An automated continuous production method of soft touch chair back panels

Abstract

The application provides an automatic continuous production method of a soft-touch chair back plate, and comprises the following steps: mold cleaning and mold release agent spraying are performed on the side far from the injection machine; the soft-touch insert is laid on the cavity bottom surface of the cleaned mold, and then the mold is closed; the rotating disc is controlled to rotate, and the mold is brought to the pouring position; the servo motor is controlled to operate, each injection mixing head is brought above the corresponding mold, and then the injection mixing head is controlled to move downward to the pouring port of the mold to pour the material, and the pouring of the corresponding number of molds is completed at one time according to the number of injection mixing heads; the telescopic cylinder is reset, the rotating disc continues to rotate, the poured mold is driven to leave the pouring position, and the next batch of molds to be poured reaches the pouring position, and the pouring is continuously performed; the discharged mold is completed on the side far from the injection machine, the above steps are recycled, and the continuous production of the chair back plate is performed. The application can realize multi-station continuous production, and is beneficial to improving the pouring efficiency and saving the labor cost.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile seat, in particular to an automatic continuous production method of soft-touch chair back plate. BACKGROUND

[0002] At present, the chair back plates on the market mainly have the following forms: face cover sewing type back plate, injection type back plate and injection + coating back plate. The face cover sewing type back plate is difficult to realize complex modeling, the sewing time is too long, the labor cost is high, and wrinkles are prone to appear on the surface. The injection type back plate is made of PP, ABS and other materials by injection molding, the overall cost is high, the mold cost is also high, and the texture is hard, which cannot protect the passenger's body more. The overall cost of the injection + coating back plate is also high, the mold cost is also high, and a layer of soft fabric is coated on the surface to achieve the purpose of soft touch. The glue used in the coating has a great influence on the odor and VOC, and the labor cost and material cost are also greatly increased. The existing chair back plate production method is usually a fixed production method, which is single person and single station. Generally, the injection mixing head is manually dragged to the specified pouring position by manpower, the material is poured into the mold pouring port, and the injection mixing head is manually dragged to the cleaning position after the injection of the material, and the nozzle of the injection mixing head is cleaned. The problems of the above method are: long personnel waiting time, low automation degree, low production efficiency and high labor cost. SUMMARY

[0003] In view of the problems existing in the prior art, the present application aims to provide an automatic continuous production method of soft-touch chair back plate to solve the problems of low automation degree, low production efficiency and high labor cost of the existing chair back plate production method.

[0004] In order to achieve the above-mentioned purpose, the present application provides an automatic continuous production method of soft-touch chair back plate, which comprises a chair back plate production line, the chair back plate production line comprises a turntable, a first rotary motor driving the turntable to rotate and an injection machine arranged on one side of the edge of the turntable, a plurality of mold frames are uniformly arranged on the turntable in the circumferential direction, a mold is installed on the mold frame, the injection machine comprises a rack, at least one horizontal mechanical arm is slidably arranged on the rack in the X direction, a vertical mechanical arm is slidably arranged on each horizontal mechanical arm in the Y direction, each horizontal mechanical arm and vertical mechanical arm is equipped with a servo motor driving the sliding thereof, a telescopic cylinder is installed on the vertical mechanical arm in the Z direction, the cylinder head of the telescopic cylinder faces downward, and an injection mixing head is installed on the cylinder head, a visual identification system for assisting in identifying the pouring port position of the mold is further arranged on the vertical mechanical arm, and a cleaning device for cleaning the nozzle of the injection mixing head is further arranged on the rack. The production method based on the chair back plate production line comprises the following steps:

[0005] S1, the mold is cleaned and treated with mold release agent on the side away from the injection machine;

[0006] S2, the mold comprises an upper mold and a lower mold, a cavity is arranged between the upper mold and the lower mold, the soft-touch insert is laid on the cavity bottom surface of the cleaned lower mold, and then the mold is controlled to be closed;

[0007] S3, the first rotary motor is controlled to rotate to drive the rotating disc to rotate, so that the mold is brought to a pouring position close to the injection machine;

[0008] S4, the corresponding mold position is recognized through the visual recognition system, and the servo motor is controlled to operate to drive the horizontal mechanical arm to slide along the X direction and drive the vertical mechanical arm to move to slide along the Y direction, so that each injection mixing head is brought to above the pouring port of the corresponding mold, then the telescopic cylinder is controlled to operate to drive the injection mixing head to move downward to the pouring port of the mold to pour material, and the pouring of the corresponding number of molds is completed at one time according to the number of the injection mixing heads;

[0009] S5, the telescopic cylinder is reset, the rotating disc continues to rotate to drive the poured mold to leave the pouring position, and meanwhile the next batch of molds to be poured reaches the pouring position, and the telescopic cylinder continues to pour by moving downward;

[0010] S6, the poured mold is unloaded at the side away from the injection machine to obtain the chair back plate with soft touch, and the continuous production of the chair back plate is performed through the circulation of steps S1-S5;

[0011] S7, after the injection is completed, the injection mixing head is moved to the cleaning device to clean the nozzle.

[0012] In the above scheme, a mold changing station is further arranged at one side of the edge of the rotating disc, and the mold changing station can be used to replace the damaged mold.

[0013] In the above scheme, the soft-touch insert is a single leather fabric layer.

[0014] In the above scheme, the soft-touch insert comprises a composite fabric of a fabric layer, a composite cotton layer and a plastic film layer, the composite cotton layer is compounded on the front surface of the fabric layer, and the plastic film layer is compounded on the front surface of the composite cotton layer, flame compounding is adopted between the two, the material layer poured in the mold is integrally formed with the soft-touch insert, so that the chair back plate with soft touch on the back surface is formed, and the material layer is integrally formed on the front surface of the plastic film layer.

[0015] In the above scheme, the rack is a door-shaped frame, two horizontal mechanical arms are arranged at intervals on the top beams of the door-shaped frame, and two cleaning devices are arranged on the vertical beams on the two sides of the door-shaped frame. The double injection mixing heads are poured at the same time, which is beneficial to improve the pouring efficiency, and each cleaning device is used to clean one injection mixing head, so that the cleaning efficiency is high.

[0016] In the scheme, the visual identification system adopts the CV-X400 visual system of Keyence, and high-precision rapid positioning can be realized.

[0017] In the scheme, the cleaning device comprises a soft sponge and a second rotating motor for driving the soft sponge to rotate, so as to clean the nozzle of the injection mixing head.

[0018] In the scheme, the chair back plate production line further comprises an HMI control system for controlling the first rotating motor, the second rotating motor, the servo motor, the telescopic cylinder and the visual identification system, and the production line can be continuously and automatically operated under program control.

[0019] In the scheme, the upper surface of the upper die is an upper die parting surface, the lower surface of the lower die is a lower die parting surface, the upper die parting surface is provided with a ring-shaped exhaust groove surrounding the cavity and communicating with the cavity, and a plurality of longitudinal exhaust grooves are communicated with the ring-shaped exhaust groove, the longitudinal exhaust grooves are uniformly distributed along the circumference of the ring-shaped exhaust groove, and communicate with the outside of the cavity. The function of the ring-shaped exhaust groove is to communicate all the longitudinal exhaust grooves. If there is gas accumulation in the position without longitudinal exhaust grooves, the gas can first enter the ring-shaped exhaust groove and then be distributed to each longitudinal exhaust groove to be discharged from the mold, effectively solving the problem of poor exhaust effect after laying the soft-touch insert in the mold cavity.

[0020] In the scheme, the lower die parting surface is provided with a plurality of vertical screw holes surrounding the cavity, and the upper die parting surface is provided with a vertical butt joint hole corresponding to each vertical screw hole. The soft-touch insert is fixed to the lower die by a plurality of positioning pins, and the positioning pins correspond one-to-one to each vertical screw hole and vertical butt joint hole. When the upper die and the lower die are closed, the lower end of the positioning pin is inserted into the vertical screw hole, and the upper end of the positioning pin is inserted into the vertical butt joint hole. The soft-touch insert is fixed to the mold by the positioning pins, and the mounting holes of the positioning pins are provided on the upper die and the lower die, which avoids the influence of the positioning pins on the mold closing and makes the soft-touch insert easy to lay.

[0021] In the scheme, the pouring gate is provided on the upper die, and the pouring gate is provided with an insert block. The insert block protrudes from the outer surface of the upper die by 15-20 mm, and the overall height of the insert block is equal to the length of the gun head of the injection mixing head. The traditional soft back plate mold has the following characteristics: the insert block at the pouring gate of the upper die is flush with the upper surface of the upper die, and the gun head is long. When the gun head is inserted into the insert block at the pouring gate of the mold for material pouring, it is difficult to ensure that the end of the gun head and the insert block in the mold are flush. If the gun head is inserted too deeply, it is easy to produce a pouring gate mark. The mold increases the height of the insert block to ensure that the end of the gun head and the insert block in the mold are flush during pouring, thereby ensuring the pouring quality.

[0022] The beneficial effects of the present application are: 1. The soft-touch insert is laid on the cavity bottom surface in advance, and then the mold is closed for pouring, so as to integrally form the chair back plate with soft touch. Compared with the traditional production method of soft-touch chair back plate, the production cost is low, and the manufacturing process is simple; 2. The number of injection mixing heads can be expanded according to actual needs, and multiple mixing heads can be used for pouring at the same time, or a single mixing head can be used for pouring, which is flexible; 3. The visual identification system is set to assist the positioning and pouring of the injection mixing head, and high-precision rapid positioning can be realized; 4. The mixing head nozzle cleaning device is set, which moves the injection mixing head to the specified position for nozzle cleaning after injection, which can prevent residual material from blocking the nozzle; in short, the automatic continuous production method of the soft-touch chair back plate can realize multi-station continuous production, which is beneficial to improve the pouring efficiency, save labor cost, and the working area of the operator is fixed, the walking is less, there is no waiting time, the energy consumption is low, and the comprehensive cost is low. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 is a structural schematic view of a chair back plate production line.

[0024] Figure 2 is a top view of the present application.

[0025] Figure 3 is Figure 1 a structural schematic view of an injection molding machine.

[0026] Figure 4 is an effect comparison diagram of the present application and the traditional production method.

[0027] Figure 5 is a structural schematic view of the upper mold.

[0028] Figure 6 is Figure 5 a schematic view from another angle.

[0029] Figure 7 is a schematic view of the pouring port without installing the insert block.

[0030] Figure 8 is a schematic view of the pouring port after installing the insert block. DETAILED DESCRIPTION

[0031] As Figure 1 shown in Fig. 8, an automatic continuous production method of soft-touch chair back plate is based on a chair back plate production line.

[0032] The chair back plate production line comprises a turntable 1, a first rotary motor driving the turntable 1 to rotate, and an injection machine A arranged at one side of the edge of the turntable 1. A plurality of mold frames 2 are uniformly arranged on the turntable 1 in the circumferential direction, and a mold 3 is arranged on the mold frame 2.

[0033] The injection machine A comprises a rack 4, at least one transverse mechanical arm 5 is arranged on the rack 4 and slides along the X direction, one vertical mechanical arm 6 is arranged on each transverse mechanical arm 5 and slides along the Y direction, each transverse mechanical arm 5 and vertical mechanical arm 6 is equipped with a servo motor 7 to drive the sliding, a telescopic cylinder 8 is installed on the vertical mechanical arm 6 and slides along the Z direction, the cylinder head of the telescopic cylinder 8 faces downward, an injection mixing head is installed on the cylinder head, a visual identification system 10 is arranged on the vertical mechanical arm 6 to assist in identifying the pouring port position of the mold 3, and a cleaning device 9 is arranged on the rack 4 to clean the gun nozzle of the injection mixing head.

[0034] The production method of the chair back plate production line mainly comprises the following steps:

[0035] S1, the mold 3 is cleaned and treated with mold release agent on the side away from the injection machine A.

[0036] S2, the mold 3 comprises an upper mold 31 and a lower mold, a cavity is arranged between the upper mold 31 and the lower mold, the soft touch insert is laid on the cavity bottom surface of the cleaned lower mold, and then the mold 3 is controlled to be closed.

[0037] S3, the first rotary motor is controlled to rotate to drive the rotating disc 1 to rotate, so that the mold 3 is brought to the pouring position close to the injection machine A.

[0038] S4, the corresponding mold 3 position is identified by the visual identification system 10, the servo motor 7 is controlled to operate to drive the transverse mechanical arm 5 to slide along the X direction, drive the vertical mechanical arm 6 to move to slide along the Y direction, so that each injection mixing head is brought to the above of the pouring port 15 of the corresponding mold 3, then the telescopic cylinder 8 is controlled to operate to drive the injection mixing head to move downward to the pouring port 15 of the mold 3 to pour, and the corresponding number of molds 3 is poured at one time according to the number of injection mixing heads.

[0039] S5, the telescopic cylinder 8 returns to the original position, the rotating disc 1 continues to rotate to drive the poured mold 3 to leave the pouring position, and at the same time, the next batch of molds 3 to be poured reaches the pouring position, and the telescopic cylinder 8 continues to pour by moving downward.

[0040] S6, the poured mold 3 is unloaded on the side away from the injection machine A to obtain the chair back plate with soft touch, and the steps S1-S5 are cycled to continuously produce the chair back plate.

[0041] S7, after the injection is completed, the injection mixing head is moved to the cleaning device 9 for gun nozzle cleaning.

[0042] Preferably, a mold changing station is arranged on the side of the edge of the rotating disc 1, and the damaged mold 3 can be replaced by using the mold changing station.

[0043] Preferably, the soft touch insert is a single leather fabric layer.

[0044] Preferably, the soft-touch insert comprises a fabric layer, a composite cotton layer and a plastic film layer, the composite cotton layer is compounded on the front surface of the fabric layer, and the plastic film layer is compounded on the front surface of the composite cotton layer. Both of them are connected by flame compounding, glue spraying or film pasting process. The material layer poured in the mold 3 is integrally formed with the soft-touch insert, thereby forming a chair back plate with soft-touch back surface, and the material layer is integrally formed on the front surface of the plastic film layer.

[0045] Preferably, the rack 4 is a door-shaped frame, two transverse mechanical arms are arranged on the top beam 41 of the door-shaped frame, and two cleaning devices 9 are arranged on the two vertical beams 42 of the door-shaped frame. The double-injection mixing head is used for pouring at the same time, which is beneficial to improve the pouring efficiency, and each cleaning device 9 is used for cleaning one injection mixing head, thereby improving the cleaning efficiency.

[0046] Preferably, the visual identification system 10 adopts a CV-X400 visual system of Keyence, which can realize high-precision and rapid positioning.

[0047] Preferably, the cleaning device 9 comprises a soft sponge and a second rotating motor for driving the soft sponge to rotate, so as to clean the nozzle of the injection mixing head.

[0048] Preferably, the chair back plate production line further comprises an HMI control system for controlling the first rotating motor, the second rotating motor, the servo motor 7, the telescopic cylinder 8 and the visual identification system 10. The production line can be continuously and automatically operated under the control of the program.

[0049] Preferably, the upper surface of the lower die is an upper die parting surface 311, the lower surface of the upper die is a lower die parting surface, the upper die parting surface 311 is provided with a ring-shaped exhaust groove 11 surrounding the cavity and communicating with the cavity, and a plurality of longitudinal exhaust grooves 12 are communicated with the ring-shaped exhaust groove 11, the longitudinal exhaust grooves 12 are uniformly distributed along the circumference of the ring-shaped exhaust groove 11 and communicate with the outside of the cavity. The ring-shaped exhaust groove 11 is used for connecting all the longitudinal exhaust grooves 12. If there is gas accumulation in the position without the longitudinal exhaust groove 12, the gas can first enter the ring-shaped exhaust groove 11 and then be distributed to each longitudinal exhaust groove 12 to be discharged from the mold 3, thereby effectively solving the problem of poor exhaust effect of the mold 3 after the soft-touch insert is laid in the cavity.

[0050] Preferably, the lower mold parting surface around the cavity is provided with a plurality of vertical pin holes, the upper mold parting surface 311 is provided with a vertical butt joint hole 13 corresponding to the position of each vertical pin hole, the soft touch insert is fixed to the lower mold by a plurality of positioning pins, the positioning pins correspond one-to-one to each vertical pin hole and vertical butt joint hole 13, when the upper mold 31 and the lower mold are closed, the lower end of the positioning pin is inserted into the vertical pin hole, and the upper end of the positioning pin is inserted into the vertical butt joint hole 13. The soft touch insert is fixed to the mold 3 by the positioning pins, and the upper mold 31 and the lower mold are both provided with mounting holes for the positioning pins, which avoids the influence of the positioning pins on the mold 3 closing, and also makes the soft touch insert paving convenient.

[0051] Preferably, the pouring gate 15 is provided on the upper mold 31, the pouring gate 15 is embedded with an insert 14, the insert 14 protrudes from the outer surface of the upper mold 31 by 15-20 mm, and the overall height of the insert 14 is equal to the length of the gun head of the material mixing head. The traditional soft back plate mold has the following characteristics: the insert 14 at the pouring gate 15 of the upper mold 31 is flush with the upper surface of the upper mold 31, the gun head is long, and it is difficult to ensure that the end of the gun head and the insert 14 are flush in the mold 3 when the gun head is inserted into the insert 14 at the pouring gate 15 of the mold for material pouring; the present mold increases the height of the insert 14 to ensure that the end of the gun head and the insert 14 are flush in the mold 3 during pouring, thereby ensuring the pouring quality.

[0052] As shown in Figure 4 Compared with the traditional chair back plate production method, the present production method can reduce energy consumption by 37.5% and labor cost by 46.7%.

Claims

1. An automated continuous production method of soft touch chair back panels, comprising a chair back panel production line, characterized by: The chair back panel production line includes a turntable (1), a first rotary motor that drives the turntable (1) to rotate, and an injection machine (A) located on one side of the edge of the turntable (1). Several mold frames (2) are evenly arranged circumferentially on the turntable (1), and molds (3) are mounted on the mold frames (2). The injection machine (A) includes a frame (4), on which at least one horizontal robotic arm (5) is slidably arranged along the X-direction. Each horizontal robotic arm (5) has a vertical robotic arm (6) slidably arranged along the Y-direction. (5) and the vertical robotic arm (6) are both equipped with servo motors (7) that drive their sliding. A telescopic cylinder (8) is installed on the vertical robotic arm (6) along the Z direction. The cylinder head of the telescopic cylinder (8) faces downward and an injection mixing head is installed on the cylinder head. The vertical robotic arm (6) is also equipped with a visual recognition system (10) for assisting in identifying the position of the pouring gate of the mold (3). The frame (4) is also equipped with a cleaning device (9) for cleaning the nozzle of the injection mixing head. The production method based on the chair back panel production line includes the following steps: S1. Clean the mold (3) and spray release agent on the side away from the injection machine (A); S2. The mold (3) includes an upper mold (31) and a lower mold. A cavity is provided between the upper mold (31) and the lower mold. The soft-touch insert is placed on the bottom surface of the cavity of the cleaned lower mold, and then the mold (3) is closed. The lower surface of the upper mold (31) is the upper mold parting surface (311), and the upper surface of the lower mold is the lower mold parting surface. The upper mold parting surface (311) is provided with an circumferential venting groove (11) that surrounds the cavity and communicates with the cavity. The circumferential venting groove (11) is connected to a number of longitudinal venting grooves (12). The longitudinal venting grooves (12) are evenly distributed along the circumference of the circumferential venting groove (11) and communicate with the outside of the cavity. The lower mold parting surface is provided with a number of vertical mounting holes around the cavity. The upper mold parting surface (311) is provided with vertical docking holes (13) corresponding to the position of each vertical mounting hole. The soft touch insert is fixed to the lower mold by a number of positioning pins. The positioning pins correspond one-to-one with each vertical mounting hole and vertical docking hole (13). When the upper mold (31) and the lower mold are closed, the lower end of the positioning pin is driven into the vertical mounting hole, and the upper end of the positioning pin is inserted into the vertical docking hole (13). S3. Control the first rotary motor to rotate and drive the turntable (1) to rotate, thereby bringing the mold (3) to the pouring position near the injection machine (A); S4. The visual recognition system (10) identifies the position of the corresponding mold (3) and controls the servo motor (7) to run, driving the horizontal robotic arm (5) to slide along the X direction and the vertical robotic arm (6) to move along the Y direction, thereby bringing each injection mixing head above the pouring port (15) of the corresponding mold (3). Then, the telescopic cylinder (8) is controlled to run, driving the injection mixing head to move down to the pouring port (15) of the mold (3) to inject material. The corresponding number of molds (3) are poured in one go according to the number of injection mixing heads. The pouring gate (15) is arranged on the upper die (31), and the pouring gate (15) is embedded with an insert block (14), the insert block (14) protrudes from the outer surface of the upper die (31) by a height of 15-20 mm, and the overall height of the insert block (14) is equal to the length of the gun head of the material mixing head; S5, the telescopic air cylinder (8) returns, the turntable (1) continues to rotate, drives the already-poured mold (3) to leave the pouring position, and drives the next batch of molds (3) to be poured to reach the pouring position, and the telescopic air cylinder (8) continues to pour by moving downward; S6, the discharging of the already-poured mold (3) is completed on the side away from the material injection machine (A), a chair back plate with soft touch is obtained, and the continuous production of the chair back plate is performed through the steps S1-S5. S7, after the material injection is completed, the material mixing head is moved to the cleaning device (9) to clean the gun nozzle.

2. The automated continuous production method of soft touch seatback panels of claim 1, wherein: A mold changing station is further arranged on one side of the edge of the turntable (1).

3. The automated continuous production method of soft touch seat back panels according to claim 1, characterized in that: The soft touch insert comprises a fabric layer, a composite cotton layer and a plastic film layer, the composite cotton layer is compounded on the front surface of the fabric layer, and the plastic film layer is compounded on the front surface of the composite cotton layer, and flame compounding, glue spraying or film pasting processes are adopted between the two.

4. The method of claim 1, wherein: The machine frame (4) is a door-shaped frame, two transverse mechanical arms are arranged on the top beam (41) of the door-shaped frame, and two cleaning devices (9) are arranged on the two vertical beams (42) of the door-shaped frame.

5. The method of claim 1, wherein: The visual identification system (10) adopts a Keyence CV-X400 visual system.

6. The method of claim 1, wherein: The cleaning device (9) comprises a soft sponge and a second rotary motor for driving the soft sponge to rotate.

7. The method of claim 6, wherein: The chair back plate production line further comprises an HMI control system for controlling the first rotary motor, the second rotary motor, the servo motor (7), the telescopic air cylinder (8) and the visual identification system (10).

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