Automatic sewing equipment for one-step forming of airbag guide bag and manufacturing process thereof

Abstract

The present invention discloses an automatic sewing device for one-step forming of an airbag guide bag and a manufacturing process thereof. The device comprises a transmission module, which is provided with multiple groups and is used for transferring and folding the airbag; a sewing module, which is used for sewing the airbag, and the transmission module transfers the airbag to the sewing module; in the scheme of the present invention, by providing an image recognition module, a folding module and a transmission module, the image recognition module can be used to take photos of the workpiece before and after sewing, and the photos are sent to an information processing industrial computer for data processing, and compared with a preset pattern, so as to determine the material placement position and whether the quality is qualified.

Description

Technical Field

[0001] The invention relates to automatic sewing equipment for a one-step-molded safety airbag guide bag and a manufacturing process thereof, belonging to the field of safety airbag guide bag manufacturing. Background Art

[0002] Before assembly, one-shot airbag products need to be installed with an air guide bag to protect the outer sewing tissue of the one-shot airbag from being burned by the instantaneous heat generated by the generator when the one-shot airbag is detonated, causing the one-shot airbag to fail to protect the occupants.

[0003] Currently, the industry faces persistent problems with missing, over-stitched, or substandard sizing of cut pieces during the sewing process. This can cause one-shot airbags to fail to deploy fully in the event of an accident, failing to protect people. More seriously, product failures can lead to vehicle recalls. For smaller companies, the losses from a single recall could lead to bankruptcy. Therefore, ensuring that the air guides of one-shot airbags are manufactured to specifications is crucial.

[0004] The existing one-shot airbag sewing process typically involves two to three steps, requiring two to three operators to operate the equipment. Each step is completed on a separate sewing machine. To prevent errors, error-proofing must be implemented on each sewing machine. However, due to various reasons, this often fails to fully prevent errors. Furthermore, operators must perform self-inspections, which is labor-intensive and increases fatigue due to long hours. Furthermore, manual inspections carry a high risk of missed inspections, making this production method unsuitable for mass production of airbags. Summary of the Invention

[0005] In view of the deficiencies in the prior art, the present invention aims to provide an automatic sewing device for a one-step formed safety airbag guide bag and a manufacturing process thereof to solve the problem.

[0006] In order to achieve the above-mentioned object, the present invention is implemented by the following technical solutions: an automatic sewing device for a one-step forming airbag guide bag, the structure of which includes a conveying module, the conveying module is provided with multiple groups for transferring and folding the guide bag;

[0007] A sewing module is used to sew the air guide bag, and its transfer module transfers the air guide bag to the sewing module;

[0008] Image recognition module, whose transmission module sends the semi-finished or finished air guide bag to the image recognition module for collecting appearance image information and comparing it with the set information;

[0009] The folding module is used to fold the air guide bag in half, and its conveying module fixes one side of the air guide bag and then folds it;

[0010] The alarm module generates an alarm based on the information detected by the image recognition module, and the sewing module is stopped when the alarm module is triggered.

[0011] Preferably, the conveying module includes a robot arm having a clamping member for fixing the air guide bag.

[0012] Preferably, the clamping member includes a plurality of electric suction cups.

[0013] Preferably, a heat insulating sheet is placed on the air guide bag to form a workpiece, which is fixed by a clamping structure and sent to a sewing module for sewing.

[0014] Preferably, a thickness detection device for detecting the workpiece is provided on one side of the conveying module station; the detection device is a photoelectric sensor.

[0015] Preferably, the folding module includes a platform for placing the workpiece and a folding device located on one side of the platform; the folding device includes a driving member and an insertion rod fixed to the output end of the driving member; the output end of the driving member drives the insertion rod to extend and retract, and the insertion rod corresponds to the central axis of the platform.

[0016] Preferably, the sewing module includes a sewing machine acting on the inner periphery of the workpiece and a sewing machine acting on the outer periphery of the workpiece; the inner periphery sewing machine is used to sew and fix the heat insulation sheet to the middle of the air guide bag; the outer periphery sewing machine is used to sew and fix the outer edge of the workpiece after folding.

[0017] A manufacturing process for automatically sewing a one-shot molded airbag guide bag, the manufacturing process comprising: sewing a heat insulation sheet to the middle of the airbag, and using an inner sewing machine to sew the seam to the edge of the heat insulation sheet at a distance of ±2mm; after the airbag is flipped over, the protrusion of both edges of the airbag is less than 2mm; and the distance between the seam of the airbag sewn by the outer sewing machine and its edge is ±3mm.

[0018] Beneficial effects

[0019] In the solution of the present invention, by setting up an image recognition module, a folding module and a transmission module, the workpiece can be photographed using the image recognition module before and after sewing, and the photos are sent to an information processing industrial computer for data processing and compared with a preset pattern, so as to obtain the material placement position and whether the quality is qualified.

[0020] In addition, by adding folding modules and multiple conveying modules, this series of automated devices has largely automated production error prevention work, reducing the operator's labor intensity. Manual work is basically to troubleshoot equipment failures and prepare raw materials. Work efficiency has been improved, and the A-grade rate of products has also been greatly improved.

[0021] The comprehensive application of automation has completely replaced manual work, and after each piece is produced, it will immediately pass through the image recognition module to truly achieve single-piece flow, basically avoiding the risk of batch anomalies. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Other features, objects and advantages of the present invention will become more apparent upon reading the detailed description of non-limiting embodiments with reference to the following drawings:

[0023] Figure 1 This is a schematic top view of the structure of an automatic sewing device for one-step forming of an airbag guide bag of the present invention;

[0024] Figure 2 This is a schematic diagram of the southwest corner of the three-dimensional structure of an automatic sewing device for one-step forming of an airbag air guide bag of the present invention;

[0025] Figure 3 This is a schematic diagram of the southeast corner of the three-dimensional structure of an automatic sewing device for one-step forming of an airbag guide bag of the present invention;

[0026] Figure 4 It is a structural schematic diagram of the folding device of the present invention;

[0027] Figure 5 It is a structural schematic diagram of the clamping structure of the present invention;

[0028] Figure 6 It is a structural schematic diagram of the temporary fixing device of the present invention. DETAILED DESCRIPTION

[0029] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below in conjunction with specific implementation methods.

[0030] See also Figures 1-6 The present invention provides a technical solution for an automatic sewing device for forming airbag guide bags in one step. The device comprises a material trolley 4 on which are stacked airbags A and heat-insulating sheets B. Preferably, at least 200 sheets are stacked on the material trolley 4, and a spare trolley can be provided. The device is provided with a partition on the periphery, and the partition has a door for pushing the material trolley 4 and the spare trolley into the device.

[0031] The transfer module includes multiple manipulators 1, each of which has a plurality of electric suction cups at its gripping end, which suck up the air guide bag A or the heat insulation sheet B for transfer; the electric suction cups on the manipulators 1 sequentially suck up the air guide bag A and the heat insulation sheet B, and place the heat insulation sheet B in the middle of the air guide bag A to form a workpiece;

[0032] The conveying module further includes a clamping structure 5 installed on a manipulator, which is used to fix the stacked air guide bags A and heat insulation sheets B through the clamping structure 5 and then send them to the sewing module;

[0033] The thickness detection device acts on the above-mentioned workpiece, and the detection device is a photoelectric sensor, which is used to detect the thickness of the workpiece. Only when it meets the rated thickness will the control unit brake the conveying module;

[0034] The clamping structure 5 includes an upper clamping plate 51 for clamping the workpiece, a lower clamping plate 52, and a small cylinder 53 for moving the upper clamping plate; wherein the upper clamping plate 51, the lower clamping plate 52, and the small cylinder 53 are all mounted on a base frame, and preferably, multiple clamping structures 5 can be distributed on the base frame to fully fix the workpiece; wherein the upper clamping plate 51 is connected to the piston of the small cylinder 53, and the lower clamping plate 52 is fixed to the base frame, so that the forward extension of the piston of the small cylinder 53 drives the upper clamping plate 51 to extend forward and cooperate with the lower clamping plate 52 to fix the workpiece; wherein the base frame is mounted on the manipulator 1;

[0035] The sewing module is an existing sewing machine, which is divided into a sewing machine for the inner periphery of the workpiece and a sewing machine for the outer periphery of the workpiece according to the order of the working process. The inner periphery sewing machine 21 is used to sew and fix the heat insulation sheet B to the middle of the air guide bag A; the outer periphery sewing machine 22 is used to sew and fix the outer edge of the folded workpiece.

[0036] After the workpiece is sewn by the inner sewing machine 21, the image recognition module 3 takes a photo and compares it. The comparison mainly checks whether the heat insulation sheet B is sewn and fixed to the middle of the air guide bag A, and whether the distance between the seam line and the edge of the heat insulation sheet B is ±2mm. If both meet the rated range parameters, the robot 1 grabs the workpiece and transfers it to the folding module 6. Preferably, the image recognition module 3 is placed at the bottom of the folding module 6, and a fill light is provided at the position where the image recognition module 3 takes the photo.

[0037] The folding module 6 includes a platform for placing the workpiece and a folding device located on one side of the platform; the folding device includes a driving member 61 and an insertion rod 62 fixed to the output end of the driving member; the output end of the driving member drives the insertion rod to extend and retract, and the insertion rod 62 corresponds to the central axis of the platform; the driving member is a cylinder; in order to facilitate the above-mentioned image recognition module 3 to be placed at the bottom of the folding module 6, the platform needs to be made of transparent material; when folding is required, the robot 1 places the workpiece on the platform, and its driving member drives the insertion rod to extend so that the insertion rod is placed at the central axis of the workpiece, and then the robot 1 absorbs half of the workpiece to perform a folding action (the suction cup of the robot 1 at this location only holds half of the page), and when the folding is completed, the insertion rod is reset; and then it is fixed by the above-mentioned clamping structure 5 (the clamping structure 5 is independent and placed on the robot 1 and moves with the robot 1);

[0038] See also Figure 6 Preferably, after the half-page electric suction cup of the above-mentioned manipulator 1 absorbs the half-page workpiece and completes the folding, a temporary fixing device is provided on one side of the platform. The temporary fixing device will fix the folded workpiece and wait for the manipulator 1 to reset (the purpose of resetting is to align the clamping structure 5 on the manipulator 1 with the workpiece) before releasing; the temporary fixing device includes a clamping plate 71 on the outer edge of the platform, a hinge part 72 for hinged movable clamping plates, a small cylinder for driving the clamping plate ( Figure 6 (not shown); the clamping plate 71 is hinged with two sets of shafts serving as hinge members (the other end of the shaft on the right is hingedly connected to the base frame of the workbench), and the piston of the small cylinder is hingedly connected to the shaft on the left. When the small cylinder is extended or retracted, it will drive the clamping plate 71 to move and achieve the purpose of fixing the workpiece;

[0039] After the workpiece is sewn by the peripheral sewing machine 22, the image recognition module 3 takes a photo and compares it. The comparison mainly checks: the protrusion length of the double edges of the air guide bag A after flipping is less than 2mm; the distance between the seam of the air guide bag A sewn by the peripheral sewing machine 22 and its edge is ±3mm. If both meet the rated range parameters, the robot 1 grabs the workpiece and transfers it to the finished product box for holding the finished products. The image recognition module 3 is placed at the top of the inspection station.

[0040] The alarm module alarms based on the detection information of the image recognition module 3, wherein the alarm module realizes the alarm based on a control unit, which is compiled by personnel in this field. Its purpose is that after the sewing module sews, its image recognition module 3 will take pictures of the workpiece for comparison (the specific comparison parameters are as mentioned above). If it meets the parameters, it will enter the next process. If it does not meet the parameters, the robot 1 will grab the defective workpiece and put it into the waste box; if the parameters are not matched for many times (the number of times is adjustable), the sound and light alarm light electrically connected to the image recognition module 3 will alarm, notifying the technical staff to go and solve the problem (the problem usually occurs because the electric suction cup is powered off or the image recognition module 3 takes the wrong picture at an incorrect angle); it is worth mentioning that after folding (not sewing), the image recognition module 3 can be used for detection first. If the detection is unqualified, the robot 1 will adjust it until it is qualified before proceeding to the next process of sewing.

[0041] A manufacturing process for automatically sewing a one-step formed airbag guide bag comprises the following steps:

[0042] Step 1: Push the incoming material trolley with the air guide bag A and the heat insulation sheet B into the designated area for the robot 1 to grab;

[0043] Step 2: After grabbing the air guide bag A, the robot 1 grabs the heat insulation sheet B again and places the heat insulation sheet B in the middle of the air guide bag A;

[0044] Step 3: Based on step 2, the robot 1 again grabs the workpiece formed by the air guide bag A and the heat insulation sheet B and places it on the inner sewing machine 21 for sewing;

[0045] Step 4: After sewing is completed, the robot 1 grabs the workpiece and brings it to the image recognition module 3 to take a photo of the seam on the thermal insulation sheet B. The distance between the seam and the edge of the thermal insulation sheet B is required to be ±2MM. If it is qualified, it will be sent to the next process. If it is unqualified, the robot will grab it and send it to the waste box. Preferably, if it fails to meet the requirements for multiple times in a row, the alarm module will be activated to notify the technician to go and handle it.

[0046] Step 5: The robot 1 grabs the qualified workpiece to the folding module 6, and the robot 1 cooperates with the folding module 6 to fold the workpiece in half, and then the robot 1 sends the folded workpiece to the peripheral sewing machine;

[0047] Step 6: Based on step 4, the robot 1 grabs the qualified workpiece and brings it to the folding module 6. The robot 1 cooperates with the folding module 6 to fold the workpiece in half. Then, the image recognition module 3 detects and takes pictures. If it does not meet the requirements, the robot 1 adjusts the folding edge until it meets the requirements. The folded workpiece is then sent to the peripheral sewing machine 22.

[0048] Step 7; the image recognition module 3 takes a photo of the workpiece for inspection, requiring that the protruding length of both edges of the air guide bag A after flipping over is less than 2MM; the distance between the seam sewn by the peripheral sewing machine 22 and the edge of the air guide bag A is ±3MM; if it meets the standard, the robot 1 will grab it and put it into the finished product box; if it does not meet the standard, it will be sent to the waste box. Preferably, if it fails to meet the standard for multiple times in a row, the alarm module will be activated to notify the technician to go and handle it.

[0049] The image recognition module mentioned in this patent can be purchased directly on the market. People skilled in the art can operate the device by uploading interval parameters, so its structural principle will not be described in detail.

[0050] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It is obvious to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, from all points of view, the embodiments should be regarded as illustrative and non-restrictive. The scope of the present invention is defined by the appended claims rather than the above description, and it is intended that all changes that fall within the meaning and range of equivalents of the claims are included in the present invention. Any reference signs in the claims should not be construed as limiting the claim to which they relate.

[0051] In addition, it should be understood that although this specification is described in terms of implementation methods, not every implementation method contains only one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

Claims

1. An automatic sewing device for forming a safety airbag guide bag in one step, characterized by: Its structure includes a conveying module, which is provided with multiple groups for transferring and folding the air guide bag; A sewing module is used to sew the air guide bag, and the transfer module transfers the air guide bag to the sewing module; An image recognition module, wherein the conveying module delivers the semi-finished or finished air guide bag to the image recognition module for collecting appearance image information and comparing it with the set information; A folding module is used to fold the air guide bag in half, and the conveying module fixes one side of the air guide bag and then folds it; An alarm module, which generates an alarm based on the information detected by the image recognition module and stops the sewing module when triggered; The sewing module includes a sewing machine for sewing the inner periphery of the workpiece and a sewing machine for sewing the outer periphery of the workpiece; the inner periphery sewing machine is used to sew and fix the heat insulation sheet to the middle of the air guide bag; the outer periphery sewing machine is used to sew and fix the outer periphery of the folded workpiece; A heat-insulating sheet is placed on the air guide bag to form a workpiece, which is fixed by a clamping structure and sent to a sewing module for sewing; The folding module includes a platform for placing the workpiece and a folding device located on one side of the platform; The clamping structure is independent and is placed on the conveying module and moves along with the conveying module; After the folding is completed, a temporary fixing device is provided on one side of the platform, which fixes the folded workpiece and waits for the transfer module to reset before releasing it.

2. The automatic sewing equipment for one-step forming of airbag guide bags according to claim 1, characterized in that: The conveying module comprises a robot arm, and the robot arm is provided with a clamping member for fixing the air guide bag.

3. The automatic sewing equipment for one-step forming of airbag guide bags according to claim 2, characterized in that: The clamping member includes a plurality of electric suction cups.

4. The automatic sewing equipment for one-step forming of airbag guide bags according to claim 1, characterized in that: A thickness detection device for detecting the workpiece is provided on one side of the conveying module station; the detection device is a photoelectric sensor.

5. The automatic sewing equipment for one-step forming of airbag guide bags according to claim 1, characterized in that: The folding device includes a driving member and an insertion rod fixed to the output end of the driving member; the output end of the driving member drives the insertion rod to extend and retract, and the insertion rod corresponds to the central axis of the platform.

6. A manufacturing process for automatically sewing a one-step formed airbag guide bag, characterized by: The invention is realized by using an automatic sewing device for one-time forming of an airbag guide bag as described in any one of claims 1 to 5, and the manufacturing process includes: a heat insulation sheet is sewn and fixed to the middle of the air guide bag, and the seam after sewing by the inner sewing machine is ±2MM away from the edge of the heat insulation sheet; after the air guide bag is turned over, the protruding length of both sides of the air guide bag is less than 2MM; the seam of the air guide bag sewn by the outer sewing machine is ±3MM away from the edge.

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