A modular side delivery system

Abstract

The application discloses a combined side wall conveying system, which is sequentially divided into a checking unit in the form of a side wall end EMS conveying, a storage unit in the form of a non-EMS, and a departure unit in the form of a main assembly end EMS conveying from a side wall feeding port to a main assembly discharging port; side wall feeding is performed in the checking unit, manual checking and repairing operations are performed, the side wall that has completed checking is transferred to the storage unit by a robot, side wall storage is performed in the storage unit according to vehicle types, then corresponding side walls are transferred from the storage unit to the departure unit by the robot according to the sequence requirement of the main assembly line, and discharging is completed in the departure unit. The application is applied to the side wall conveying process from the side wall line to the main assembly line, can cope with various situations in the side wall checking and repairing process under the premise of completing the main function of the side wall conveying, can improve the area utilization, expand the storage capacity and the number of side wall varieties, and can ensure the accurate and reliable matching of the main assembly line and the function of processing abnormal situations.

Description

Technical Field

[0001] This invention belongs to the technical field of automatic conveying systems for welding production lines, specifically relating to a combined side panel conveying system, which is mainly used for aerial side panel conveying, inspection, storage, and matching of vehicle sequences between the side panel line and the main assembly line, and has more comprehensive mobility functions. Background Technology

[0002] With the continuous advancement of manufacturing technology in the passenger vehicle manufacturing industry, new technologies are being widely applied, and new welding production lines have achieved extremely high levels of automation due to the demand for large-scale production capacity. This automation is not only reflected in the automatic assembly, handling, and welding of process lines, but also prominently in the automatic overhead transport of large components between production lines, such as the lower body, side panel assemblies, and body welding assemblies. The side panel assemblies, in particular, commonly utilize electric self-propelled trolley transport systems (also known as EMS transport systems) to achieve automatic transport from the side panel line to the main assembly line. The EMS side panel transport system completes the transport function using electric self-propelled trolleys operating throughout the entire range, while also providing functions such as manual operation, vehicle model-specific storage, and vehicle sequence matching for dispatch. It is functionally divided into five parts: loading port, inspection and repair area, storage area, unloading port, and return line. Figure 1 As shown.

[0003] At the side panel loading port, the empty EMS trolley descends into the production line, and the side panel assembly is picked up by the robot and placed onto the EMS trolley. The EMS trolley then rises into the air and enters the transport process, heading to the inspection and repair area.

[0004] The inspection and repair area can be further divided into a work area and a temporary storage area. When the EMS trolley passes through the work area, it will automatically stop at the work station. The side panels will be inspected and repaired manually. If there are no problems, they will be released to continue transporting. Side panels that cannot be repaired or require a long time to repair will be stored and processed in the temporary storage area. After processing, qualified side panels can leave the temporary storage area and enter the transport route.

[0005] The side panels leaving the inspection and repair area enter the storage area, where they are divided into multiple storage lanes via switches. Each storage lane stores one type of vehicle model. The reason for storing vehicles by model is to address the situation where some side panels are stuck in the inspection and repair area. By redistributing them in the storage area, the order in which the vehicles are delivered to the main assembly line is ensured.

[0006] EMS receives the vehicle models in sequence from the main assembly line. The side panels are released from the storage area in sequence and transported to the main assembly line's unloading port. The EMS trolley descends into the line body, where the main assembly line robot grabs the side panels. The empty EMS trolley rises into the air and leaves the unloading port.

[0007] The empty EMS trolley leaves the main loading dock and enters the return line, then travels to the side loading dock, completing one cycle.

[0008] The aforementioned typical EMS side conveyor system can basically meet normal production conveying needs and can also cope with small-scale fluctuations in the order of vehicle models on the side conveyor. However, it is difficult to cope with or even solve large-scale changes in vehicle model order in a short period of time, and it also has some other shortcomings, as follows:

[0009] 1. The trolley moves with the side panels along its sides. At turns, the trajectory of the side panels is relatively large, requiring ample clearance and space between adjacent rows of conveyor tracks. This results in low utilization of the overhead platform area, with an effective area ratio of approximately 0.3%, significantly lower than the 0.6-0.7% effective area ratio of the roller bed skid line. Due to this low area utilization, setting a large storage capacity in the storage area is significantly constrained by the available overhead space.

[0010] 2. Under normal circumstances, according to the production plan, the order in which the side panel models enter the upper part port is consistent with the order in which the side panel models leave the lower part port. However, if it is found that a certain side panel needs to be detained for repair for a long time after inspection and repair, the sequence will change due to the lack of parts. If the same model model is not restored after the storage area is emptied, it will affect the lower part port and cause the machine to stop due to the lack of parts.

[0011] 3. The electric trolley is a traction-type traveling trolley, and the carbon brush arm is a rear-swinging pressure-contact sliding contact line, so it is only suitable for forward travel. If a running error occurs or the trolley needs to be moved backward, the carbon brush and motor brakes must be manually released before pushing and pulling backward, which is a cumbersome and laborious process and will cause some downtime.

[0012] 4. Since an inspection and repair area is set up on the air EMS transport path, some side panels that cannot be repaired and are scrapped cannot be left in the temporary storage area for a long time, as this will affect normal production operations. The scrapped side panels need to be manually lifted away. The empty trolley can only enter the return line by circulating with the normal side panels. The manual handling process affects normal transport and unloading.

[0013] 5. Due to a certain fault or cause, the side panel model arriving at the unloading port does not match the lower part of the vehicle body. It is necessary to manually operate the trolley to drive out of the unloading port, lift the side panel off, and then put the empty trolley into the return line. Normal operation can only be restored after the electrical program and signal processing are completed. The process affects normal conveying and unloading. Summary of the Invention

[0014] To address the aforementioned problems in existing technologies, this invention provides a combined side panel conveying system, which is applied in the side panel conveying process from the side panel line to the main assembly line. While fulfilling the main function of side panel conveying, it can handle various situations that arise during the side panel inspection and repair process, improve area utilization, expand storage capacity and the number of side panel varieties it can accommodate, and ensure the accuracy and reliability of the main assembly line's vehicle sequence matching and the function of handling abnormal situations.

[0015] To achieve the above objectives, the present invention adopts the following technical solution:

[0016] A combined side panel conveying system, from the side panel loading port to the main assembly unloading port, is sequentially divided into an inspection unit in the form of EMS conveying for the side panel end, a storage unit in the form of non-EMS conveying, and a dispatching unit in the form of EMS conveying for the main assembly end. Side panels are loaded in the inspection unit and manually inspected and repaired. After inspection, the side panels are transferred by a robot to the storage unit, where they are stored according to vehicle model. Then, the robot transfers the corresponding side panels from the storage unit to the dispatching unit according to the vehicle model sequence requirements of the main assembly line, where the unloading is completed.

[0017] Furthermore, the inspection unit adopts a separate circulating EMS conveying method. The inspection unit is equipped with a loading port, a manual inspection and repair work area, an overdue temporary storage processing area, a scrap storage processing area, and a delivery station, and is equipped with a multi-branch conveying mode. The EMS descends to receive the part at the loading port, rises to the air for conveying, and enters the manual inspection and repair work area through the side. Then, depending on the situation, it enters the normal delivery path, the temporary storage and repair path, or the scrap processing path.

[0018] Furthermore, the normal delivery path is as follows: the side panel completes normal inspection, the trolley transports the side panel to the delivery station, the robot transfers the side panel into the storage unit at the delivery station, and the empty trolley enters the unit return line and returns to the loading port.

[0019] Furthermore, the temporary storage and repair path is as follows: when the side panel needs to be temporarily stored or repaired for a longer period of time, the trolley turns around and enters the overdue temporary storage processing area for temporary storage or processing of the side panel. The repaired side panel is then checked and confirmed again by the manual inspection and repair work area. After the inspection is completed, it enters the normal delivery path.

[0020] Furthermore, the scrapping process is as follows: when the side panel is determined to be scrapped after passing through the manual inspection and repair work area, the trolley turns and enters the scrapping storage and processing area for storage and processing. After the side panel is removed and processed, the empty trolley enters the unit return line.

[0021] Furthermore, the storage unit adopts a multi-row, segmented, air-filled buffer storage format, with different model buffers set up for the side panels of different car models.

[0022] Furthermore, the dispatching unit adopts a separate cyclic EMS delivery method, which is responsible for delivering dispatched vehicles to the main assembly line. The robot places the side panels onto the dispatching station EMS trolley of the dispatching unit according to the vehicle model sequence requirements of the main assembly line. If there are no abnormalities, the trolley moves to the unloading port, descends, and is picked up by the robot in the main assembly line. The empty trolley rises and enters the unit return line, returning to the dispatching station to complete the cycle.

[0023] Furthermore, the dispatching unit is equipped with a fault tolerance zone; if an abnormality occurs at the dispatching station, the side panel enters the fault tolerance zone for storage and processing; or if an abnormality occurs at the unloading port, the side panel that is not taken away enters the fault tolerance zone for storage and processing; after the side panel is processed in the fault tolerance zone, it can be resent to the unloading port.

[0024] Furthermore, the fault-tolerant zone includes a path for an empty trolley to enter the unit return line.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] This invention provides a combined side-mounted conveyor system that introduces a non-EMS storage method, forming a combination of multiple functional block units. Units primarily for walking and conveying still utilize the EMS method, leveraging its advantages of high efficiency and suitability for manual operation; units primarily for storage employ a non-EMS method, achieving high storage density without affecting or minimizing interference with vehicle sequences, while significantly avoiding the very low area utilization of EMS storage areas.

[0027] Replacing the original EMS storage method with an air buffer storage method can greatly improve the area utilization rate. The storage quantity will no longer be limited by the area. Multiple buffers can also increase the expansion capability of side panel products and have higher storage efficiency. Each model has its own buffer storage, and there is no model ratio or car sequence lock. Each model can supply the main assembly line more fully, and the problem of car sequence fluctuations caused by part shortages, which in turn affect the main assembly line's downtime, can be eliminated.

[0028] The inspection unit still uses EMS transport. After the side panel is loaded, a multi-branch path structure is set in the manual inspection and repair area. Side panels that cannot be repaired normally are automatically transported to different branch paths for temporary storage and processing. You only need to select different branches to move forward, and there is no need for manual backing, lifting or other operations.

[0029] The same EMS delivery method is used in the dispatch unit. The main assembly line sequence matching is only performed at the unloading port. The sequence matching is no longer affected by changes in other areas. The branch loop path method is used to deal with and correct any abnormal situations that may occur. There is no need for manual backing or lifting operations.

[0030] Unlike existing EMS conveyor systems that include loading, unloading, inspection, sorting and storage, and matching of vehicles, the modular conveyor system described in this invention is divided into functional zones and composed of multiple regional units. It leverages the functional advantages of each unit independently, avoids its shortcomings and deficiencies, and enhances the overall system's ability to handle various anomalies and special needs. Attached Figure Description

[0031] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 This is a schematic diagram of an existing EMS side conveyor system;

[0033] Figure 2 This is a schematic diagram of the combined side conveyor system described in this invention. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] A combined side panel conveying system, from the side panel loading port to the main assembly unloading port, is sequentially divided into an inspection unit in the form of EMS conveying for the side panel end, a storage unit in the form of non-EMS conveying, and a dispatching unit in the form of EMS conveying for the main assembly end. Side panels are loaded in the inspection unit and manually inspected and repaired. After inspection, the side panels are transferred by a robot to the storage unit, where they are stored according to vehicle model. Then, the robot transfers the corresponding side panels from the storage unit to the dispatching unit according to the vehicle model sequence requirements of the main assembly line, where the unloading is completed.

[0036] Furthermore, the inspection unit adopts a separate circulating EMS conveying method. The inspection unit is equipped with a loading port, a manual inspection and repair work area, an overdue temporary storage processing area, a scrap storage processing area, and a delivery station, and is equipped with a multi-branch conveying mode. The EMS descends to receive the part at the loading port, rises to the air for conveying, and enters the manual inspection and repair work area through the side. Then, depending on the situation, it enters the normal delivery path, the temporary storage and repair path, or the scrap processing path.

[0037] Furthermore, the normal delivery path is as follows: the side panel completes normal inspection, the trolley transports the side panel to the delivery station, the robot transfers the side panel into the storage unit at the delivery station, and the empty trolley enters the unit return line and returns to the loading port.

[0038] Furthermore, the temporary storage and repair path is as follows: when the side panel needs to be temporarily stored or repaired for a longer period of time, the trolley turns around and enters the overdue temporary storage processing area for temporary storage or processing of the side panel. The repaired side panel is then checked and confirmed again by the manual inspection and repair work area. After the inspection is completed, it enters the normal delivery path.

[0039] Furthermore, the scrapping process is as follows: when the side panel is determined to be scrapped after passing through the manual inspection and repair work area, the trolley turns and enters the scrapping storage and processing area for storage and processing. After the side panel is removed and processed, the empty trolley enters the unit return line.

[0040] Furthermore, the storage unit adopts a multi-row, segmented, air-filled buffer storage format, with different model buffers set up for the side panels of different car models.

[0041] Furthermore, the dispatching unit adopts a separate cyclic EMS delivery method, which is responsible for delivering dispatched vehicles to the main assembly line. The robot places the side panels onto the dispatching station EMS trolley of the dispatching unit according to the vehicle model sequence requirements of the main assembly line. If there are no abnormalities, the trolley moves to the unloading port, descends, and is picked up by the robot in the main assembly line. The empty trolley rises and enters the unit return line, returning to the dispatching station to complete the cycle.

[0042] Furthermore, the dispatching unit is equipped with a fault tolerance zone; if an abnormality occurs at the dispatching station, the side panel enters the fault tolerance zone for storage and processing; or if an abnormality occurs at the unloading port, the side panel that is not taken away enters the fault tolerance zone for storage and processing; after the side panel is processed in the fault tolerance zone, it can be resent to the unloading port.

[0043] Furthermore, the fault-tolerant zone includes a path for an empty trolley to enter the unit return line.

[0044] Example

[0045] Please see Figure 2 This embodiment is a combined side panel conveying system, which is a combined conveying mode that is divided into three units: two functional areas and a middle storage area, from the side panel loading port to the main assembly unloading port. Specifically, it is an inspection unit in the form of EMS conveying at the side panel end, a storage unit in the middle with a robot and multiple rows of buffers, and a dispatching unit in the form of EMS conveying at the main assembly end.

[0046] The side panels are loaded into the inspection unit and manually inspected and repaired. The inspected side panels are then transferred to the storage unit by a robot. The side panels are stored in the storage unit according to the vehicle model. Then, the robot transfers the corresponding side panels from the storage unit to the dispatch unit according to the vehicle model sequence requirements of the main assembly line. The side panels are unloaded in the dispatch unit.

[0047] It consists of three independently operating units, each of which operates independently and has its own unique functions. The units use a highly reliable standard robot to transfer workpieces, which not only achieves physical connection between the units to complete the entire transportation process, but also achieves intermittent isolation in the control system to simplify the system and control logic and improve operating efficiency.

[0048] 1. Inspection Unit:

[0049] The inspection unit adopts a separate circulating EMS conveying method. The inspection unit is equipped with a loading port, a manual inspection and repair work area, an overdue temporary storage area, a scrap storage and processing area, and a delivery station, and is equipped with a multi-branch conveying mode.

[0050] The EMS system lowers the package at the loading port, then raises it for aerial transport, and it enters the manual inspection and repair work area via the side panel; then, three different paths are selected:

[0051] (1) Normal delivery path: The side panel is inspected normally and transported to the delivery station. The seven-axis robot transfers the side panel into the storage unit at the delivery station. The empty trolley enters the unit return line and returns to the loading port.

[0052] (2) Temporary storage and repair path: If the side panel needs to be temporarily stored or repaired for a longer period of time, the trolley turns around and enters the overdue temporary storage processing area for temporary storage or processing of the side panel. The repaired side panel is checked and confirmed again by the manual inspection and repair operation area. After the inspection is completed, it enters the normal delivery path, that is, the side panel is transported to the delivery station. The seven-axis robot transfers the side panel into the storage unit at the delivery station. The empty trolley enters the unit return line and returns to the loading port.

[0053] (3) Scrap disposal path: If the side panel is determined to need to be scrapped after manual inspection and repair work area, it will turn to the scrap storage and processing area for storage and processing. After the side panel is removed and disposed of, the empty trolley will enter the unit return line.

[0054] This embodiment features multiple selection channels specifically designed for different scenarios within the inspection unit. Items loaded onto the side panel at the loading port and transported normally enter the inspection area. Items requiring further, lengthy repair after inspection then enter the temporary storage area; items that cannot be repaired and must be scrapped enter the scrap storage area. Each area operates with a closed-loop path that runs automatically. The control logic is clear, well-defined, highly programmed, and automated, eliminating the need for manual backtracking or lifting, thus reducing the difficulty and workload for personnel.

[0055] 2. Storage unit:

[0056] The storage unit adopts a non-EMS form, including a unit entrance, a vehicle model buffer, and a unit exit. At the unit entrance, a seven-axis robot grabs the side panel from the EMS trolley at the delivery station of the inspection unit and hangs it on the corresponding vehicle model buffer. At the unit exit, a seven-axis robot grabs the side panel from the corresponding vehicle model buffer and places it on the EMS trolley at the dispatch station of the dispatch unit.

[0057] In this embodiment, a multi-row, segmented, air-filled buffer storage method is adopted. Different model buffers are set up for the side panels of different models. The side panels of different models can be stored on the model buffers corresponding to the model. This method has high area utilization, large storage capacity, and higher expansion capability for side panel varieties. It also has a stronger ability to isolate and buffer the differences in vehicle sequence between the side panel line and the main assembly line.

[0058] The storage unit adopts a hanging buffer design, with small spacing between adjacent workpieces, similar to workpiece stacking, which can meet the needs of a sufficiently large storage capacity. The effective area ratio of the buffer storage area can reach more than 0.6, which means that for the same area width, the number of storage channels is twice that of the EMS method, and it can accommodate more types of car models or side panel types.

[0059] 3. Departure Unit:

[0060] The dispatching unit adopts a separate circulating EMS conveyor system, which is mainly responsible for dispatching vehicles to the main assembly line. The seven-axis robot places the side panels onto the dispatching station EMS trolley of the dispatching unit according to the vehicle model sequence requirements of the main assembly line. If there are no abnormalities, the robot moves to the unloading port, the trolley descends, and the robot in the main assembly line takes away the side panels. The empty trolley rises and enters the unit return line, returning to the dispatching station to complete the cycle.

[0061] Due to the isolation buffer of the large-capacity storage unit, the tolerance for the difference in train sequence between the loading port and the unloading port is greatly improved. The main train sequence matching is only performed in the dispatching unit. Under normal circumstances, there is no misorder factor, and the downtime caused by misorder can be basically eliminated.

[0062] The dispatching unit is equipped with a fault-tolerant zone. If an anomaly occurs at the dispatching station, the side panel can be stored and processed in the fault-tolerant zone. Side panels that are not retrieved due to anomalies at the unloading point can also be stored and processed in the fault-tolerant zone. After processing in the fault-tolerant zone, the side panel can be reissued to the unloading point, and empty trolleys can also enter the unit's return line from the fault-tolerant zone. Side panels of a certain model used for debugging can also be repeatedly supplied to the main assembly line for debugging using the fault-tolerant zone. The fault-tolerant multi-cycle channel specifically designed for the dispatching unit eliminates the need for manual lifting and reversing, reducing the difficulty and workload of personnel and resulting in higher operating efficiency and automation.

[0063] The dispatch unit adopts a separate, cyclical EMS delivery system, which provides more accurate and reliable vehicle sequence matching capabilities. It also features a comprehensive internal loop path for handling anomalies. Besides handling abnormal situations, it can also be used for repeated side-channel detours to supply the main assembly line during commissioning. It also boasts clear and explicit logic, a high degree of standardization and automation.

[0064] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. It can be applied to various fields suitable for the invention. Further modifications can be readily made by those skilled in the art. Therefore, without departing from the general concept defined by the claims and their equivalents, the invention is not limited to the specific details and illustrations shown and described herein.

Claims

1. A modular side delivery system characterized in that, From the side wall upper part to the main assembly lower part, it is divided into a side wall end EMS conveying form inspection unit, a non-EMS form storage unit, and a main assembly end EMS conveying form dispatch unit in sequence; side wall upper part is carried out in the inspection unit, and manual inspection and repair work is carried out, the side wall which completes inspection is transferred to the storage unit by the robot, the side wall is stored by vehicle type in the storage unit, and then the corresponding side wall is transferred from the storage unit to the dispatch unit by the robot according to the main assembly line vehicle type sequence requirement, and the lower part is completed in the dispatch unit; the inspection unit adopts a separate circulating EMS conveying form, the inspection unit is provided with an upper part, a manual inspection and repair work area, an overtime temporary storage treatment area, a scrap storage treatment area and a delivery station, and a plurality of branch conveying modes are correspondingly provided; the EMS is lowered to receive the part at the upper part, is raised to the air conveying, the side wall enters the manual inspection and repair work area; then it is divided into the normal delivery path, the temporary repair path or the scrap treatment path; the storage unit adopts a multi-row type air BUFFER storage form, and the side walls of different vehicles are respectively provided with vehicle type BUFFER; the dispatch unit adopts a separate circulating EMS conveying form, which is responsible for conveying and dispatching to the main assembly line, and the robot puts the side wall on the delivery station EMS trolley of the dispatch unit according to the main assembly line vehicle type sequence requirement; if there is no exception, it advances to the lower part, the trolley is lowered, the side wall is taken away by the robot in the main assembly line, the empty trolley is raised to enter the unit return line, and the cycle is completed by returning to the delivery station; the dispatch unit is provided with a fault tolerance area, if the delivery station has an exception, the side wall enters the fault tolerance area for storage and treatment; or the lower part has an exception, the side wall which is not taken away enters the fault tolerance area for storage and treatment; the side wall is sent to the lower part again after being treated in the fault tolerance area.

2. A modular side delivery system as claimed in claim 1, wherein, The normal delivery path is that the side wall normally completes inspection, the trolley conveys the side wall to the delivery station, waits for the robot to transfer the side wall into the storage unit at the delivery station, the empty trolley enters the unit return line and returns to the upper part.

3. A modular side delivery system as in claim 1, wherein, The temporary repair path is that when the side wall needs to be temporarily stored or repaired for a long time, the trolley turns to enter the overtime temporary storage treatment area for temporary storage or treatment, the repaired side wall is checked and confirmed again through the manual inspection and repair work area, and enters the normal delivery path after completing the inspection.

4. A modular side delivery system as in claim 1, wherein, The scrap treatment path is that when the side wall is determined to need scrap treatment through the manual inspection and repair work area, the trolley turns to enter the scrap storage treatment area for storage and treatment, and the empty trolley enters the unit return line after the side wall is taken away and handled.

5. A modular side delivery system as claimed in claim 1, wherein, The fault tolerance area is provided with a path for the empty trolley to enter the unit return line.

Images