A method of producing a vehicle side intrusion assembly

Abstract

The application provides a production method of a car side surrounding assembly. Four adhesive work stations and two buckle mounting work stations are set according to the structural characteristics of each subassembly. Through reasonable arrangement and processing of each subassembly on the four adhesive work stations, the adhesive work of 12 subassemblies can be completed in a short time. Then, the two adhesive work stations share one buckle mounting work station, and the installation of buckles of each subassembly is completed through the buckle mounting work station. The method can ensure that the production rhythm of the side surrounding assembly of each car is less than or equal to 135 seconds, and greatly improves the production efficiency.

Description

Technical Field

[0001] This invention relates to a method for processing automotive parts, specifically a method for producing an automotive side skirt assembly. Background Technology

[0002] The vehicle side skirt assembly includes 12 sub-assemblies: left front wheel arch assembly, right front wheel arch assembly, left front door trim panel assembly, right front door trim panel assembly, left rear door trim panel assembly, right rear door trim panel assembly, left rear wheel arch 1, right rear wheel arch 1, left rear wheel arch 2 assembly, right rear wheel arch 2 assembly, left sill assembly, and right sill assembly. The front wheel arch assembly (left and right front wheel arch assemblies) includes an outer front wheel arch panel and an inner front wheel arch panel. The outer front wheel arch panel is primed and glued. The inner side of the inner front wheel arch panel, connecting to the outer panel, is primed and glued, then tape is applied. The inner and outer panels are pressed together. The outer side of the inner front wheel arch panel, connecting to the vehicle body, is primed and glued, then tape is applied, and clips are installed. The door trim panels (left and right of the front door trim panel assembly) include the outer front door trim panel and the inner front door trim panel. After applying primer and adhesive to the outer front door trim panel, tape is applied. After applying primer and adhesive to the inner side of the inner front door trim panel that connects to the outer panel, tape is applied. The inner and outer panels are then pressed together. After applying primer and adhesive to the outer side of the inner front door trim panel that connects to the vehicle body, tape is applied. Clips are then installed. The rear door trim panel assembly and the rear wheel arch 2 assembly are also composed of inner and outer panels, and the production method is the same as above. The rear wheel arch 1 assembly and the sill assembly have only one outer panel. After applying primer and adhesive to the outer side of the rear wheel arch 1 assembly that connects to the vehicle body, tape is applied. After applying primer and adhesive to the outer side of the sill assembly that connects to the vehicle body, tape is applied. Clips are then installed. The current production of automotive side skirt assemblies requires each sub-assembly to be processed separately in the manner described above, resulting in long processing times and low production efficiency. Furthermore, the existing primer coating process is mainly done manually, and the primer coating contains harmful substances such as cyclohexane, xylene, ethylbenzene, ethanol, acrylate polymers, chlorinated rubber, ethyl acetate, methanol, epoxy resin, and toluene. Therefore, it is necessary to add air after-treatment equipment, which has a significant impact on environmental impact assessments and also affects the occupational health of employees. Summary of the Invention

[0003] The purpose of this invention is to provide a production method for automotive side skirt assemblies. This production method establishes four bonding workstations and two clip-on workstations based on the structural characteristics of each sub-assembly. By rationally arranging and processing the various sub-assemblies on the four bonding workstations, the bonding work of 12 sub-assemblies can be completed in a short time. Afterwards, the two bonding workstations share a clip-on workstation to complete the installation of clips for each sub-assembly. Using this method, the production cycle time of the side skirt assembly for each vehicle can be ≤135 seconds, greatly improving production efficiency.

[0004] To achieve the above objectives, the present invention employs the following technical solution:

[0005] A method for producing a car side skirt assembly, the method comprising the following steps:

[0006] Step S1: Set up four bonding workstations and two snap-fit ​​workstations. The four bonding workstations are designated as A, B, C, and D. A and B are positioned opposite each other, with a shared snap-fit ​​workstation in the middle. C and D are also positioned opposite each other, with a shared snap-fit ​​workstation in the middle. A and B are positioned opposite C and D, with a walkway in between. A manual workbench is set up next to each snap-fit ​​workstation. Each bonding workstation includes two robots, two plasma flame cleaning systems, two first adhesive tape systems, and two second adhesive tape systems. The bonding workstations for bonding the front and rear wheel arch assemblies are also equipped with two foam bonding systems.

[0007] Step S2: Manually retrieve the part from the tooling car and place it on the manual workbench. Clean the inner and outer panels of the side-surrounding sub-assembly on the manual workbench. Then pre-install the inner and outer panels of the sub-assembly and clean the inner panel manually.

[0008] Step S3: Loading parts. Place the left rear wheel arch assembly 2 and the right front wheel arch assembly on the mold of the bonding workstation A; place the right rear wheel arch assembly 2 and the left front wheel arch assembly on the mold of the bonding workstation B; place the right rear wheel arch assembly 1, the left rear wheel arch assembly, the left rear door trim panel assembly, the right rear door trim panel assembly, and the right sill assembly on the mold of the bonding workstation C; place the left front door trim panel assembly, the right front door trim panel assembly, and the left sill assembly on the mold of the bonding workstation D. Each bonding workstation mold includes a bottom mold and an upper mold. The bottom mold can move forward, backward, left, and right, and the upper mold can be flipped and pressed together. Both the bottom and upper molds are equipped with non-marking suction cups. After the bottom and upper molds are closed, the pressure is controlled at 30-50 Newtons.

[0009] Step S4: The four bonding workstations operate simultaneously. The bottom and upper membranes of each bonding workstation are closed, and the product parts of the side-enclosing sub-assembly are vacuum-adsorbed. Then the mold is opened, the bottom membrane moves towards the robot end, and the upper membrane flips over so that the outer and inner plates of the side-enclosing sub-assembly on the bottom and upper membranes face upward and are staggered.

[0010] In step S5, the two robots in the A-group bonding workstation respectively use a plasma flame cleaning system to perform plasma cleaning on the outer panel of the front wheel arch R, the inner side of the inner panel of the front wheel arch R connecting to the outer panel, the outer panel of the rear wheel arch 2L, and the inner side of the inner panel of the rear wheel arch 2L connecting to the outer panel; then the first robot sequentially uses the first adhesive tape system and the foam bonding system to perform tape bonding and foam bonding on the inner side of the inner panel of the front wheel arch R connecting to the outer panel; the second robot uses the first adhesive tape system to perform tape bonding on the inner side of the inner panel of the rear wheel arch 2L connecting to the outer panel.

[0011] The two robots in the B-group bonding workstation respectively used a plasma flame cleaning system to clean the outer panel of the front wheel arch L, the inner side of the inner panel of the front wheel arch L connecting to the outer panel, the outer panel of the rear wheel arch 2R, and the inner side of the inner panel of the rear wheel arch 2R connecting to the outer panel. Then, the first robot used the first adhesive tape system and the foam bonding system to apply adhesive tape and foam to the inner side of the inner panel of the front wheel arch L connecting to the outer panel. The second robot used the first adhesive tape system to apply adhesive tape to the inner side of the inner panel of the rear wheel arch 2R connecting to the outer panel.

[0012] Two robots at the bonding workstation in Group C used a plasma flame cleaning system to clean the outer rear door trim panel R, the inner side of the inner rear door trim panel R connecting to the outer panel, the outer rear door trim panel L, the inner side of the inner rear door trim panel L connecting to the outer panel, the outer rear wheel arch 1R, the outer rear wheel arch 1L, and the outer sill R. Then, the first robot used a first adhesive tape system to apply tape to the outer rear door trim panel R and the inner side of the inner rear door trim panel R connecting to the outer panel, and used a second adhesive tape system to apply tape to the outer rear wheel arch 1R. The second robot used the first adhesive tape system to apply tape to the outer rear door trim panel L and the inner side of the inner rear door trim panel L connecting to the outer panel, and used a second adhesive tape system to apply tape to the outer rear wheel arch 1L. Finally, the robot with the larger range of motion used the second adhesive tape system to complete the tape application on the outer sill R.

[0013] The two robots in the D-group bonding workstation respectively used a plasma flame cleaning system to clean the outer panel of the front door trim panel R, the inner side of the inner panel of the front door trim panel R connecting to the outer panel, the outer panel of the front door trim panel L, the inner side of the inner panel of the front door trim panel L connecting to the outer panel, and the outer panel of the door sill L. Then, the first robot used a first adhesive tape system to apply adhesive tape to the outer panel of the front door trim panel R and the inner side of the inner panel of the front door trim panel R connecting to the outer panel; the second robot used the first adhesive tape system to apply adhesive tape to the outer panel of the front door trim panel L and the inner side of the inner panel of the front door trim panel L connecting to the outer panel; finally, the robot with a larger range of motion was selected to use the second adhesive tape system to complete the adhesive tape bonding of the outer panel of the door sill L.

[0014] Step S6: The bottom membrane of each bonding workstation moves away from the robot, the upper membrane flips over, the bottom membrane and the upper membrane are closed, pressure is maintained, and the bonding of the inner and outer panels of each sub-assembly is completed.

[0015] Step S7: The bottom and upper tire films of each tire film in the bonding workstation are re-molded. Each sub-assembly of the side skirt is placed on the bottom tire film. The bottom tire film is moved again. The robot uses the plasma flame cleaning system, the second adhesive tape system, and the foam bonding system to complete the plasma cleaning, tape bonding, and foam bonding of the outer side of the front wheel arch R inner panel and the side connecting to the body, the outer side of the front wheel arch L inner panel and the side connecting to the body; the plasma cleaning and tape bonding of the outer side of the front door trim R inner panel and the outer side of the front door trim L inner panel and the side connecting to the body; the plasma cleaning and tape bonding of the outer side of the rear door trim R inner panel and the outer side of the rear door trim L inner panel and the side connecting to the body; the plasma cleaning, tape bonding, and foam bonding of the outer side of the rear wheel arch 2R inner panel and the outer side of the rear wheel arch 2L inner panel and the side connecting to the body.

[0016] Step S8: After the bonding workstation completes the bonding of each sub-assembly, the bottom membrane moves forward, backward, left, and right to the snap-fit ​​workstation. The snap-fit ​​workstation uses a robot and snap-fit ​​system to snap-fit ​​each sub-assembly.

[0017] Step S9: After the buckle installation is completed, the bottom membrane moves to the end away from the robot in the buckle installation workstation, and the part is manually picked up and the processed sub-assembly is placed on the turnover cart.

[0018] Step S10: The bottom membrane continues to move back to its respective bonding workstation, and then steps S3 to S10 are repeated.

[0019] As a preferred embodiment of the present invention, the plasma equipment used in the plasma flame cleaning system has the following characteristics: processing width: 18-20mm; processing speed: 250-300mm / s; processing distance: 5-10mm; input voltage: 220V; power: not less than 1000W; working gas: external compressed air; high-voltage transformer: dry oil-free transformer; plasma flame temperature: low-temperature plasma, temperature below 120 degrees Celsius.

[0020] As a preferred embodiment of the present invention, the four bonding workstations include: four upper membranes and eight lower membranes; the four upper membranes are upper-folding and pressing membranes, and the eight lower membranes are reversible membranes; the acrylic tape provided by the first adhesive tape system has a thickness of 0.8 mm, and the acrylic tape provided by the second adhesive tape system has a thickness of 1.5 mm.

[0021] As a preferred embodiment of the present invention, a vacuum suction button is provided on the front side of the mold of the four bonding workstations. The suction cup on the mold is controlled by the vacuum suction button to suction or release the parts; the side of the mold that contacts the outer surface of the side enclosure sub-assembly is provided with PU soft rubber.

[0022] As a preferred embodiment of the present invention, corresponding material sensors are configured on the upper mold and the bottom mold, and the bonding workstation identifies the material according to the actual feeding situation; a corresponding pressure sensor is also installed on the upper mold to provide feedback on the pressure value of the mold after closing, and an alarm will be triggered when the pressure is less than the preset value.

[0023] As a preferred embodiment of the present invention, the four sets of bonding workstations further include a tape visual inspection system and a flame monitoring system. The tape visual inspection system is used to detect whether the tape is missing and whether the tape bonding position meets the standard. The flame monitoring system is used to monitor the plasma flame.

[0024] As a preferred embodiment of the present invention, the buckle installation workstation includes a robot, a tire mold positioning component, a buckle installation system, a buckle supply system, a buckle replenishment system, and a buckle vision inspection system; wherein, the robot controls the buckle installation system to install the buckles; the tire mold positioning component is used to position the side enclosure sub-assembly; the buckle supply system is used to continuously supply buckles; the buckle replenishment system is used to provide and replenish buckles; and the buckle vision inspection system is used to detect whether buckles are missing or not and whether buckles are installed in place.

[0025] As a preferred embodiment of the present invention, the robot is equipped with a quick-change disc male plate, and the ion flame cleaning system, the first adhesive tape system, the second adhesive tape system, and the foam bonding system are all equipped with quick-change disc female plates, which enable rapid replacement.

[0026] As a preferred embodiment of the present invention, scratches or indentations are not permitted on the surface of the workpiece during the pressing of the diaphragm, and the workpiece is not allowed to shift from the positioning diaphragm during the pressing process.

[0027] As a preferred embodiment of the present invention, the four sets of bonding workstations need to be equipped with heating equipment to ensure that the bonding environment temperature is between 18℃ and 35℃.

[0028] As a preferred embodiment of the present invention, the pressure holding time in step S6 is not less than 10 seconds.

[0029] As a preferred embodiment of the present invention, during the processing of each sub-assembly, the materials are transported to the bonding workstation by AGV carts, and at least one AGV cart is responsible for transporting the materials from the buckle assembly workstation to the assembly sorting station.

[0030] Advantages and beneficial effects of the present invention:

[0031] (1) The production method provided by the present invention sets up four bonding workstations and two buckle mounting workstations according to the structural characteristics of each sub-assembly. By rationally arranging and processing each sub-assembly on the four bonding workstations, the production cycle of the four bonding workstations can be basically consistent, ensuring that the bonding work of 12 sub-assemblies can be completed in a short time. After that, the two bonding workstations share one buckle mounting workstation, and the buckle of each sub-assembly is installed through the buckle mounting workstation. Using this method, the production cycle of the side body assembly of each vehicle can be ≤135 seconds, which greatly improves the production efficiency.

[0032] (2) In the side enclosure assembly processing, the present invention uses plasma flame cleaning treatment to replace the base coating adhesive. By controlling the plasma flame treatment process parameters, it can ensure that the surface tension of the product parts after treatment is greater than ≥72 dynes, and the sub-assemblies after pressing and bonding meet the German Volkswagen standard (pull-out force F≥150N for bonding, welding and screwing).

[0033] (3) In this invention, plasma flame cleaning is performed first when processing each sub-assembly, and then the tape is pasted. This method greatly improves the bonding performance of acrylic tape. Experimental verification has shown that it has exceeded the pull-out force level of the primer coating process. Moreover, it is healthy and environmentally friendly, and improves the operating environment for operators.

[0034] (4) The production method provided by the present invention has only a small part of the operation completed manually, which reduces the intensity of manual operation and lowers the labor cost. Attached Figure Description

[0035] Figure 1 This is a schematic diagram showing the arrangement of the bonding workstation and the buckle mounting workstation of the present invention. Detailed Implementation

[0036] To enable those skilled in the art to better understand the technical solutions and advantages of the present invention, the present application is described in detail below, but it is not intended to limit the scope of protection of the present invention.

[0037] A method for producing a car side skirt assembly, the method comprising the following steps:

[0038] Step S1: Set up four bonding workstations and two snap-fit ​​workstations; the four bonding workstations are designated as A-group bonding workstation 1, B-group bonding workstation 2, C-group bonding workstation 3, and D-group bonding workstation 4. A-group bonding workstation 1 and B-group bonding workstation 2 are positioned opposite each other, with a shared snap-fit ​​workstation 5 in the middle. C-group bonding workstation 3 and D-group bonding workstation 4 are positioned opposite each other, with a shared snap-fit ​​workstation 6 in the middle. Bonding workstations 1 and 2 (Group B) are positioned opposite each other to bonding workstations 3 (Group C) and 4 (Group D), with a passageway in between for logistics vehicles or AGVs to move through. A manual workbench is set up next to each set of buckle workstations. Each set of bonding workstations includes 2 sets of robots, 2 sets of plasma flame cleaning systems, 2 sets of first adhesive tape systems, and 2 sets of second adhesive tape systems. The bonding workstations used for bonding the front wheel arch assembly and the rear wheel arch assembly are also equipped with 2 sets of foam bonding systems.

[0039] The plasma flame cleaning system uses plasma equipment with the following characteristics: processing width: 18-20mm; processing speed: 250-300mm / s; processing distance: 5-10mm; input voltage: 220V; power: not less than 1000W; working gas: external compressed air; high-voltage transformer: dry oil-free transformer; plasma flame temperature: low-temperature plasma, temperature below 120 degrees Celsius; preferred plasma equipment includes Hansheng Plasma, Jinbolilai Plasma, and Pushiman Plasma; the surface tension of the treated product is ≥72 dynes.

[0040] The acrylic tape provided by the first adhesive tape system is 0.8 mm thick, and the acrylic tape provided by the second adhesive tape system is 1.5 mm thick.

[0041] Step S2: Transport the material to the bonding workstation via AGV cart, manually retrieve the part from the AGV cart, place it on the manual worktable, clean the inner and outer panels of the side-surrounding sub-assembly on the manual worktable, then pre-assemble the inner and outer panels of the sub-assembly, and then manually clean the inner panel.

[0042] Step S3: Place the rear wheel arch assembly 2 (left) and front wheel arch assembly (right) on the mold of the bonding workstation in Group A; place the rear wheel arch assembly 2 (right) and front wheel arch assembly (left) on the mold of the bonding workstation in Group B; place the rear wheel arch assembly 1 (right), rear wheel arch assembly 1 (left), rear door trim panel assembly (left), rear door trim panel assembly (right), and sill assembly (right) on the mold of the bonding workstation in Group C; place the front door trim panel assembly (left), front door trim panel assembly (right), and sill assembly (left) on the mold of the bonding workstation in Group D; Each bonding workstation... The mold of the station includes a bottom mold and an upper mold. The four bonding workstations include a total of 4 upper molds and 8 bottom molds. The 4 upper molds are upper flip-pressing molds, meaning that the upper molds can be flipped and pressed together. The 8 bottom molds are movable in all directions, meaning that the bottom molds can move in all directions. Both the bottom and upper molds are equipped with non-marking suction cups. After the bottom and upper molds are molded together, the pressure is controlled at 30-50 Newtons.

[0043] Step S4: The four bonding workstations operate simultaneously. The bottom and upper membranes of each bonding workstation are closed, and the product parts of the side-enclosing sub-assembly are vacuum-adsorbed. Then the mold is opened, the bottom membrane moves towards the robot end, and the upper membrane flips over so that the outer and inner plates of the side-enclosing sub-assembly on the bottom and upper membranes face upward and are staggered.

[0044] In step S5, the two robots in the A-group bonding workstation respectively use a plasma flame cleaning system to perform plasma cleaning on the outer panel of the front wheel arch R, the inner side of the inner panel of the front wheel arch R connecting to the outer panel, the outer panel of the rear wheel arch 2L, and the inner side of the inner panel of the rear wheel arch 2L connecting to the outer panel; then the first robot sequentially uses the first adhesive tape system and the foam bonding system to perform tape bonding and foam bonding on the inner side of the inner panel of the front wheel arch R connecting to the outer panel; the second robot uses the first adhesive tape system to perform tape bonding on the inner side of the inner panel of the rear wheel arch 2L connecting to the outer panel.

[0045] The two robots in the B-group bonding workstation respectively used a plasma flame cleaning system to clean the outer panel of the front wheel arch L, the inner side of the inner panel of the front wheel arch L connecting to the outer panel, the outer panel of the rear wheel arch 2R, and the inner side of the inner panel of the rear wheel arch 2R connecting to the outer panel. Then, the first robot used the first adhesive tape system and the foam bonding system to apply adhesive tape and foam to the inner side of the inner panel of the front wheel arch L connecting to the outer panel (the adhesive tape and foam bonding positions were the plasma-cleaned areas). The second robot used the first adhesive tape system to apply adhesive tape to the inner side of the inner panel of the rear wheel arch 2R connecting to the outer panel.

[0046] Two robots at the bonding workstation in Group C used a plasma flame cleaning system to clean the outer rear door trim panel R, the inner side of the inner rear door trim panel R connecting to the outer panel, the outer rear door trim panel L, the inner side of the inner rear door trim panel L connecting to the outer panel, the outer rear wheel arch 1R, the outer rear wheel arch 1L, and the outer sill R. Then, the first robot used a first adhesive tape system to apply tape to the outer rear door trim panel R and the inner side of the inner rear door trim panel R connecting to the outer panel, and used a second adhesive tape system to apply tape to the outer rear wheel arch 1R. The second robot used the first adhesive tape system to apply tape to the outer rear door trim panel L and the inner side of the inner rear door trim panel L connecting to the outer panel, and used a second adhesive tape system to apply tape to the outer rear wheel arch 1L. Finally, the robot with the larger range of motion (the robot closer to the buckle installation workstation had the larger range of motion) used the second adhesive tape system to complete the tape application to the outer sill R.

[0047] Two robots in the D-group bonding workstation respectively used a plasma flame cleaning system to clean the outer panel of the front door trim panel R, the inner side of the front door trim panel R connecting to the outer panel, the outer panel of the front door trim panel L, the inner side of the front door trim panel L connecting to the outer panel, and the outer panel of the door sill L. Then, the first robot used a first adhesive tape system to apply adhesive tape to the outer panel of the front door trim panel R and the inner side of the front door trim panel R connecting to the outer panel; the second robot used the first adhesive tape system to apply adhesive tape to the outer panel of the front door trim panel L and the inner side of the front door trim panel L connecting to the outer panel. Finally, the robot with the larger range of motion was selected to use the second adhesive tape system to complete the adhesive tape bonding of the outer panel of the door sill L (the robot closer to the buckle installation workstation had the larger range of motion).

[0048] Step S6: The bottom membrane of each bonding workstation moves away from the robot, the upper membrane flips over, the bottom membrane and the upper membrane are closed, and pressure is maintained (the pressure maintenance time is not less than 10 seconds) to complete the bonding of the inner and outer panels of each sub-assembly on the side.

[0049] Step S7: The bottom and upper tire films of each tire film in the bonding workstation are re-molded. Each sub-assembly of the side skirt is placed on the bottom tire film. The bottom tire film is moved again. The robot uses the plasma flame cleaning system, the second adhesive tape system, and the foam bonding system to complete the plasma cleaning, tape bonding, and foam bonding of the outer side of the front wheel arch R inner panel and the side connecting to the body, the outer side of the front wheel arch L inner panel and the side connecting to the body; the plasma cleaning and tape bonding of the outer side of the front door trim R inner panel and the outer side of the front door trim L inner panel and the side connecting to the body; the plasma cleaning and tape bonding of the outer side of the rear door trim R inner panel and the outer side of the rear door trim L inner panel and the side connecting to the body; the plasma cleaning, tape bonding, and foam bonding of the outer side of the rear wheel arch 2R inner panel and the outer side of the rear wheel arch 2L inner panel and the side connecting to the body.

[0050] Step S8: After the bonding workstation completes the bonding of each sub-assembly, the bottom membrane moves forward, backward, left, and right to the snap-fit ​​workstation. The snap-fit ​​workstation uses a robot and snap-fit ​​system to snap-fit ​​each sub-assembly.

[0051] Step S9: After the buckle installation is completed, the bottom membrane moves to the end away from the robot in the buckle installation workstation, and the part is picked up manually. The processed sub-assembly is placed on the turnover cart (AGV trolley), and the processed sub-assembly is transported through the turnover cart to transport the material from the buckle installation workstation to the assembly sorting station.

[0052] Step S10: The bottom membrane continues to move back to its respective bonding workstation, and then steps S3 to S10 are repeated.

[0053] The four bonding workstations described in this embodiment are equipped with vacuum suction buttons on the front of the mold. The vacuum suction buttons control the action of the suction cups on the mold to suction or release parts. The side of the mold that contacts the outer surface (painted surface) of the side enclosure sub-assembly is made of PU soft rubber. The PU soft rubber needs to have a quick-replacement function so that it can be easily replaced after wear.

[0054] Furthermore, in this embodiment, corresponding material sensors are configured on the upper and lower molds, and the bonding workstation identifies the material according to the actual feeding situation; a corresponding pressure sensor is also installed on the upper mold to provide feedback on the pressure value of the mold after closing, and an alarm will be triggered when the pressure is less than the preset value.

[0055] Furthermore, the four bonding workstations described in this embodiment also include a tape visual inspection system and a flame monitoring system. The tape visual inspection system is used to detect whether the tape is missing and whether the tape bonding position meets the standard. The flame monitoring system is used to monitor the plasma flame.

[0056] Furthermore, the buckle installation workstation described in this embodiment includes a robot, a tire mold positioning component, a buckle installation system, a buckle supply system, a buckle replenishment system, and a buckle vision inspection system; wherein, the robot controls the buckle installation system to install the buckles; the tire mold positioning component is used to position the side body kit sub-assembly; the buckle supply system is used to continuously supply buckles; the buckle replenishment system is used to provide and replenish buckles; and the buckle vision inspection system is used to detect whether buckles are missing or not and whether buckles are installed in place.

[0057] Furthermore, in this embodiment, the robot is equipped with a quick-change disc male plate, and the ion flame cleaning system, the first adhesive tape system, the second adhesive tape system, and the foam bonding system are all equipped with quick-change disc female plates, enabling rapid replacement through the quick-change discs.

[0058] During the pressing of the membrane in this embodiment, scratches and indentations on the workpiece surface are not allowed. The workpiece is not allowed to shift from the positioning membrane during the pressing process. The four bonding workstations mentioned above need to be equipped with heating equipment to ensure that the bonding environment temperature of the tape is between 18℃ and 35℃ in any season of the year.

[0059] When the method provided by this invention is used to produce the side skirt assembly of a car, there are no harmful substances in the production process, which is healthy and environmentally friendly. It can also ensure that the production cycle of the side skirt assembly of each car is ≤135 seconds, and the pull force F of each sub-assembly is ≥200N, which meets the German Volkswagen standard and exceeds the pull force level (155-160N) of the base coating process.

Claims

1. A method for producing a side skirt assembly for automobiles, characterized in that, The method includes the following steps: Step S1: Set up four bonding workstations and two snap-fit ​​workstations. The four bonding workstations are designated as A, B, C, and D. A and B are positioned opposite each other, with a shared snap-fit ​​workstation in the middle. C and D are also positioned opposite each other, with a shared snap-fit ​​workstation in the middle. A and B are positioned opposite C and D, with a walkway in between. A manual workbench is set up next to each snap-fit ​​workstation. Each bonding workstation includes two robots, two plasma flame cleaning systems, two first adhesive tape systems, and two second adhesive tape systems. The bonding workstations for bonding the front and rear wheel arch assemblies are also equipped with two foam bonding systems. Step S2: Manually retrieve the part from the tooling car and place it on the manual workbench. Clean the inner and outer panels of the side-surrounding sub-assembly on the manual workbench. Then pre-install the inner and outer panels of the sub-assembly and clean the inner panel manually. Step S3: Loading parts. Place the left rear wheel arch assembly 2 and the right front wheel arch assembly on the mold of the bonding workstation A; place the right rear wheel arch assembly 2 and the left front wheel arch assembly on the mold of the bonding workstation B; place the right rear wheel arch assembly 1, the left rear wheel arch assembly, the left rear door trim panel assembly, the right rear door trim panel assembly, and the right sill assembly on the mold of the bonding workstation C; place the left front door trim panel assembly, the right front door trim panel assembly, and the left sill assembly on the mold of the bonding workstation D. Each bonding workstation mold includes a bottom mold and an upper mold. The bottom mold can move forward, backward, left, and right, and the upper mold can be flipped and pressed together. Both the bottom and upper molds are equipped with non-marking suction cups. After the bottom and upper molds are closed, the pressure is controlled at 30-50 Newtons. Step S4: The four bonding workstations operate simultaneously. The bottom and upper membranes of each bonding workstation are closed, and the product parts of the side-enclosing sub-assembly are vacuum-adsorbed. Then the mold is opened, the bottom membrane moves towards the robot end, and the upper membrane flips over so that the outer and inner plates of the side-enclosing sub-assembly on the bottom and upper membranes face upward and are staggered. In step S5, the two robots in the A-group bonding workstation respectively use the plasma flame cleaning system to perform plasma cleaning on the right outer panel of the front wheel arch assembly, the inner side of the right inner panel of the front wheel arch assembly connecting to the outer panel, the left outer panel of the rear wheel arch assembly 2, and the inner side of the left inner panel of the rear wheel arch assembly 2 connecting to the outer panel; then the first robot sequentially uses the first adhesive tape system and the foam bonding system to perform tape bonding and foam bonding on the inner side of the right inner panel of the front wheel arch assembly connecting to the outer panel; the second robot uses the first adhesive tape system to perform tape bonding on the inner side of the left inner panel of the rear wheel arch assembly 2 connecting to the outer panel. The two robots in the B-group bonding workstation respectively used a plasma flame cleaning system to clean the left outer panel of the front wheel arch assembly, the inner side of the left inner panel of the front wheel arch assembly connecting to the outer panel, the right outer panel of the rear wheel arch assembly 2, and the inner side of the right inner panel of the rear wheel arch assembly 2 connecting to the outer panel. Then, the first robot used the first adhesive tape system and the foam bonding system to apply adhesive tape and foam to the inner side of the left inner panel of the front wheel arch assembly connecting to the outer panel. The second robot used the first adhesive tape system to apply adhesive tape to the inner side of the right inner panel of the rear wheel arch assembly 2 connecting to the outer panel. Two robots at the bonding workstation in Group C used a plasma flame cleaning system to clean the right outer panel of the rear door trim assembly, the inner side of the right inner panel of the rear door trim assembly connecting to the outer panel, the left outer panel of the rear door trim assembly, the inner side of the left inner panel of the rear door trim assembly connecting to the outer panel, the right outer panel of rear wheel arch 1, the left outer panel of rear wheel arch 1, and the right outer panel of the sill assembly. Then, the first robot used a first adhesive tape system to apply tape to the right outer panel of the rear door trim assembly and the inner side of the right inner panel of the rear door trim assembly connecting to the outer panel, and used a second adhesive tape system to apply tape to the right outer panel of rear wheel arch 1. The second robot used the first adhesive tape system to apply tape to the left outer panel of the rear door trim assembly and the inner side of the left inner panel of the rear door trim assembly connecting to the outer panel, and used a second adhesive tape system to apply tape to the left outer panel of rear wheel arch 1. Finally, the robot with the larger range of motion used the second adhesive tape system to complete the tape application on the right outer panel of the sill assembly. The two robots in the D-group bonding workstation respectively used a plasma flame cleaning system to clean the right outer panel of the front door trim assembly, the inner side of the right inner panel of the front door trim assembly connecting to the outer panel, the left outer panel of the front door trim assembly, the inner side of the left inner panel of the front door trim assembly connecting to the outer panel, and the left outer panel of the sill assembly. Then, the first robot used the first adhesive tape system to apply adhesive tape to the right outer panel of the front door trim assembly and the inner side of the right inner panel of the front door trim assembly connecting to the outer panel; the second robot used the first adhesive tape system to apply adhesive tape to the left outer panel of the front door trim assembly and the inner side of the left inner panel of the front door trim assembly connecting to the outer panel; finally, the robot with the larger range of motion used the second adhesive tape system to complete the adhesive tape application on the left outer panel of the sill assembly. Step S6: The bottom membrane of each bonding workstation moves away from the robot, the upper membrane flips over, the bottom membrane and the upper membrane are closed, pressure is maintained, and the bonding of the inner and outer panels of each sub-assembly is completed. Step S7: The bottom and upper tire films of each tire film in the bonding workstation are re-molded. Each sub-assembly of the side surround is placed on the bottom tire film. The bottom tire film is moved again. The robot uses the plasma flame cleaning system, the second adhesive tape system, and the foam bonding system to complete the plasma cleaning, tape bonding, and foam bonding of the outer side of the right inner panel of the front wheel arch assembly and the side connected to the body, the outer side of the left inner panel of the front wheel arch assembly and the side connected to the body; the outer side of the right inner panel of the front door trim assembly and the outer side of the left inner panel of the front door trim assembly and the side connected to the body; the outer side of the right inner panel of the rear door trim assembly and the outer side of the left inner panel of the rear door trim assembly and the side connected to the body; the outer side of the right inner panel of the rear wheel arch 2 assembly and the outer side of the left inner panel of the rear wheel arch 2 assembly and the side connected to the body; the outer side of the right inner panel of the rear wheel arch 2 assembly and the outer side of the left inner panel of the rear wheel arch 2 assembly and the side connected to the body; the outer side of the right inner panel of the rear wheel arch 2 assembly and the side connected to the body; ... Step S8: After the bonding workstation completes the bonding of each sub-assembly, the bottom membrane moves forward, backward, left, and right to the snap-fit ​​workstation. The snap-fit ​​workstation uses a robot and snap-fit ​​system to snap-fit ​​each sub-assembly. Step S9: After the buckle installation is completed, the bottom membrane moves to the end away from the robot in the buckle installation workstation, and the part is manually picked up and the processed sub-assembly is placed on the turnover cart. Step S10: The bottom membrane continues to move back to its respective bonding workstation, and then steps S3 to S10 are repeated.

2. The method for producing an automotive side skirt assembly according to claim 1, characterized in that, The plasma equipment used in the plasma flame cleaning system has the following characteristics: processing width: 18-20mm; processing speed: 250-300mm / s; processing distance: 5-10mm; input voltage: 220V; power: not less than 1000W; working gas: external compressed air; high-voltage transformer: dry oil-free transformer; plasma flame temperature: low-temperature plasma, temperature below 120 degrees Celsius.

3. The method for producing an automotive side skirt assembly according to claim 1, characterized in that, The four bonding workstations include: 4 upper tire membranes and 8 lower tire membranes; the 4 upper tire membranes are upper flip-pressing tire membranes, and the 8 lower tire membranes are front-to-back and left-to-right rotating tire membranes; the acrylic tape provided by the first adhesive tape system is 0.8 mm thick, and the acrylic tape provided by the second adhesive tape system is 1.5 mm thick.

4. The method for producing an automotive side skirt assembly according to claim 1, characterized in that, The upper and lower molds are equipped with corresponding material sensors, and the bonding workstation identifies the material according to the actual feeding situation. The upper mold is also equipped with a corresponding pressure sensor to provide feedback on the pressure value after mold closing. When the pressure is less than the preset value, an alarm is triggered.

5. A method for producing an automotive side skirt assembly according to claim 1, characterized in that, The four bonding workstations have vacuum suction buttons on the front of the mold. The vacuum suction buttons control the action of the suction cups on the mold to suction or release parts. The side of the mold that contacts the outer surface of the side enclosure sub-assembly is covered with PU soft rubber.

6. A method for producing an automotive side skirt assembly according to claim 1, characterized in that, The four sets of bonding workstations also include a tape visual inspection system and a flame monitoring system. The tape visual inspection system is used to detect whether the tape is missing and whether the tape bonding position meets the standard. The flame monitoring system is used to monitor the plasma flame.

7. A method for producing an automotive side skirt assembly according to claim 1, characterized in that, The buckle installation workstation includes a robot, a tire mold positioning component, a buckle installation system, a buckle supply system, a buckle replenishment system, and a buckle vision inspection system. The robot controls the buckle installation system to install the buckles. The tire mold positioning component is used to position the side skirt sub-assemblies. The buckle supply system continuously supplies buckles. The buckle replenishment system provides and replenishes buckles. The buckle vision inspection system detects whether any buckles are missing or properly installed.

8. A method for producing an automotive side skirt assembly according to claim 1, characterized in that, The robot is equipped with a quick-change disc male plate, and the ion flame cleaning system, the first adhesive tape system, the second adhesive tape system, and the foam bonding system are all equipped with quick-change disc female plates, which enable rapid replacement.

9. A method for producing an automotive side skirt assembly according to claim 1, characterized in that, The bonding workstations described in Group 4 need to be equipped with heating equipment to ensure that the bonding environment temperature is between 18℃ and 35℃.

10. A method for producing an automotive side skirt assembly according to claim 1, characterized in that, The pressure holding time in step S6 shall not be less than 10 seconds.

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