A smart production line for aluminum profile frames

Abstract

This invention relates to the technical field of aluminum profile production and processing equipment for all-aluminum furniture, aluminum alloy doors and windows, shower rooms, etc., and particularly to an intelligent production line for aluminum profile frames. The technical solution includes: a feeding buffer device, a sawing device, a stamping device, and a riveting device. The sawing device is located on one side of the feeding buffer device, the stamping device on one side, and the riveting device on one side. This invention integrates the processing of aluminum profile frames into automated equipment, mainly realizing functions such as feeding buffer, cutting, punching, corner bracket installation, inspection, riveting, and unloading collection of aluminum profile frames. Through highly integrated automated equipment, it replaces the original manual, separate production mode, shortening the time for aluminum profiles to flow and wait between processes, improving processing efficiency, increasing factory capacity, and reducing manual input in the production process, thereby achieving labor reduction and efficiency improvement, and enhancing quality.

Description

Technical Field

[0001] This invention relates to the technical field of aluminum profile production and processing equipment for all-aluminum furniture, aluminum alloy doors and windows, shower rooms, etc., specifically to an intelligent production line for aluminum profile frames. Background Technology

[0002] Many products, including all-aluminum furniture, aluminum alloy doors and windows, and shower rooms, involve aluminum alloy frames. These frames need to be bent into rectangular shapes before use. Aluminum profile frame processing is generally a separate, stand-alone production model, with cutting, punching, riveting, and inspection processes separated. Workers must manually transfer the components to pallets or trolleys before moving them to the next processing step. Fully automated processing equipment for the aluminum profile frame industry is relatively new due to development difficulties; previously, it relied on a separate, stand-alone production model. The large variety of frame materials, production processes, and models leads to poor workshop environments, low efficiency, poor quality, high manual workload, and certain safety hazards for operators. Therefore, we propose an intelligent production line for aluminum profile frames to solve these problems. Summary of the Invention

[0003] The purpose of this invention is to provide an intelligent production line for aluminum profile frames to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: an intelligent production line for aluminum profile frames, comprising a feeding buffer device, a sawing device, a stamping device, and a riveting device. The feeding buffer device has a sawing device on one side, a stamping device on one side, and a riveting device on one side. The feeding buffer device includes a protective fence, a pushing gantry mechanism, a pushing clamp, a receiving and transferring robot, a dragging non-powered roller mechanism, a feeding buffer mechanism, a first frame, a clamping rotating robot, and a first electrical cabinet. The pushing gantry mechanism is located inside the protective fence, and a pushing clamp is installed on the pushing gantry mechanism. A first frame is located on one side of the pushing gantry mechanism, and a feeding buffer mechanism is installed on the top of the first frame. A dragging non-powered roller mechanism is located below the pushing gantry mechanism. A clamping rotating robot is installed on one side of the top rear end of the first frame, and a receiving and transferring robot is installed on one side of the inner rear end of the first frame. A first electrical cabinet is installed on one side of the outer wall of the first frame.

[0005] Preferably, the sawing device includes a first sawing head, a sawing and unloading robot, a first sawing positioning mechanism, a second frame, a second sawing head, a second sawing positioning mechanism, a conveying mechanism, a waste removal and unloading robot, a display screen, control buttons, and a control box. The conveying mechanism is provided on the lower inner side of the second frame. The first sawing head and the second sawing head are respectively installed at the front and rear ends of the top of the conveying mechanism. The first sawing positioning mechanism is provided on one side of the first sawing head.

[0006] Preferably, a second sawing positioning mechanism is provided on one side of the second sawing head, a sawing and unloading robot is installed on the inner top of the second frame, a waste removal and unloading robot is installed on one side of the inner top of the second frame, a control box is installed on one side of the outer wall of the second frame, and a display screen and control buttons are provided on one side of the outer wall of the control box, with the display screen located on one side of the control buttons.

[0007] Preferably, the stamping device includes an outflow conveyor line, a stamping loading robot, a stamping unloading robot, a vertical stamping mechanism, a third frame, an inflow conveyor line, a blocking mechanism, a second electrical cabinet, a fourth frame, a clamping and lifting robot, a fifth frame, and a stamping positioning mechanism. An outflow conveyor line and an inflow conveyor line are provided between the third frame and the fourth frame, and the inflow conveyor line is located at the front end of the outflow conveyor line. The third frame and the fourth frame are connected by the stamping loading robot. Both the outflow conveyor line and the inflow conveyor line are installed on the top of the fifth frame.

[0008] Preferably, a blocking mechanism is provided on the inner side of one end of the inflow conveyor line, a clamping and lifting robot is provided on the inner side of the inflow conveyor line, a stamping positioning mechanism is installed on the top of the third frame, a vertical stamping mechanism is provided on one side of the stamping positioning mechanism and is installed on the top of the third frame, a stamping unloading robot is provided at the front end of the stamping positioning mechanism and is installed at the front end of the third frame, and a second electrical cabinet is installed at the front end of the fourth frame.

[0009] Preferably, the riveting device includes a sixth frame, a corner code hopper, a corner code feeding and distributing mechanism, a riveting mold, a corner code pick-and-place robot, a corner code pushing mechanism, a length detection mechanism, a third electrical cabinet, and a pick-and-place transfer robot. A length detection mechanism is installed on one side of the top of the sixth frame, and a pick-and-place transfer robot is provided on one side of the length detection mechanism. The pick-and-place transfer robot is installed on the top of the sixth frame, and a corner code pushing mechanism is provided on one side of the pick-and-place transfer robot. The corner code pushing mechanism is installed on the top of the sixth frame.

[0010] Preferably, a corner code picking and placing robot is provided above the corner code pushing mechanism, and the corner code picking and placing robot is installed on the inner wall of one side of the sixth frame. A corner code feeding and distributing mechanism and a corner code hopper are installed above the rear end face of the sixth frame, and the corner code hopper is located at the rear end of the corner code feeding and distributing mechanism. A third electrical cabinet is installed below the front end of the sixth frame.

[0011] Compared with existing technologies, the beneficial effects of this invention are as follows: Through a series of structural arrangements, this invention has the advantages of small footprint (adopting a unique linear layout with loading and unloading on the same side, saving about 30% of the space compared to traditional methods, facilitating overall plant layout, allowing employees to easily monitor multiple machines, facilitating logistics operations, and enabling fully automated robotic loading, meeting the needs of different application scenarios), high efficiency (cycle time between 3.2 and 3.5 seconds, continuous operation for 11 hours, with a maximum production capacity of over 12,000 pieces), and high precision (processing accuracy: cutting length accuracy ±0.2mm, cutting angle accuracy ±0.05mm). .15° (punching accuracy ±0.2mm), high compatibility (raw material length 4-7.5 meters, finished product size (customizable) short frame: 800-2600mm, cutting angle (freely switchable) 35°-90°), low loss (low equipment power, small waste head, low air consumption, few vulnerable parts, few consumables), high reliability (the entire process adopts a "handover" design to ensure the stability of the aluminum profile during the "turnover" of various mechanisms, reducing the impact of large bending of raw materials on the processing process; it is designed with multiple safety protections such as mechanical protection, electrical detection, and software interlocks, ensuring safety regardless of power outages, gas outages, etc.) In case of misoperation or other abnormal situations, the safety of personnel, equipment mechanisms, and system data can be well guaranteed. It is easy to maintain (the equipment adopts a modular design concept; all operating mechanisms and vulnerable parts are "exposed"; and there are access channels for replacement and maintenance between major units). It is easy to change types (based on the modular design, we have implemented a universal compatibility design; except for stamping dies and a very few mechanisms that require manual adjustment, most mechanisms can be changed with one click or are fully compatible). It is easy to operate (workers only need to place the aluminum profiles on the conveyor line according to their orientation; it can be seamlessly integrated with fully automated robotic feeding). The design incorporates error-proof detection, enabling timely detection of issues such as incorrect or reversed material placement by workers. It features a main control screen and a handheld operating screen; the mold is vertically punched, and all operating mechanisms are "exposed," facilitating simple maintenance and easy replacement; the corner brackets use a clip-type feeding system, offering high compatibility, fast feeding, and a simple and reliable mechanism. It is also easily adjustable (fully modular design and manufacturing, with each module having an independent electrical box, all controls centralized in a main electrical control box, and communication control between boxes; the wiring is clean, simple, and clear, facilitating maintenance and installation; installation time is short, generally about 10 days after preparation).

[0012] Therefore, this invention can integrate the processing of aluminum profile frames into automated equipment, mainly realizing functions such as feeding, buffering, cutting, punching, corner bracket installation, inspection, riveting, unloading and collection of aluminum profile frames. Through highly integrated automated equipment, the original manual and separate production mode is replaced, shortening the time for aluminum profiles to flow and wait between processes, improving processing efficiency, increasing factory capacity, and reducing manual input in the production process, thereby achieving staff reduction and efficiency improvement, and improving quality. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of the present invention;

[0014] Figure 2 This is a schematic diagram of the feeding buffer device of the present invention;

[0015] Figure 3 This is a schematic diagram of the sawing device of the present invention;

[0016] Figure 4 This is a schematic diagram of the stamping device of the present invention;

[0017] Figure 5 This is a schematic diagram of the riveting device of the present invention.

[0018] In the diagram: 1. Feeding buffer device; 101. Protective fence; 102. Pushing gantry mechanism; 103. Pushing clamp; 104. Receiving and transferring robot; 105. Material dragging non-powered roller mechanism; 106. Feeding buffer mechanism; 107. First frame; 108. Clamping rotating robot; 109. First electrical cabinet; 2. Sawing device; 201. First sawing head; 202. Sawing and unloading robot; 203. First sawing positioning mechanism; 204. Second frame; 205. Second sawing head; 206. Second sawing positioning mechanism; 207. Conveying mechanism; 208. Waste removal and unloading robot; 209. Display screen; 210. Control button; 211. Control box; 3. 301. Stamping device; 302. Outflow conveyor line; 303. Stamping loading robot; 304. Stamping unloading robot; 305. Vertical stamping mechanism; 306. Third frame; 307. Inflow conveyor line; 308. Blocking mechanism; 309. Second electrical cabinet; 310. Fourth frame; 311. Clamping and lifting robot; 312. Fifth frame; 313. Stamping positioning mechanism; 4. Riveting device; 401. Sixth frame; 402. Corner code hopper; 403. Corner code feeding and distributing mechanism; 404. Riveting die; 405. Corner code pick-and-place robot; 406. Corner code pushing mechanism; 407. Length detection mechanism; 408. Third electrical cabinet; 409. Pick-and-place transfer robot. Detailed Implementation

[0019] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0020] Example 1

[0021] like Figure 1-5 As shown, the present invention proposes an intelligent production line for aluminum profile frames, comprising a feeding buffer device 1, a sawing device 2, a stamping device 3, and a riveting device 4. The sawing device 2 is located on one side of the feeding buffer device 1, the stamping device 3 is located on one side of the sawing device 2, and the riveting device 4 is located on one side of the stamping device 3. The feeding buffer device 1 includes a protective fence 101, a pushing gantry mechanism 102, a pushing clamp 103, a receiving and transferring robot 104, a dragging non-powered roller mechanism 105, a feeding buffer mechanism 106, a first frame 107, a clamping rotating robot 108, and a first electrical cabinet 109. The inner side of the protective fence 101 is provided with a material pushing gantry mechanism 102, and a material pushing clamp 103 is installed on the material pushing gantry mechanism 102. A first frame 107 is provided on one side of the material pushing gantry mechanism 102. A feeding buffer mechanism 106 is installed on the top of the first frame 107. A dragging non-powered roller mechanism 105 is provided below the material pushing gantry mechanism 102. A clamping rotary robot 108 is installed on one side of the top rear end of the first frame 107. A receiving and transferring robot 104 is installed on one side of the inner rear end of the first frame 107. A first electrical cabinet box 109 is installed on one side of the outer wall of the first frame 107.

[0022] The working principle of the intelligent aluminum profile frame production line based on Embodiment 1 is as follows: During operation, an external power supply is connected, and workers place aluminum profiles on the feeding buffer mechanism 106 for buffering. The feeding buffer mechanism 106 automatically feeds one profile at a time according to instructions from the front-end PLC. Then, a clamping rotary robot 108 clamps the aluminum profile and rotates it 180°. A receiving and transfer robot 104 then receives the profile, repeating this process twice. After receiving two profiles, the receiving and transfer robot 104 is driven to move, placing the two profiles on a non-drag, non-powered roller mechanism 105. Finally, a gantry robot clamps the tail end of the aluminum profile for feeding and sawing. After the gantry mechanism 102 feeds the aluminum profile into the sawing machine, the downward pressure cylinders on the first sawing positioning mechanism 203 and the second sawing positioning mechanism 206 push the reference plate down, and the upward lifting cylinders on the first sawing positioning mechanism 203 and the second sawing positioning mechanism 206 push the lower surface of the aluminum profile, pressing the upper surface of the aluminum profile against the reference plate. Then, the damping cylinder mechanism pushes out the high-speed rotating saw blade for sawing. The sawing machine is designed for double-head sawing, and each feed can cut both ends of the aluminum profile. After cutting, the sawing unloading robot 202 clamps the two aluminum profiles and places them in the waste removal mechanism. After the waste is removed, the waste removal and unloading robot 208 picks up one aluminum profile at a time, repeating twice. After picking up the aluminum profile and rotating it 90°, it is placed on the conveyor line and flows into the next process. The inflow conveyor line 306 sends the cut aluminum profile to a fixed position. Multiple sets of clamping and lifting robots 310 clamp and lift the aluminum profile. Then, the stamping loading robot 302 picks up the aluminum profile and sends it into the stamping die. The stamping positioning mechanism 312 clamps and positions the aluminum profile. After the hydraulic cylinder presses down the die, it punches and cuts. Then, the stamping unloading robot 303 puts the stamped product into the outflow conveyor line 30. 1. The outflow conveyor 301 delivers the stamped aluminum profile to a fixed position. The pick-and-place robot 409 clamps the product into the measuring position for length measurement. Then, the pick-and-place robot 409 clamps the measured product into the riveting position. The corner code pusher mechanism 406 pushes out a corner code from the hopper. Then, the corner code pick-and-place robot 405 picks up the corner code and places it into the riveting position. The corner code pusher mechanism 406 pushes the corner code into the aluminum profile. Then, the hydraulic cylinder mechanism drives the riveting die 404 to perform riveting. After that, the pick-and-place robot 409 places the riveted product on the conveyor mechanism 207 for outflow and packaging.

[0023] Example 2

[0024] like Figure 1-5As shown, the intelligent production line for aluminum profile frames proposed in this invention, compared with Embodiment 1, further includes: a sawing device 2 comprising a first sawing head 201, a sawing and unloading robot 202, a first sawing positioning mechanism 203, a second frame 204, a second sawing head 205, a second sawing positioning mechanism 206, a conveying mechanism 207, a waste removal and unloading robot 208, a display screen 209, control buttons 210, and a control box 211. A conveying mechanism 207 is provided on the lower inner side of the second frame 204. The first sawing head 201 and the second sawing head 205 are respectively installed at the front and rear ends of the top of the conveying mechanism 207. A first sawing positioning mechanism 203 is provided on one side of the first sawing head 201, and a first sawing positioning mechanism 203 is provided on one side of the second sawing head 205. The second sawing positioning machine mechanism includes a sawing unloading robot 202 installed on the inner top of the second frame 204, a waste removal unloading robot 208 installed on one side of the inner top of the second frame 204, a control box 211 installed on one side of the outer wall of the second frame 204, a display screen 209 and control buttons 210 installed on one side of the outer wall of the control box 211, with the display screen 209 located to the side of the control buttons 210. The stamping device 3 includes an outflow conveyor line 301, a stamping loading robot 302, a stamping unloading robot 303, a vertical stamping mechanism 304, a third frame 305, an inflow conveyor line 306, a blocking mechanism 307, a second electrical cabinet 308, a fourth frame 309, a clamping and lifting robot 310, a fifth frame 311, and a punching... A pressing positioning mechanism 312 is provided. An outflow conveyor line 301 and an inflow conveyor line 306 are provided between the third frame 305 and the fourth frame 309, with the inflow conveyor line 306 located at the front end of the outflow conveyor line 301. The third frame 305 and the fourth frame 309 are connected by a stamping loading robot 302. Both the outflow conveyor line 301 and the inflow conveyor line 306 are installed on the top of the fifth frame 311. A blocking mechanism 307 is provided on the inner side of one end of the inflow conveyor line 306, and a clamping and lifting robot 310 is provided on the inner side of the inflow conveyor line 306. A stamping positioning mechanism 312 is installed on the top of the third frame 305, and a vertical stamping mechanism 304 is provided on one side of the stamping positioning mechanism 312, and the vertical stamping mechanism 304 is installed on the third frame. At the top of frame 305, a stamping blanking robot 303 is installed at the front end of the stamping positioning mechanism 312. The stamping blanking robot 303 is installed at the front end of the third frame 305. A second electrical cabinet box 308 is installed at the front end of the fourth frame 309. The riveting device 4 includes a sixth frame 401, a corner code hopper 402, a corner code feeding and distributing mechanism 403, a riveting die 404, a corner code pick-and-place robot 405, a corner code pushing mechanism 406, a length detection mechanism 407, a third electrical cabinet box 408, and a pick-and-place transfer robot 409. A length detection mechanism 407 is installed on one side of the top of the sixth frame 401, and a pick-and-place transfer robot 409 is installed on one side of the length detection mechanism 407. The pick-and-place transfer robot 409 is installed on the top of the sixth frame 401.A corner code pushing mechanism 406 is provided on one side of the pick-and-place transfer robot 409, and the corner code pushing mechanism 406 is installed on the top of the sixth frame 401. A corner code picking and placing robot 405 is provided above the corner code pushing mechanism 406, and the corner code picking and placing robot 405 is installed on the inner wall of one side of the sixth frame 401. A corner code feeding and distributing mechanism 403 and a corner code hopper 402 are installed above the rear end face of the sixth frame 401, and the corner code hopper 402 is located at the rear end of the corner code feeding and distributing mechanism 403. A third electrical cabinet box 408 is installed below the front end of the sixth frame 401.

[0025] In this embodiment, a series of structures such as the first electrical cabinet box 109, the control box 211, the second electrical cabinet box 308, and the third electrical cabinet box 408 are arranged in a coordinated manner. Each module has an independent electrical box, and all controls are concentrated in a main electrical control box. Communication and control are between each electrical box. The wiring is clean, simple, and clear, which facilitates maintenance and installation. The installation time is short. After the preparation work is in place, the installation and commissioning work can generally be completed in about 10 days.

[0026] The above specific embodiments are merely several preferred embodiments of the present invention. Based on the technical solutions of the present invention and the relevant teachings of the above embodiments, those skilled in the art can make various alternative improvements and combinations to the above specific embodiments.

Claims

1. An intelligent production line for aluminum profile frames, comprising a feeding buffer device (1), a sawing device (2), a stamping device (3), and a riveting device (4), characterized in that: A sawing device (2) is provided on one side of the feeding buffer device (1), a stamping device (3) is provided on one side of the sawing device (2), and a riveting device (4) is provided on one side of the stamping device (3). The feeding buffer device (1) includes a protective fence (101), a pushing gantry mechanism (102), a pushing clamp (103), a receiving and transferring robot (104), a dragging non-powered roller mechanism (105), a feeding buffer mechanism (106), a first frame (107), a clamping rotating robot (108), and a first electrical cabinet (109). The pushing gantry mechanism (102) is provided on the inner side of the protective fence (101). The material pushing gantry mechanism (102) is equipped with a material pushing clamp (103). A first frame (107) is provided on one side of the material pushing gantry mechanism (102). A feeding buffer mechanism (106) is installed on the top of the first frame (107). A dragging non-powered roller mechanism (105) is provided below the material pushing gantry mechanism (102). A clamping rotary robot (108) is installed on one side of the top rear end of the first frame (107). A receiving and transfer robot (104) is installed on one side of the inner rear end of the first frame (107). A first electrical cabinet box (109) is installed on one side of the outer wall of the first frame (107). The sawing device (2) includes a first sawing head (201), a sawing and unloading robot (202), a first sawing positioning mechanism (203), a second frame (204), a second sawing head (205), a second sawing positioning mechanism (206), a conveying mechanism (207), a waste removal and unloading robot (208), a display screen (209), control buttons (210), and a control box (211). The conveying mechanism (207) is provided on the lower inner side of the second frame (204). The first sawing head (201) and the second sawing head (205) are respectively installed at the front and rear ends of the top of the conveying mechanism (207). The first sawing positioning mechanism (203) is provided on one side of the first sawing head (201). A second sawing positioning mechanism (206) is provided on one side of the second sawing head (205), a sawing unloading robot (202) is installed on the inner top of the second frame (204), a waste removal unloading robot (208) is installed on one side of the inner top of the second frame (204), a control box (211) is installed on one side of the outer wall of the second frame (204), a display screen (209) and a control button (210) are provided on one side of the outer wall of the control box (211), and the display screen (209) is located on one side of the control button (210); The stamping device (3) includes an outflow conveyor line (301), a stamping loading robot (302), a stamping unloading robot (303), a vertical stamping mechanism (304), a third frame (305), an inflow conveyor line (306), a blocking mechanism (307), a second electrical cabinet (308), a fourth frame (309), a clamping and lifting robot (310), a fifth frame (311), and a stamping positioning mechanism (312). An outflow conveyor line (301) and an inflow conveyor line (306) are provided between the third frame (305) and the fourth frame (309), and the inflow conveyor line (306) is located at the front end of the outflow conveyor line (301). The third frame (305) and the fourth frame (309) are connected by the stamping loading robot (302). The outflow conveyor line (301) and the inflow conveyor line (306) are both installed on the top of the fifth frame (311).

2. The intelligent production line for aluminum profile frames according to claim 1, characterized in that: A blocking mechanism (307) is provided on the inner side of one end of the inflow conveyor line (306), a clamping and lifting robot (310) is provided on the inner side of the inflow conveyor line (306), a stamping positioning mechanism (312) is installed on the top of the third frame (305), a vertical stamping mechanism (304) is provided on one side of the stamping positioning mechanism (312), and the vertical stamping mechanism (304) is installed on the top of the third frame (305), a stamping unloading robot (303) is provided at the front end of the stamping positioning mechanism (312), and the stamping unloading robot (303) is installed at the front end of the third frame (305), and a second electrical cabinet (308) is installed at the front end of the fourth frame (309).

3. The intelligent production line for aluminum profile frames according to claim 1, characterized in that: The riveting device (4) includes a sixth frame (401), a corner code hopper (402), a corner code feeding and distributing mechanism (403), a riveting mold (404), a corner code pick-and-place robot (405), a corner code pushing mechanism (406), a length detection mechanism (407), a third electrical cabinet (408), and a pick-and-place transfer robot (409). The sixth frame (401) has a length detection mechanism (407) installed on one side of its top. The pick-and-place transfer robot (409) is installed on one side of the length detection mechanism (407) and is mounted on the top of the sixth frame (401). The pick-and-place transfer robot (409) is installed on one side of the pick-and-place transfer robot (409) and is mounted on the top of the sixth frame (401).

4. The intelligent production line for aluminum profile frames according to claim 3, characterized in that: A corner code picking and placing robot (405) is provided above the corner code pushing mechanism (406), and the corner code picking and placing robot (405) is installed on the inner wall of one side of the sixth frame (401). A corner code feeding and distributing mechanism (403) and a corner code hopper (402) are installed above the rear end face of the sixth frame (401), and the corner code hopper (402) is located at the rear end of the corner code feeding and distributing mechanism (403). A third electrical cabinet box (408) is installed below the front end of the sixth frame (401).

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