-in torque sensor that collects the tightening curve in real time (sampling rate 1kHz). Abnormal data (such as a sudden change in slope > 0.8) triggers an alarm and is uploaded to the MES.

[0039] 4. Tightening detection system

[0040] The photoelectric sensor array (diffusion-reflection type) is mounted on both sides of the electric screwdriver bracket with M3 screws. The cable is led out through a waterproof connector (protection level IP67) and enters the DI module of the control cabinet through a cable tray.

[0041] The photoelectric sensor array monitors the screw status (present / missing), with a process error rate of <0.1% (statistics from 100,000 tests).

[0042] III. Central Control Module

[0043] Dual-controller architecture:

[0044] The PLC (Siemens S7-1500) is responsible for the motion control of the robotic arm and the linkage of the gripper.

[0045] Industrial PCs identify bolt hole positions and plan the optimal path in real time.

[0046] This equipment successfully achieved fully automated, high-precision installation of car door anti-collision beams, completely solving the pain points of large accuracy fluctuations and low efficiency inherent in traditional manual operations. By employing 3D vision to real-time fit the curvature of the car door surface (recognition accuracy ±0.02mm) and dynamically compensating for the installation trajectory, the equipment controls the normal deviation of the anti-collision beam installation point within ±0.1mm, a 14-fold improvement in accuracy compared to the ±1.5mm of traditional manual operations. It also ensures that the gap between the anti-collision beam and the car door is consistently less than 0.2mm, fundamentally eliminating the high-speed wind noise problem caused by uneven gaps. In terms of operational efficiency, the equipment significantly reduces the installation cycle time per piece from 120 seconds manually to 45 seconds, an improvement of 166%.

[0047] In terms of quality control, through the collaborative operation of a four-axis servo electric screwdriver and triple monitoring of torque, angle, and slope, the bolt tightening qualification rate reaches 99.8% (torque fluctuation CV value <3%), and the axial preload fluctuation range is compressed to ±5%, far superior to the ±30% of traditional pneumatic tools, greatly ensuring vehicle collision safety performance. The equipment reliability is also excellent, with a failure rate of less than 0.1% after 2000 hours of continuous operation.

[0048] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, the phrase "comprising an element defined as..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0049] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-precision automatic installation device for a car door anti-collision beam, comprising a first six-axis robotic arm (1), characterized in that, The first six-axis robotic arm (1) is equipped with a gripper frame (2), the gripper frame (2) is equipped with a handling gripper (3), the gripper frame (2) is equipped with a 3D vision camera (4), a pneumatic clamping unit (5), and a high-precision adjustable positioning pin (6). The first six-axis robotic arm (1) is equipped with a collision beam clamp (7) on the right side. The collision beam clamp (7) is equipped with a second six-axis robotic arm (8) on the right side. The second six-axis robotic arm (8) is equipped with a frame (9), the frame (9) is equipped with a tightening gun adjustable connecting block (10), a tightening gripper (11), an electric valve island (12), a servo electric screwdriver (13), and a photoelectric sensor (14).

2. The high-precision automatic installation equipment for vehicle door anti-collision beams according to claim 1, characterized in that, The anti-collision beam clamp (7) is equipped with a clamp main frame (15), a clamping cylinder unit (16), and a swing cylinder unit (17). The swing cylinder unit (17) is equipped with a floating mechanism (18). The floating mechanism (18) has positioning pins (19) and contour blocks (20) on both sides.

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