High-thickness fabric stitching end effector, stitching robot device and weaving method

Abstract

The present invention relates to a high-thickness fabric stitching end effector, a stitching robot device and a weaving method. The stitching end effector includes a servo displacement mechanism, a tool switching mechanism, a presser foot mechanism and a yarn feeding mechanism; the stitching robot device includes a six-degree-of-freedom robot, a robot base and a preform stitching platform. The six-degree-of-freedom robot is installed on a horizontal plane through the robot base, and the end of the robotic arm of the six-degree-of-freedom robot is connected to the stitching end effector through a connecting flange; a modular core mold is installed on the preform stitching platform, and the modular core mold makes a rotary motion driven by a horizontal vertical and horizontal rotary worktable. A modular foam bottom felt is installed on the surface of the modular core mold. The present invention adopts a prefabricated hole technology, effectively reducing the wear and breakage of the stitching yarns, improving the product quality of the preform fabric, and realizing the tufting stitching and forming of high-thickness preform fabrics; reducing the equipment downtime caused by the breakage of the stitching yarns.

Description

Technical Field

[0001] The present invention belongs to the technical field of high-thickness direction punching and stitching of composite material preforms, and particularly relates to a high-thickness fabric stitching end effector, a stitching robot device and a weaving method. Background Art

[0002] In recent years, the stitching forming technology of composite materials has always been a research hotspot at home and abroad. The literature "Development and optimization of the tufting process for textile composite reinforcement" discloses a cylinder-based tufting device for tufting and stitching of textile composite preform fabrics on a plane; the literature "3D reinforcement of stiffener-to-skin T-joints by Z-pinning and tufting" discloses a tufting stitching robot, which uses a KSL KL150 tufting stitching end effector and can be used for single-sided stitching of preform fabrics with complex curved surfaces.

[0003] However, during the stitching process of the above-mentioned existing tufting stitching devices, the stitching yarns are severely worn. When tufting and stitching high-thickness fabrics, the stitching yarns often break during the stitching process, affecting the product quality and production efficiency of the stitched preform fabrics. Summary of the Invention

[0004] The present invention provides a high-thickness fabric stitching end effector, a stitching robot device and a weaving method to solve the technical problems existing in the known technology, which can realize the tufting stitching forming of high-thickness preform fabrics, and the device has a simple structure, is convenient for maintenance, has simple operation, and is flexible and efficient.

[0005] The present invention includes the following technical solutions:

[0006] A high-thickness fabric stitching end effector includes a servo displacement mechanism, a tool switching mechanism, a presser foot mechanism and a yarn feeding mechanism;

[0007] The servo displacement mechanism includes a lead screw, a lead screw servo motor, a guide shaft and a linear bearing; the lead screw and the guide shaft are both installed in a box body mechanism, the guide shaft is installed on a guide shaft connecting plate, and the linear bearing is connected to the guide shaft connecting plate by screws and slides relative to the guide shaft; the lead screw servo motor drives the synchronous pulley to rotate and then drives the lead screw to rotate;

[0008] The tool switching mechanism includes a rotary cylinder, a punching needle, a sewing needle, and an electric spindle; the rotary cylinder is threadedly connected to the side surface of the first connecting block and the side surface of the second connecting block respectively; the punching needle is connected to the electric spindle through a built-in locking mechanism, and the electric spindle is connected to the electric spindle fixture by screws; the sewing needle is connected to the syringe through a sewing needle setscrew; both the syringe and the electric spindle fixture are installed on the second connecting block;

[0009] The presser foot mechanism includes a guide plate cylinder and a presser foot cylinder; the output end of the presser foot cylinder is connected to the third connecting block; the presser foot is connected to the third connecting block, and the other end of the presser foot cylinder is connected to the box body structure; the side surface of the guide plate cylinder is fixedly installed on the third connecting block, and the output end is connected to a guide plate with micropores; when the guide plate is pushed outwards by the guide plate cylinder, the guide plate passes through the channel in the middle of the presser foot and is pushed out along the upper surface of the horizontal plate of the presser foot; a long hole is provided in the middle of the horizontal plate of the presser foot along the movement track of the guide plate, and the width of the long hole is greater than the diameter of the micropores and less than the width of the guide plate;

[0010] The yarn feeding mechanism includes a yarn storage device, a yarn storage device servo motor, rollers, and a tension sensor; the yarn storage device is connected to the yarn storage device shaft through a shaft shoulder and a yarn storage device setscrew, and is strengthened by mounting gaskets and lock nuts; the yarn passes through the yarn storage device, a thread guide loop, the tension sensor, and several rollers and then is connected to the sewing needle; a proximity switch is installed on the front side plate of the box body mechanism by threaded connection, and a connecting flange is provided on the top plate of the box body mechanism.

[0011] The sewing end effector uses the compressed air in the rotary cylinder as a power source to push the piston rod of the rotary cylinder to make a rotary motion, thereby driving the rotation of the punching needle and the sewing needle; the lead screw servo motor drives the lead screw, and at the same time the electric spindle drives the punching needle to punch holes, and the punching needle rotates and pierces into the fabric in the thickness direction; the presser foot cylinder and the guide plate cylinder drive the presser foot and the guide plate, so that the punching needle accurately pierces into the fabric along the micropores on the guide plate, preventing the punching needle from tilting or shifting; the yarn storage device servo motor controls the yarn storage device to supply yarn to the sewing needle, and cooperates with the alternating motion of the punching needle and the sewing needle to achieve the sewing of high-thickness fabrics.

[0012] Further, both the first connecting block and the second connecting block are triangular prism structures with a right-angled triangle bottom surface; the syringe and the electric spindle fixture are respectively installed on two mutually perpendicular side surfaces of the second connecting block. This installation method has a simple, compact structure and is convenient for maintenance. After the sewing needle and the punching needle are installed, they are perpendicular to each other, which is convenient for being perpendicular to the cutting plane of the sewing point during punching or sewing work, and the control program is simple and the working state is convenient to observe during alternating work.

[0013] Further, the box body mechanism includes a top plate, a bottom plate, a partition plate, a right side plate, a front side plate, and a rear side plate; the partition plate is welded between the top plate and the bottom plate, and the tension sensor is connected to the top plate by screws; a wire passing loop is welded on the right side plate; the front side plate is connected to a roller through a mandrel, and the front side plate and the rear side plate are arranged opposite to each other.

[0014] Further, both ends of the guiding shaft are respectively connected to the top plate and the bottom plate by screws; one end of the guiding shaft connecting plate is fixedly installed with a first connecting block, and a nut for connecting a lead screw is fixedly installed in the middle of the bottom surface of the guiding shaft connecting plate; the lead screw is connected to the bottom plate through a bearing seat, and the bearing seat is connected to the top plate and the bottom plate by interference fit; a bearing end cover is provided on the bearing seat.

[0015] Further, the synchronous belt pulley is connected to the synchronous belt by a tension force, and the synchronous belt pulley is respectively connected to the lead screw and the lead screw reducer by keys; the yarn storage servo motor is connected to the yarn storage reducer by screws, and the yarn storage reducer is connected to the yarn storage shaft by a key and is strengthened by a yarn storage setscrew.

[0016] A high-thickness fabric stitching robot device includes a six-degree-of-freedom robot, a robot base, and a preform stitching platform. The six-degree-of-freedom robot is installed on a horizontal plane through the robot base, and the end of the robotic arm of the six-degree-of-freedom robot is connected to a stitching end effector through a connecting flange; a building block type core mold is installed on the preform stitching platform, and the building block type core mold makes a rotary motion driven by a horizontal vertical and horizontal rotary worktable, and a building block type foam bottom felt is installed on the surface of the building block type core mold.

[0017] Further, the building block type core mold is connected to the preform stitching platform one by one by screws for several combined core molds; the building block type foam bottom felt includes several combined foam bottom felts, and each combined foam bottom felt is correspondingly arranged with a combined core mold.

[0018] Further, several setscrew holes are machined in the combined core mold, which is convenient for removing the building block type core mold and the building block type foam bottom felt on its outer surface in segments simultaneously after stitching is completed.

[0019] A high-thickness fabric stitching and weaving method uses a stitching robot device and includes the following steps:

[0020] S1. Connect the combined core molds to the preform stitching platform one by one with screws and check the reliability of the connection; install the combined foam bottom felts on the surface of the combined core molds one by one and check the flatness and continuity of the curved surface; lay a base cloth with a specified thickness on the building block type foam bottom felt;

[0021] S2. Wind the yarn evenly on the yarn storage device, and sequentially pass it through the wire passing loop and the roller with a tension sensor, and finally pass it into the stitching needle;

[0022] S3. Power on and start the device. The six-degree-of-freedom robot drives the suture end effector to move to the pre-suture point according to the set program for punching and suturing. During the process, the punching needle and the suture needle are always perpendicular to the tangent plane of the suture point. The six-degree-of-freedom robot drives the suture end effector to move to the pre-suture point and switch to the punching needle. Then, the lead screw servo motor drives the lead screw to make the punching needle mounted on the electric spindle rotate and penetrate into the fabric in the thickness direction by a specified distance and then withdraw to form a prefabricated micropore. During the punching process, the guide plate cylinder and the presser foot cylinder cooperate with each other to output and control the guide plate and the presser foot so that the punching needle accurately penetrates the fabric along the micropore on the guide plate. Then, the rotary cylinder switches to the suture needle, the yarn storage servo motor rotates forward, and the lead screw servo motor drives the lead screw to make the suture needle move towards the fabric by a specified distance and penetrate into the micropore. Then, the yarn storage servo motor rotates in reverse, the suture needle withdraws, and the suture yarn remains in the fabric by the tightening force of the fabric, and the first point of suturing is completed.

[0023] S4. The six-degree-of-freedom robot drives the suture end effector to move to the next suture position. The horizontal vertical rotary workbench on the preform suture platform drives the modular core mold to rotate so that the fabric completes the feeding at a predetermined angle, and continue punching and suturing.

[0024] S5. Repeat step S4 until the entire fabric is sutured, and the six-degree-of-freedom robot drives the suture end effector to return to the target stop position.

[0025] Further, during the suturing process of S3, the tension sensor continuously detects the tension value and feeds it back to the PLC to control the forward and reverse rotation of the yarn storage servo motor to maintain the constant tension of the yarn. The proximity switch monitors the upper and lower limit strokes of the servo displacement mechanism. The six-degree-of-freedom robot and the PLC communicate continuously through IO signals to achieve the efficient connection of actions in the whole process flow.

[0026] The advantages and positive effects of the present invention are as follows:

[0027] 1. The present invention adopts the prefabricated hole technology. Through the tool switching mechanism, the punching needle and the suture needle can cooperate with each other efficiently, effectively reducing the wear and breakage of the suture yarn, improving the product quality of the preform fabric, and realizing the tufting and forming of high-thickness preform fabrics. At the same time, it reduces the equipment downtime caused by the breakage of the suture yarn and improves the production efficiency.

[0028] 2. The present invention adopts the presser foot mechanism as the guiding device for the punching needle. The horizontal output of the guide plate and the vertical output of the presser foot are independent structures and do not interfere with each other. When the guide plate cylinder extends, the guide plate passes through the channel in the middle of the presser foot and is pushed out along the upper surface of the horizontal plate of the presser foot. The guide plate and the presser foot are controlled by the cooperation of the guide plate cylinder and the presser foot cylinder. The guide plate is provided with micropores, which effectively ensure that the prefabricated hole needle can accurately penetrate the fabric and generate prefabricated holes with accurate trajectories.

[0029] 3. The present invention uses a rotary cylinder as the actuator for switching between punching and tufting stitching. The rotary cylinder is inclined and fixed through a first connecting block and a second connecting block, with a simple, compact structure and convenient maintenance; both the first connecting block and the second connecting block are triangular prism structures with a right-angled triangle at the bottom. After the sewing needle and the punching needle are installed, they are perpendicular to each other, which is convenient for being perpendicular to the cutting plane of the sewing point during punching or stitching operations. When working alternately, the control program is simple and the working state is convenient to observe.

[0030] 4. The present invention uses an electric spindle as the punching actuator. The output end of the electric spindle can drive the punching needle to rotate continuously and move up and down under the drive of a lead screw, with a simple structure and low cost; the lead screw servo motor rotates forward and backward to drive the lead screw through a belt drive. The lead screw drives the tool switching mechanism to move up and down through a guide shaft connecting plate, thereby realizing the telescopic movement of the punching needle.

[0031] 5. The present invention uses a horizontally and vertically rotatable worktable driven by a servo motor, which has high positioning accuracy, large load-bearing capacity, and stable and reliable operation, providing a guarantee for ensuring the sewing accuracy and product quality.

[0032] 6. The present invention uses a modular core mold and bottom felt foam, and the core mold is processed with set screw holes, which is easy for the demolding of the preform fabric after stitching, reduces the deformation and damage of the fabric during demolding, and improves the demolding efficiency at the same time. Brief Description of the Drawings

[0033] Figure 1 is a three-dimensional schematic diagram of the overall structure of the equipment according to an embodiment of the present invention;

[0034] Figure 2 is a three-dimensional structure schematic diagram of the sewing end effector according to an embodiment of the present invention;

[0035] Figure 3 is a three-dimensional structure schematic diagram of the sewing end effector from another angle according to an embodiment of the present invention;

[0036] Figure 4 is a front view structure schematic diagram of the sewing end effector according to an embodiment of the present invention;

[0037] Figure 5 is a rear view structure schematic diagram of the sewing end effector according to an embodiment of the present invention;

[0038] Figure 6 is an enlarged structure schematic diagram of the guide plate and presser foot structure in the sewing end effector according to an embodiment of the present invention;

[0039] Figure 7 is an exploded view of the installation of the yarn storage device in the sewing end effector according to an embodiment of the present invention;

[0040] Figure 8It is an exploded view of the installation of a suture needle in a syringe in an embodiment of the present invention;

[0041] Figure 9 It is a schematic diagram of the modular core mold and foam bottom felt structure in an embodiment of the present invention;

[0042] In the figure, 1 - preform stitching platform; 2 - stitching end effector;

[0043] 2.1 - connecting flange; 2.2 - top plate; 2.3 - syringe; 2.4 - suture needle; 2.5 - bottom plate; 2.6 - punching needle; 2.7 - synchronous belt pulley; 2.8 - synchronous belt; 2.9 - right side plate; 2.10 - bearing seat; 2.11 - bearing end cover; 2.12 - yarn storage shaft; 2.13 - yarn storage device; 2.14 - tension sensor; 2.15 - first connecting block; 2.16 - rotary cylinder; 2.17 - second connecting block;

[0044] 2.18 - electric spindle; 2.19 - electric spindle fixture; 2.20 - third connecting block; 2.21 - guide plate;

[0045] 2.22 - presser foot; 2.23 - guide plate cylinder; 2.24 - presser foot cylinder; 2.25 - lead screw reducer; 2.26 - lead screw servo motor; 2.27 - guide shaft; 2.28 - lead screw; 2.29 - thread passing loop; 2.30 - yarn storage reducer; 2.31 - yarn storage servo motor; 2.32 - partition; 2.33 - linear bearing; 2.34 - nut; 2.35 - guide shaft connecting plate; 2.36 - yarn; 2.37 - roller; 2.38 - front side plate; 2.39 - rear side plate; 2.40 - yarn storage set screw; 2.41 - mounting gasket; 2.42 - lock nut; 2.43 - suture needle set screw; 2.44 - proximity switch;

[0046] 3 - six - degree - of - freedom robot; 4 - robot base;

[0047] 5 - modular core mold; 5.1 - first combined core mold; 5.2 - second combined core mold; 5.3 - third combined core mold; 5.4 - fourth combined core mold; 5.5 - fifth combined core mold;

[0048] 6 - modular foam bottom felt; 6.1 - first combined foam bottom felt; 6.2 - second combined foam bottom felt; 6.3 - third combined foam bottom felt; 6.4 - fourth combined foam bottom felt; 6.5 - fifth combined foam bottom felt;

[0049] 7 - preform fabric; 8 - inserted suture; 9 - set screw hole. Detailed implementation manners

[0050] To further disclose the content, features, and effects of the present invention, the following examples are specifically given and described in detail in conjunction with the accompanying drawings as follows.

[0051] Embodiment 1: Refer to the attached Figure 2-8 , a high-thickness fabric stitching end effector, comprising a servo displacement mechanism, a tool switching mechanism, a presser foot mechanism, and a yarn feeding mechanism;

[0052] The servo displacement mechanism includes a lead screw 2.28, a lead screw servo motor 2.26, a guide shaft 2.27, and a linear bearing 2.33; the lead screw 2.28 and the guide shaft 2.27 are both installed in the box body mechanism, the guide shaft 2.27 is installed on the guide shaft connecting plate 2.35, and the linear bearing 2.33 is connected to the guide shaft connecting plate 2.35 by screws and slides relative to the guide shaft 2.27; the lead screw servo motor 2.26 drives the synchronous pulley 2.7 to rotate, thereby driving the lead screw 2.28 to rotate; the synchronous pulley 2.7 is connected to the synchronous belt 2.8 by a tension force, and the synchronous pulley 2.7 is respectively connected to the lead screw 2.28 and the lead screw reducer 2.25 by keys; both ends of the guide shaft 2.27 are respectively connected to the top plate 2.2 and the bottom plate 2.5 by screws; one end of the guide shaft connecting plate 2.35 is fixedly installed with the first connecting block 2.15, and the other end is fixedly installed with the partition plate 2.32. The middle part of the bottom surface of the guide shaft connecting plate 2.35 is fixedly installed with a nut 2.34 for connecting the lead screw 2.28; the lead screw 2.28 is connected to the bottom plate 2.5 through a bearing seat 2.10, and the bearing seat 2.10 is connected to the top plate 2.2 and the bottom plate 2.5 by interference fit; a bearing end cover 2.11 is provided on the bearing seat 2.10.

[0053] The tool switching mechanism includes a rotary cylinder 2.16, a punching needle 2.6, a stitching needle 2.4, and an electric spindle 2.18; the rotary cylinder 2.16 is respectively threadedly connected to the side surface of the first connecting block 2.15 and the side surface of the second connecting block 2.17; the punching needle 2.6 is connected to the electric spindle 2.18 through a self-locking mechanism, and the electric spindle 2.18 is connected to the electric spindle fixture 2.19 by screws; as Figure 8 shown, the stitching needle 2.4 is connected to the needle cylinder 2.3 through a stitching needle setscrew 2.43; the needle cylinder 2.3 and the electric spindle fixture 2.19 are both installed on the second connecting block 2.17; both the first connecting block 2.15 and the second connecting block 2.17 are triangular prism structures with a right-angled triangle bottom surface; the needle cylinder 2.3 and the electric spindle fixture 2.19 are respectively installed on two mutually perpendicular side surfaces of the second connecting block 2.17. This installation method has a simple, compact structure and is convenient for maintenance. After the stitching needle 2.4 and the punching needle 2.6 are installed, they are perpendicular to each other, which is convenient for being perpendicular to the cutting plane of the stitching point during punching or stitching work. The control program is simple during alternating work, and the working state is convenient to observe.

[0054] The presser foot mechanism includes a guide plate cylinder 2.23 and a presser foot cylinder 2.24; the output end of the presser foot cylinder 2.24 is connected to the presser foot 2.22 through a third connecting block 2.20; the other end of the presser foot cylinder 2.24 is connected to the box structure; the side of the guide plate cylinder 2.23 is fixedly installed on the third connecting block 2.20, and the output end is connected to a guide plate 2.21 with micropores; when the guide plate 2.21 is pushed outwards by the guide plate cylinder 2.23, the guide plate 2.21 passes through the channel in the middle of the presser foot 2.22 and is pushed out along the upper surface of the horizontal plate of the presser foot 2.22; a long hole is provided in the middle of the horizontal plate of the presser foot 2.22 along the movement track of the guide plate 2.21, and the width of the long hole is greater than the diameter of the micropores and less than the width of the guide plate 2.21; the guide plate 2.21 is connected to the guide plate cylinder 2.23 by screws; the guide plate cylinder 2.23 and the presser foot cylinder 2.24 are connected to the bottom plate 2.5 by screws. The flange surface of the presser foot cylinder 2.24 is connected to the third connecting block 2.20 by threads, and the presser foot 2.22 is fixedly installed at one end of the bottom surface of the third connecting block 2.20; the guide plate 2.21 is connected to the flange surface of the guide plate cylinder 2.23 by threads.

[0055] The yarn feeding mechanism includes a yarn storage device 2.13, a yarn storage servo motor 2.31, rollers 2.37 and a tension sensor 2.14; the yarn storage device 2.13 is connected to the yarn storage shaft 2.12 through a shaft shoulder and a yarn storage setscrew 2.40, and is strengthened by an installation gasket 2.41 and a locking nut 2.42; the yarn 2.36 passes through the yarn storage device 2.13, a thread guide loop 2.29, the tension sensor 2.14 and several rollers 2.37 and then is connected to the sewing needle 2.4; the yarn storage servo motor 2.31 is connected to the yarn storage reducer 2.30 by screws, and the yarn storage reducer 2.30 is connected to the yarn storage shaft 2.12 by a key and is strengthened by a yarn storage setscrew 2.40.

[0056] The box structure includes a top plate 2.2, a bottom plate 2.5, a partition plate 2.35, a right side plate 2.9, a front side plate 2.38 and a rear side plate 2.39; the partition plate 2.35 is welded between the top plate 2.2 and the bottom plate 2.5, and the tension sensor 2.14 is connected to the top plate 2.2 by screws; the thread guide loop 2.29 is welded on the right side plate 2.9; the front side plate 2.38 is connected to the rollers 2.37 through a mandrel, and the front side plate 2.38 and the rear side plate 2.39 are arranged opposite to each other. A proximity switch 2.44 is installed on the front side plate 2.38 of the box structure by threads, and a connecting flange 2.1 is provided on the top plate 2.2 of the box structure.

[0057] The stitching end effector 2 uses the compressed air in the rotary cylinder 2.16 as the power source to drive the piston rod of the rotary cylinder 2.16 to make a rotary motion, thereby driving the rotation of the punching needle 2.6 and the stitching needle 2.4; the lead screw servo motor 2.26 drives the lead screw 2.28, and at the same time the electric spindle 2.18 drives the punching needle 2.6 to punch holes, and the punching needle 2.6 rotates and pierces into the fabric in the fabric thickness direction; the presser foot cylinder 2.24 and the guide plate cylinder 2.23 drive the presser foot 2.22 and the guide plate 2.21, so that the punching needle 2.6 accurately pierces into the fabric along the micropores on the guide plate 2.21, preventing the punching needle 2.6 from tilting or shifting; the yarn storage servo motor 2.31 controls the yarn storage 2.13 to supply yarn to the stitching needle 2.4, and cooperates with the alternating motion of the punching needle 2.6 and the stitching needle 2.4 to realize the stitching of high-thickness fabrics.

[0058] Embodiment 2: Refer to the appendix Figure 1-9 , a high-thickness fabric stitching robot device, including a six-degree-of-freedom robot 3, a robot base 4, and a preform stitching platform 1. The model of the six-degree-of-freedom robot 3 is Kawasaki RS30N. The six-degree-of-freedom robot 3 is installed on a horizontal plane through the robot base 4. The end of the robotic arm of the six-degree-of-freedom robot 3 is connected to the stitching end effector 2 in Embodiment 1 through a connecting flange 2.1 and can stitch at any position within its working range; a modular core mold 5 is installed on the preform stitching platform 1, and the modular core mold 5 makes a rotary motion driven by a horizontal vertical and horizontal rotary worktable, and a modular foam bottom felt 6 is installed on the surface of the modular core mold 5.

[0059] The modular core mold 5 is composed of five combined core molds (including a first combined core mold 5.1, a second combined core mold 5.2, a third combined core mold 5.3, a fourth combined core mold 5.4, and a fifth combined core mold 5.5), which are connected to the preform stitching platform 1 one by one with screws; the modular foam bottom felt 6 includes five combined foam bottom felts (including a first combined foam bottom felt 6.1, a second combined foam bottom felt 6.2, a third combined foam bottom felt 6.3, a fourth combined foam bottom felt 6.4, and a fifth combined foam bottom felt 6.5), and each combined foam bottom felt is correspondingly arranged with a combined core mold. A number of jackscrew holes 9 are machined in the combined core mold, which is convenient for removing the modular core mold 5 and the modular foam bottom felt 6 on its outer surface in segments after stitching is completed. The modular core mold 5 is connected to the clamping mechanism mounting chuck.

[0060] Embodiment 3: Refer to the appendix Figure 1-9 , a high-thickness fabric stitching and weaving method, using the stitching robot device in Embodiment 2 to produce a conical rotary preform with a closed top. In this embodiment, the preform 7 is 30 mm thick, the bottom diameter is 300 mm, and the height is 350 mm; the foam bottom felt 6 is 10 mm thick; the material is quartz satin cloth, and the surface density is 460 g / m 2, thickness is 0.45mm; quartz fiber suture yarn is used with a linear density of 100tex.

[0061] The specific steps include:

[0062] S1, connect the first combined core mold 5.1, the second combined core mold 5.2, the third combined core mold 5.3, the fourth combined core mold 5.4 and the fifth combined core mold 5.5 one by one with screws from top to bottom, and then install them as a whole on the preform sewing platform 1 and check the reliability of the connection; install the first combined foam bottom felt 6.1, the second combined foam bottom felt 6.2, the third combined foam bottom felt 6.3, the fourth combined foam bottom felt 6.4 and the fifth combined foam bottom felt 6.5 on the surface of the corresponding building block type core mold 5 one by one and check the flatness and continuity of the curved surface; lay a base cloth of a specified thickness on the building block type foam bottom felt 6. In this embodiment, the preform 7 is 30 mm thick and the foam bottom felt 6 is 10 mm thick.

[0063] S2, the yarn 2.36 is evenly wound on the yarn storage device 2.13, and passes through the thread ring 2.29 and the roller 2.37 with the tension sensor 2.14 in sequence, and finally passes through the sewing needle 2.4.

[0064] S3. Power on and start the device. The six-degree-of-freedom robot 3 drives the suture end effector 2 to move to the pre-suturing point according to the set program for punching and suturing. During the process, the punching needle 2.6 and the suture needle 2.4 are always perpendicular to the tangent plane of the suture point. The six-degree-of-freedom robot 3 drives the suture end effector 2 to move to the pre-suturing point according to the set program and switches to the punching needle 2.6. In this embodiment, the position of the pre-suturing point is where the linear distance between the tips of the punching needle 2.6 and the suture needle 2.4 and the suture point is 15 mm. Then, the lead screw servo motor 2.26 drives the lead screw 2.28 to make the punching needle 2.6 mounted on the electric spindle 2.18 rotate and penetrate 35 mm in the fabric thickness direction and then withdraw to form a prefabricated micropore. During the punching process, the guide plate cylinder 2.23 and the presser foot cylinder 2.24 cooperate with each other to output control of the guide plate 2.21 and the presser foot 2.22 to make the punching needle 2.6 accurately penetrate the fabric along the micropore on the guide plate 2.21, preventing the punching needle from tilting or shifting. Then, the rotary cylinder 2.16 switches to the suture needle 2.4. The yarn storage servo motor 2.31 rotates forward. The lead screw servo motor 2.26 drives the lead screw 2.28 to make the suture needle 2.4 move towards the fabric and penetrate the micropore by 35 mm. During the suturing process, the guide plate 2.21 and the presser foot 2.22 also ensure the accuracy of the suturing trajectory to avoid tilting or shifting. Then, the yarn storage servo motor 2.31 rotates in reverse, and the suture needle 2.4 withdraws. The suture yarn 2.36 remains in the fabric due to the fabric tightening force, and the first point of suturing is completed. During the suturing process of S3, the tension sensor 2.14 real-time detects the tension value and feeds it back to the PLC to control the forward and reverse rotation of the yarn storage servo motor 2.31 to maintain the constant tension of the yarn 2.36. The proximity switch 2.44 monitors the upper and lower limit strokes of the servo displacement mechanism. The six-degree-of-freedom robot 3 ensures the accurate positioning of the suturing position. The six-degree-of-freedom robot 3 and the PLC communicate continuously through IO signals to achieve the efficient connection of actions in the whole process flow.

[0065] S4. The six-degree-of-freedom robot 3 drives the suture end effector 2 to move to the next suturing position. The horizontal vertical and horizontal rotary worktable on the preform suturing platform 1 drives the modular core mold 5 to rotate so that the fabric completes the feeding at a predetermined angle, and continue punching and suturing.

[0066] S5. Repeat step S4 until the entire fabric is sutured. The six-degree-of-freedom robot 3 drives the suture end effector 2 to return to the target stop position.

[0067] The cooperation between the guide plate 2.21 and the presser foot 2.22 in S3 is as follows: the screw servo motor 2.26 rotates forward to drive the tool switching mechanism to insert the punching needle 2.6 into the fabric. At the same time, the presser foot cylinder 2.24 outputs first, and then the guide plate cylinder 2.23 outputs to push the guide plate 2.21 out, and cooperates with the presser foot 2.22 to prevent the punching needle 2.6 from tilting. After punching, the screw servo motor 2.26 reverses to drive the punching needle 2.6 back, and then the guide plate cylinder 2.23 retracts the guide plate 2.21, and then the rotary cylinder 2.16 outputs the switch. When it comes to the suture needle 2.4, the screw servo motor 2.26 rotates forward to drive the tool switching mechanism to insert the suture needle 2.4 into the fabric for suture (the prefabricated hole has been formed after punching, and the prefabricated hole has a guiding function, so the suture process does not require the output of the guide plate 2.21). After the suturing is completed, the presser foot cylinder 2.24 retracts the presser foot 2.22, and the screw servo motor 2.26 reverses to retract the suture needle 2.4. At this point, the punching and suturing of the first point is completed, and then the six-degree-of-freedom robot 3 drives the suture end effector 2 to move to the next suture point and repeats the above process until all points are sutured.

[0068] Although the preferred embodiments of the present invention are described above, the present invention is not limited to the above specific embodiments, which are merely illustrative and not restrictive. Under the guidance of the present invention, a person skilled in the art can make many forms without departing from the scope of the present invention and the claims. All of these belong to the protection scope of the present invention.

Claims

1. A high-thickness fabric stitching end effector, characterized in that: It includes a servo displacement mechanism, a tool switching mechanism, a presser foot mechanism, and a yarn feeding mechanism; The servo displacement mechanism includes a lead screw (2.28), a lead screw servo motor (2.26), a guide shaft (2.27), and a linear bearing (2.33); the lead screw (2.28) and the guide shaft (2.27) are both installed in the box body mechanism, the guide shaft (2.27) is installed on the guide shaft connecting plate (2.35), and the linear bearing (2.33) is connected to the guide shaft connecting plate (2.35) by screws and slides relative to the guide shaft (2.27); the lead screw servo motor (2.26) drives the synchronous pulley (2.7) to rotate and then drives the lead screw (2.28) to rotate; The tool switching mechanism includes a rotary cylinder (2.16), a punching needle (2.6), a sewing needle (2.4), and an electric spindle (2.18); the rotary cylinder (2.16) is threadedly connected to the side surface of the first connecting block (2.15) and the side surface of the second connecting block (2.17) respectively; the punching needle (2.6) is connected to the electric spindle (2.18) through a self-locking mechanism, and the electric spindle (2.18) is connected to the electric spindle fixture (2.19) by screws; the sewing needle (2.4) is connected to the needle cylinder (2.3) through a sewing needle setscrew (2.43); the needle cylinder (2.3) and the electric spindle fixture (2.19) are both installed on the second connecting block (2.17); The presser foot mechanism includes a guide plate cylinder (2.23) and a presser foot cylinder (2.24); the output end of the presser foot cylinder (2.24) is connected to the third connecting block (2.20); the presser foot (2.22) is connected to the third connecting block (2.20), and the other end of the presser foot cylinder (2.24) is connected to the box body structure; the side surface of the guide plate cylinder (2.23) is fixedly installed on the third connecting block (2.20), and the output end is connected to a guide plate (2.21) with micropores; The yarn feeding mechanism includes a yarn storage device (2.13), a yarn storage device servo motor (2.31), rollers (2.37), and a tension sensor (2.14); the yarn storage device (2.13) is connected to the yarn storage device shaft (2.12) through a shaft shoulder and a yarn storage device setscrew (2.40), and is strengthened by a mounting gasket (2.41) and a lock nut (2.42); the yarn (2.36) passes through the yarn storage device (2.13), a thread guide loop (2.29), the tension sensor (2.14), and several rollers (2.37) and then is connected to the sewing needle (2.4); a proximity switch (2.44) is installed on the front side plate (2.38) of the box body mechanism by threaded connection, and a connection flange (2.1) is provided on the top plate (2.2) of the box body mechanism.

2. The high-thickness fabric stitching end effector according to claim 1, wherein: Both the first connecting block (2.15) and the second connecting block (2.17) are triangular prism structures with a right-angled triangle bottom surface; the needle cylinder (2.3) and the electric spindle fixture (2.19) are respectively installed on two mutually perpendicular side surfaces of the second connecting block (2.17).

3. The high-thickness fabric stitching end effector according to claim 1, characterized in that: The box structure comprises a top plate (2.2), a bottom plate (2.5), a partition plate (2.32), a right side plate (2.9), a front side plate (2.38) and a rear side plate (2.39); the partition plate (2.32) is welded between the top plate (2.2) and the bottom plate (2.5); the tension sensor (2.14) is connected to the top plate (2.2) via screws; a wire ring (2.29) is welded on the right side plate (2.9); the front side plate (2.38) is connected to the roller (2.37) via a spindle, and the front side plate (2.38) and the rear side plate (2.39) are arranged opposite to each other.

4. The high-thickness fabric stitching end effector according to claim 3, characterized in that: The two ends of the guide shaft (2.27) are respectively connected to the top plate (2.2) and the bottom plate (2.5) by screws; one end of the guide shaft connecting plate (2.35) is fixed to the first connecting block (2.15), and a nut for connecting the lead screw (2.28) is fixed in the middle of the bottom surface of the guide shaft connecting plate (2.35); the lead screw (2.28) and the bottom plate (2.5) are connected by a bearing seat (2.10), and the bearing seat (2.10) is connected to the top plate (2.2) and the bottom plate (2.5) by interference fit; and a bearing end cover (2.11) is provided on the bearing seat (2.10).

5. The high-thickness fabric stitching end effector according to claim 1, characterized in that: The synchronous pulley (2.7) is connected to the synchronous belt (2.8) through tensioning force, and the synchronous pulley (2.7) is connected to the lead screw (2.28) and the lead screw reducer (2.25) through keys respectively; the yarn storage servo motor (2.31) is connected to the yarn storage reducer (2.30) through screws, and the yarn storage reducer (2.30) is connected to the yarn storage shaft (2.12) through keys and is reinforced by the yarn storage top screw (2.40).

6. A high-thickness fabric stitching robot device, comprising a six-degree-of-freedom robot (3), a robot base (4), and a preform stitching platform (1). The six-degree-of-freedom robot (3) is installed on a horizontal plane through the robot base (4), and is characterized in that: The end of the robotic arm of the six-degree-of-freedom robot (3) is connected to the suture end effector (2) as described in any one of claims 1 to 5 via a connecting flange (2.1); a building block core mold (5) is installed on the preform suturing platform (1), and the building block core mold (5) rotates under the drive of a horizontal vertical and horizontal rotary worktable, and a building block foam bottom felt (6) is installed on the surface of the building block core mold (5).

7. The high-thickness fabric stitching robot device according to claim 6, characterized in that: The building block type core mold (5) is composed of a plurality of combined core molds connected one by one to the preform sewing platform (1) by screws; the building block type foam bottom felt (6) comprises a plurality of combined foam bottom felts, each combined foam bottom felt being arranged corresponding to a combined core mold.

8. The high-thickness fabric stitching robot device according to claim 7, wherein: A plurality of top screw holes (9) are processed in the combined core mold.

9. A method for stitching and weaving high-thickness fabrics, using the stitching robot device as described in claim 6, characterized in that, The following steps are involved: S1, connect the combined core molds one by one to the preform sewing platform (1) with screws and check the reliability of the connection; install the combined foam bottom felts one by one on the surface of the combined core mold and check the flatness and continuity of the curved surface; lay a base cloth of a specified thickness on the building block foam bottom felt (6); S2, the yarn (2.36) is evenly wound on the yarn storage device (2.13), and passes through the thread ring (2.29) and the roller (2.37) with the tension sensor (2.14) in sequence, and finally passes through the sewing needle (2.4); S3. Power on and start the device. The six-degree-of-freedom robot (3) drives the suture end effector (2) to move to the pre-suture point according to the set program for punching and suturing. During the process, the punching needle (2.6) and the suture needle (2.4) are always perpendicular to the tangent plane of the suture point. The six-degree-of-freedom robot (3) drives the suture end effector (2) to move to the pre-suture point and switch to the punching needle (2.6). Then, the lead screw servo motor (2.26) drives the lead screw (2.28) to make the punching needle (2.6) installed on the electric spindle (2.18) rotate and penetrate into the fabric in the thickness direction by a specified distance and then withdraw to form a prefabricated micropore. During the punching process, the guide plate cylinder (2.23) and the presser foot cylinder (2.24) cooperate with each other to output and control the guide plate (2.21) and the presser foot (2.22) so that the punching needle (2.6) accurately penetrates into the fabric along the micropore on the guide plate (2.21). Then, the rotary cylinder (2.16) switches to the suture needle (2.4). The yarn storage servo motor (2.31) rotates forward. The lead screw servo motor (2.26) drives the lead screw (2.28) to make the suture needle (2.4) move towards the fabric and penetrate into the micropore by a specified distance. Then, the yarn storage servo motor (2.31) rotates in reverse, and the suture needle (2.4) withdraws. The suture yarn (2.36) remains in the fabric relying on the tightening force of the fabric, and the first point of suturing is completed. S4. The six-degree-of-freedom robot (3) drives the suture end effector (2) to move to the next suture position. The horizontal vertical and horizontal rotary worktable on the preform suture platform (1) drives the modular core mold (5) to rotate so that the fabric completes the feeding at a predetermined angle, and continue punching and suturing. S5. Repeat step S4 until the entire fabric is sutured. The six-degree-of-freedom robot (3) drives the suture end effector (2) to return to the target stop position.

10. The high-thickness fabric stitching and weaving method according to claim 9, characterized in that: During the suturing process of S3, the tension sensor (2.14) real-time detects the tension value and feeds it back to the PLC to control the forward and reverse rotation of the yarn storage servo motor (2.31) to maintain the constant tension of the yarn (2.36). The proximity switch monitors the upper and lower limit strokes of the servo displacement mechanism. The six-degree-of-freedom robot (3) and the PLC communicate continuously through IO signals.

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