An anti-slip mat, an anti-slip mat production system, and a production method.

Abstract

This invention discloses an anti-slip mat, an anti-slip mat production system, and a production method. The anti-slip mat includes a surface layer, a base material, and suction cups. The system includes a hot-melt device, a pressing device, and a positioning device. The hot-melt device is connected to the pressing device. The hot-melt device includes a hot-melt machine and a hot-melt table. The hot-melt machine melts the base material. The hot-melt table has a movable template on which the base material is placed. The positioning device positions and installs the suction cups. The surface layer and suction cups are located on opposite sides of the molten base material. This invention presses the surface layer, suction cups, and molten base material together, allowing them to be simultaneously hot-melted and welded to form the anti-slip mat in one step. This achieves integrated welding of the suction cups, base material, and surface layer at a single workstation, simplifying the production process and improving work efficiency. Furthermore, the hot-melt welding method provides strong tear resistance at the weld joints of the suction cups, surface layer, and base material, significantly extending the service life of the anti-slip mat.

Description

Technical Field

[0001] This invention belongs to the field of floor mat technology, and relates to an anti-slip mat, an anti-slip mat production system, and a production method. Background Technology

[0002] Indoor floor mats are especially important for the anti-slip performance of the elderly and children. Safety accidents caused by users slipping and falling due to floor mats have occurred frequently in China. Whether it is rubber material or various latex foam materials on the market, they all pose high safety hazards on wet floors such as bathrooms and kitchens.

[0003] Floor mats can achieve anti-slip properties by using suction cups. Nowadays, suction cups and floor mats are usually connected by adhesive bonding, injection molding, or other processes. However, floor mats are mostly in a humid environment, and after repeated use, the suction cups are prone to falling off, which greatly affects the lifespan of the suction cup floor mat.

[0004] The production process of suction cup floor mats requires manual intervention in the fabric alignment process. Whether the fabric is aligned or not will affect the quality of the finished floor mat. However, after a long period of monotonous and repetitive work, the eyesight and energy of the workers are easily fatigued, which makes it very easy for the fabric to be misaligned, thus affecting the production efficiency and quality of suction cup floor mats. Summary of the Invention

[0005] In order to overcome the shortcomings of the prior art, the present invention provides an anti-slip mat, an anti-slip mat production system, and a production method.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a production system for anti-slip mats, the anti-slip mat comprising a surface layer, a base material, and suction cups, including a hot-melt device, a pressing device, and a positioning device, wherein the hot-melt device is connected to the pressing device, the hot-melt device comprising a hot-melt flask and a hot-melt table, the hot-melt flask melting the base material, the hot-melt table having a movable template, the base material being placed on the movable template, the positioning device positioning and installing the suction cups, the surface layer and the suction cups being located on opposite sides of the molten base material, the pressing device pressing the surface layer and the suction cups together, simultaneously hot-melting and welding the surface layer and the suction cups to the base material to form the anti-slip mat.

[0007] Furthermore, the movable template is provided with perforations, and the positioning device is provided with a plurality of suction cup positioning holes, which are used to load suction cups. The perforations of the movable template correspond one-to-one with the suction cup positioning holes.

[0008] Furthermore, the pressing device includes a cylinder, a frame, a pressure plate, and a pressing table. The cylinder is fixed on the frame, the pressure plate is fixed at the output end of the cylinder, the pressing table is located below the pressure plate, the cylinder drives the pressure plate to move up and down vertically above the pressing table, and a positioning device is installed on the pressing table.

[0009] Furthermore, it also includes a vision device, which includes a controller and a first camera, a second camera, an image processor, and an alarm connected to the controller. The first camera and the second camera are respectively connected to the image processor. The controller controls the first camera and the second camera to capture images. The first camera and the second camera acquire images and generate corresponding image signals, and send the image signals to the image processor. The image processor processes the images and outputs a processing signal to the controller. The controller outputs a trigger signal to the alarm based on the processing signal to control the alarm to start the alarm.

[0010] Furthermore, it also includes a cooling mechanism that cools the semi-finished anti-slip mat.

[0011] Furthermore, it also includes a trimming mechanism, which comprises a conveyor belt mechanism, a limiting plate, a third camera, a vision processing module, and a trimming machine. The conveyor belt mechanism is located between the pressing device and the trimming machine, and is connected to both the pressing device and the trimming machine respectively. The limiting plate is located on both sides of the conveyor belt mechanism to limit the movement of the semi-finished anti-slip mat during the conveying process. The third camera is set above the trimming area to capture a fourth image of the semi-finished anti-slip mat located on the trimming machine and transmit the image to the vision processing module. The vision processing module is connected to the controller. The vision processing module receives the image and processes the fourth image to determine whether the semi-finished anti-slip mat is located in the trimming area and the cutting line. The center of the trimming area coincides with the center of the two sets of cutters. When the semi-finished anti-slip mat is located in the trimming area, the centers of the two coincide.

[0012] A method for producing an anti-slip mat includes the following steps:

[0013] Step 1: Place the movable template and base material in the designated positions on the hot melt table;

[0014] Step 1.1: Place the movable template on the hot melt table;

[0015] Step 1.2: The first camera captures the initial image of the active template and determines whether the placement position of the active template is offset. If yes, the alarm is activated and step 1.1 is executed; otherwise, step 1.3 is executed.

[0016] Step 1.3: Place the substrate on the movable template;

[0017] Step 1.4: The first camera captures the first image of the substrate and determines whether the placement of the substrate is off-center. If yes, the alarm is activated and step 1.3 is executed; otherwise, step 2 is executed.

[0018] Step 2: The hot melt table transports the movable template and substrate to the hot melt machine for hot melting until the substrate reaches a molten state, after which it is removed;

[0019] Step 3: Place the top layer in the designated position on the substrate;

[0020] Step 4: Move the second integrated body, consisting of the movable template, base material and surface layer, onto the positioning device with the suction cups already loaded. Determine whether the placement position of the second integrated body is the set position. If yes, proceed to step 5. If no, adjust the placement position of the second integrated body.

[0021] Step 5: The cylinder controls the pressure plate to press down, pressing the second integrated body tightly, so that the surface layer and suction cup are thermally welded to the molten base material to obtain a semi-finished anti-slip mat;

[0022] Step 6: The cooling mechanism cools down the semi-finished anti-slip mat, the semi-finished anti-slip mat is demolded, the conveyor belt mechanism transports the semi-finished anti-slip mat from the pressing device to the edge cutting machine, and limits it by the limiting plate. The edge cutting machine moves the semi-finished anti-slip mat to the edge cutting area.

[0023] Step 7: The edge trimming machine trims off the excess base material along the cutting line to obtain the finished anti-slip mat;

[0024] Step 8: End of steps.

[0025] Furthermore, the step 1.2 of determining whether the placement position of the active template is offset is as follows:

[0026] Step 1.2.1: The first camera acquires image A of the hot melt table surface, and the image processor processes image A to obtain the outline B1 of the positioning line;

[0027] Step 1.2.2: The first camera acquires the initial image of the active template 5; the image processor processes the initial image to obtain the outline B2 of the active module;

[0028] Step 1.2.3: Calculate the distance h1 between contour line B1 and contour line B2, and obtain the maximum value of the distance h, denoted as h1a;

[0029] Step 1.2.4: Compare h1a with the set first offset threshold Z1. If h1a is not greater than Z1, it is determined that the placement position of the active template 5 has not shifted. If h1a is greater than Z1, it is determined that the placement position of the active template 5 has shifted.

[0030] Furthermore, the step in step 6 of determining whether the semi-finished anti-slip mat is located in the cut edge area is as follows:

[0031] Step 6.1: Load the preprocessing onto the third camera so that the center of the cutting area captured by the third camera coincides with the center of the two sets of cutters;

[0032] Step 6.2: The third camera captures the fourth image of the semi-finished anti-slip mat, and the vision processing module processes the fourth image to obtain the outline B9 of the surface layer in the fourth image;

[0033] Step 6.3: Obtain the center point O1 of the fourth image; connect the diagonals of the contour line B9 to obtain the center point O2 of the surface layer;

[0034] Step 6.4: Obtain the distance H between center point O1 and center point O2, compare H with the set threshold Z5. If H is not greater than Z5, the center of the semi-finished anti-slip mat coincides with the center of the cutting edge area, and it is determined that the semi-finished anti-slip mat is located in the cutting edge area. Proceed to step 7. If H is greater than Z5, the center of the semi-finished anti-slip mat does not coincide with the center of the cutting edge area, and it is determined that the semi-finished anti-slip mat is not in the cutting edge area. Proceed to step 6.5, and increment the cumulative number of misalignments n of the semi-finished anti-slip mat by 1.

[0035] Step 6.5: Calculate the actual distance H0 between center point O1 and center point O2; H0 = S x H; S is the magnification of the image acquired by the third camera; H is the distance between center point O1 and center point O2 on the image, and H is a known parameter; The conveyor on the edge trimming machine moves the semi-finished anti-slip mat by H0, and execute step 6.2;

[0036] Step 6.6: Determine whether the number of times n of the semi-finished anti-slip mat is misaligned is greater than the set threshold. If yes, determine that the conveyor belt mechanism and / or the conveyor belt of the edge trimming machine are malfunctioning. The controller will pause the conveyor belt mechanism and / or the conveyor belt of the edge trimming machine and activate the alarm. If no, proceed to step 7.

[0037] An anti-slip mat, prepared using the aforementioned anti-slip mat production method, includes a surface layer, a base material, and suction cups. The surface layer and suction cups are located on both sides of the base material, and the surface layer and suction cups are synchronously heat-melted welded to the base material.

[0038] In summary, the advantages of this invention are:

[0039] 1) This invention presses the surface layer, suction cup, and molten substrate together, allowing the surface layer, suction cup, and molten substrate to be simultaneously heat-melted and welded together to form an anti-slip mat. Compared to the conventional solution where the suction cup is injection molded onto the substrate and the substrate and surface layer are bonded together with Velcro, this invention overcomes the shortcomings of conventional solutions that cannot achieve the integral welding of the suction cup, substrate, and surface layer at a single workstation. This simplifies the production process of the anti-slip mat, improves work efficiency, and the heat-melting connection method provides stronger tear strength at the weld joint between the suction cup, surface layer, and substrate compared to conventional solutions, greatly extending the service life of the anti-slip mat.

[0040] 2) This invention monitors the manually laid substrate, surface layer, and movable template using a vision device, effectively reducing the production efficiency and quality problems of suction cup mats caused by human factors, and greatly improving the production efficiency and quality of suction cup mats.

[0041] 3) This invention automatically identifies the position of the excess substrate to be cut line through the edge cutting mechanism and realizes automatic edge cutting, which greatly improves the automation level of suction cup floor mat production. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the anti-slip mat system of the present invention.

[0043] Figure 2 This is an exploded view of the anti-slip mat of the present invention.

[0044] Figure 3 This is an initial schematic diagram of the present invention.

[0045] Figure 4 This is a first schematic diagram of the present invention.

[0046] Figure 5 This is a second schematic diagram of the present invention.

[0047] Figure 6 This is a third schematic diagram of the present invention.

[0048] Figure 7 This is a schematic diagram of the fourth image of the present invention. Detailed Implementation

[0049] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that, unless otherwise specified, the following embodiments and features described therein can be combined with each other.

[0050] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Therefore, the drawings only show the components related to the present invention and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0051] In this embodiment of the invention, all directional indicators (such as up, down, left, right, front, back, lateral, longitudinal, etc.) are only used to explain the relative positional relationship and movement of each component in a specific posture. If the specific posture changes, the directional indicator will also change accordingly.

[0052] Due to installation errors and other reasons, the parallel relationship referred to in the embodiments of the present invention may actually be an approximate parallel relationship, and the perpendicular relationship may actually be an approximate perpendicular relationship.

[0053] Example 1:

[0054] like Figure 1-2 As shown, a production system for an anti-slip mat is provided. The anti-slip mat includes a surface layer 41, a base material 42, and suction cups 43. The system includes a hot-melt device 1, a pressing device 2, a positioning device 3, and a vision device. The hot-melt device 1 melts the base material 42, and the positioning device 3 positions and installs the suction cups 5. The surface layer 41 and the suction cups 5 are located on both sides of the base material 42, respectively. The pressing device 2 presses the surface layer 41 and the suction cups 5 together, and simultaneously heat-melts the surface layer 41 and the suction cups 5 with the base material 42 to form the anti-slip mat.

[0055] The surface layer 41 uses conventional fabric and is located on top of the anti-slip mat. It typically has water absorption properties and is treated with EVA setting adhesive at high temperature. The base material 42 uses TPE elastomer, preferably styrene-based TPR overmolding material. The hardness of the base material 42 is 50-60HA. The base material 42 has strong adhesion to the surface layer, preventing the base material 42 from separating from the surface layer during washing.

[0056] In this embodiment, the hot melt device 1 includes a hot melter and a hot melt table 11. The hot melter is used to melt the substrate 42, and the hot melt table 11 is used to support the substrate 42. The substrate 42 is transported to the hot melter for hot melting through the hot melt table 11. In this embodiment, the determination of the melting state of the substrate 42 is that the substrate 42 is sticky and the surface does not degrease, and the surface begins to smoke.

[0057] The hot melt table 11 is equipped with positioning lines, which are used to position the substrate 42.

[0058] The hot melt machine uses conventional heating devices such as ovens and heating plates to melt the substrate 42. The hot melt temperature and hot melt time are adjusted according to the material of the substrate 42.

[0059] The production system also includes a movable template 5, which has perforations 51. The movable template 5 carries the base material 42. The external dimensions of the movable template 5 match the external dimensions of the base material 42. The hot-melt device 1 is connected to the pressing device 2. The movable template 5 moves between the hot-melt device 1 and the pressing device 2. The movable template 5 located in the hot-melt device 1, along with the molten base material 42 and surface layer 41 it carries, is manually moved to the pressing device 2.

[0060] The pressing device 2 includes a cylinder 20, a frame 21, a pressure plate 22, and a pressing table 23. The cylinder 20 is fixed on the frame 21, the pressure plate 22 is fixed at the output end of the cylinder 20, and the pressing table 23 is located below the pressure plate 22. The cylinder 20 drives the pressure plate 22 to move up and down vertically above the pressing table 23. The positioning device 3 is set on the pressing table 23.

[0061] The pressing device 2 presses the base material 42, the surface layer 41, and the suction cup 43 together, so that the surface layer 41 and the suction cup 43 are simultaneously heat-melted and welded to the molten base material 41 to form a semi-finished anti-slip mat. Compared with the conventional solution where the suction cup is injection molded onto the base material and the base material and the surface layer are bonded together with Velcro, this application overcomes the disadvantage that the conventional solution cannot achieve the integral welding of the suction cup, the base material, and the surface layer at a single station. It simplifies the production process of the anti-slip mat, improves work efficiency, and the heat-melting connection method has a stronger tear strength at the weld joint of the suction cup, the surface layer, and the base material compared with the conventional solution, which greatly improves the service life of the anti-slip mat.

[0062] Preferably, the pressing pressure of the cylinder 20 is set to 3MPa and the pressing time is set to 5 seconds, so as to ensure that the surface of the surface layer 41 is not flattened while the suction cup 43 and the surface layer 41 are fully heat-fused to the substrate 42.

[0063] The positioning device 3 is provided with several suction cup positioning holes 31. The through holes 51 of the movable template 5 correspond one-to-one with the suction cup positioning holes 31. The diameter of the through holes 51 is larger than the diameter of the suction cup 43, which facilitates the separation of the movable template 5 after the anti-slip pad has cooled and solidified. The movable template 5 matches the external dimensions of the positioning device 3. When the movable template 5 and the positioning device 3 are attached, as long as the sides of the two are flush, the through holes 51 can be aligned one-to-one with the suction cup positioning holes 31. This makes it convenient for the staff to align the through holes 51 with the suction cup positioning holes 31. The structure is simple and the operation is convenient.

[0064] The suction cup positioning hole 31 is used to mount the suction cup 43. The suction cup 43 includes a fixed end connected to the substrate 42 and an adsorption end for adsorption. The suction cup 43 is mounted in the suction cup positioning hole 31 with the fixed end on top and the adsorption end on the bottom. The fixed end of the suction cup 43 is flush with the surface of the positioning device 3, so that the fixed end of the suction cup 43 can directly contact the molten substrate 42 carried by the positioning device 3.

[0065] To further ensure the stability of the suction cup 43 when loaded in the positioning device 3, a positioning block is provided in the suction cup positioning hole 31. The outer diameter of the positioning block is smaller than the inner diameter of the suction end of the suction cup 43. When the suction cup 43 is loaded, the positioning block is located inside the suction end to position the loading of the suction cup 43.

[0066] The vision device includes a controller and a first camera, a second camera, an image processor, and an alarm connected to the controller. The first camera and the second camera are respectively connected to the image processor. The controller controls the first camera and the second camera to capture images. The first camera and the second camera acquire images and generate corresponding image signals, and send the image signals to the image processor. The image processor processes the images and outputs a processing signal to the controller. The controller outputs a trigger signal to the alarm based on the processing signal to control the alarm to start the alarm.

[0067] The first camera is positioned above the hot melt table 11 to capture images of the table surface, including an initial image of the movable template 5 on the table surface, a first image of the first integrated body formed by the movable template 5 and the substrate 42, and a second image of the second integrated body formed by the surface layer 41 when it is attached to the first integrated body. The image processor receives the images and processes the initial image, the first image, and the second image to determine whether the placement of the movable template 5, the substrate 42, and the surface layer 41 is correct. If the position is not in the set position, the alarm is activated to remind the staff to rearrange the parts.

[0068] The second camera is located above the positioning device 3 and is used to capture a third image of the second integrated unit on the positioning device 3. The image processor receives the third image and processes it to determine whether the placement of the second integrated unit is correct. If the position is not in the set position, the alarm is activated to remind the staff to rearrange it.

[0069] The production system also includes a cooling mechanism, which cools the semi-finished anti-slip mat to 60°C. After cooling, the semi-finished anti-slip mat is demolded.

[0070] The production system also includes a trimming mechanism, which cuts the excess substrate 42 on the semi-finished anti-slip mat to obtain the finished anti-slip mat. The trimming mechanism includes a conveyor belt mechanism, limiting plates, a third camera, a vision processing module, and a trimming machine. The conveyor belt mechanism is located between the pressing device 2 and the trimming machine, and is connected to both. The semi-finished anti-slip mat is conveyed from the pressing device 2 to the trimming machine via the conveyor belt mechanism. The limiting plates are located on both sides of the conveyor belt mechanism to limit the movement of the semi-finished anti-slip mat during transport, preventing it from shifting. The trimming machine has its own conveyor, which moves the semi-finished anti-slip mat to the trimming area. The third camera is positioned above the trimming area to capture images of the semi-finished anti-slip mat located on the trimming machine. The fourth image is received and transmitted to the vision processing module, which is connected to the controller. The vision processing module receives the image and processes it to determine whether the semi-finished anti-slip mat is located in the cutting area and the cutting line. The center of the cutting area coincides with the center of the two sets of cutters. When the semi-finished anti-slip mat is in the cutting area, the centers of the two coincide. If it is not in the cutting area, the conveyor of the cutting machine will move the semi-finished anti-slip mat a certain distance to determine whether the semi-finished anti-slip mat is in the cutting area. If the semi-finished anti-slip mat is misaligned multiple times, it is determined that the conveyor belt mechanism and / or the conveyor of the cutting machine are malfunctioning. The controller will stop the conveyor belt mechanism and / or the conveyor of the cutting machine and activate the alarm.

[0071] The edge trimming machine includes a cutter, a cutter displacement mechanism, a cutting rotation mechanism, and a cutting drive mechanism. There are two sets of cutters, each connected to a cutter displacement mechanism. The cutter displacement mechanism controls the cutter to move to the position of the line to be cut. The cutter displacement mechanism is located in the cutting rotation mechanism, which controls the cutter and the cutter displacement mechanism to rotate 90°. The cutting rotation mechanism is located in the cutting drive mechanism, which controls the cutter to move downwards and trim the edge along the line to be cut, thus obtaining the finished anti-slip mat.

[0072] In this embodiment, the movable template 5 is placed on the hot melt table 11. The first camera captures an initial image of the movable template 5 on the surface of the hot melt table 11. The image processor processes the initial image to determine whether the position of the movable template 5 is within the set position. The set position of the movable template 5 is that it is within the positioning line of the hot melt table 11. If not, an alarm is activated to remind the staff to readjust until the position of the movable template 5 is within the set position. The substrate 42 is then placed on the movable template 5. The first camera captures a first image of the first integrated body. The image processor processes the first image to determine whether the position of the substrate 42 on the movable template 5 is within the set position. The set position of the substrate 42 is that it is flush with the movable template 5. If not, an alarm is activated to remind the staff to readjust until the position of the substrate 42 is within the set position. The hot melt table 11 transports the movable template 5 and the substrate 42 to the hot melt machine for hot melting. When the substrate 42 reaches a molten state, the movable template 5 and the substrate 42 are removed from the hot melt machine. The surface layer 41 is placed on the molten substrate 42. The first camera captures a second image of the second integrated body. The image processor processes the second image to determine if the position of the surface layer 41 is within the set position. If not, an alarm is activated to remind the staff to readjust until the surface layer 41 is within the set position. The set position of the surface layer 41 is that it is located in the middle of the substrate 42. The suction cup 43 is mounted on the positioning device 3, which moves the second integrated body to the positioning device 3. The second camera captures the third image, and the image processor processes the third image to determine if the position of the second integrated body is within the set position. If not, an alarm is activated to remind the staff to readjust. Until the second integrated body is positioned at the set position, where the movable module 5 is flush with the positioning device 3, the through hole 51 of the movable module 5 corresponds one-to-one with the suction cup positioning hole 31 of the positioning device 3. The cylinder 20 starts the pressure plate 22 to press down and press the second integrated body tightly, so that the surface layer 41 and the suction cup 43 are hot-melted and welded with the molten base material 41 to obtain a semi-finished anti-slip mat. The cooling mechanism cools down the semi-finished anti-slip mat. After the semi-finished anti-slip mat is cooled, it is demolded. The edge cutting mechanism cuts off the excess base material 42 on the semi-finished anti-slip mat to obtain the finished anti-slip mat.

[0073] like Figure 3-7As shown, this application also provides a method for producing an anti-slip mat, based on the above-described anti-slip mat production system, comprising the following steps:

[0074] Step 1: Place the movable template 5 and the base material 42 in the designated positions on the hot melt table 11;

[0075] Step 2: The hot melt table 11 conveys the movable template 5 and the base material 42 to the hot melt machine for hot melting until the base material 42 reaches a molten state and is then removed.

[0076] Step 3: Place the surface layer 41 at the designated position on the substrate 42;

[0077] Step 4: Move the second integrated body, consisting of the movable template 5, the base material 42, and the surface layer 41, onto the positioning device 3 with the suction cup 43 already loaded. Determine whether the placement position of the second integrated body is the set position. If yes, proceed to step 5. If no, adjust the placement position of the second integrated body.

[0078] Step 5: The cylinder 20 controls the pressure plate 22 to press down, pressing the second integrated body tightly, so that the surface layer 41 and the suction cup 43 are hot-melted and welded to the molten base material 41 to obtain a semi-finished anti-slip mat.

[0079] Step 6: The cooling mechanism cools down the semi-finished anti-slip mat, the semi-finished anti-slip mat is demolded, the conveyor belt mechanism transports the semi-finished anti-slip mat from the pressing device 2 to the edge cutting machine, and limits it by the limiting plate. The edge cutting machine moves the semi-finished anti-slip mat to the edge cutting area.

[0080] Step 7: The edge trimming machine trims the excess base material 42 along the cutting line to obtain the finished anti-slip mat;

[0081] Step 8: End of steps.

[0082] Step 1, placing the movable template 5 and the base material 42 at the designated positions on the hot melt table 11, involves the following steps:

[0083] Step 1.1: Place the movable template 5 on the hot melt table 11;

[0084] Step 1.2: The first camera captures the initial image of the active template 5 and determines whether the placement position of the active template 5 is offset. If yes, the alarm is activated and step 1.1 is executed; otherwise, step 1.3 is executed.

[0085] Step 1.3: Place the base material 42 on the movable template 5;

[0086] Step 1.4: The first camera captures the first image of the substrate 42 and determines whether the placement position of the substrate 42 is offset. If yes, the alarm is activated and step 1.3 is executed; otherwise, step 2 is executed.

[0087] The step in step 1.2 to determine whether the placement position of the active template 5 is offset is as follows:

[0088] Step 1.2.1: The first camera acquires image A of the hot melt table 11 surface, and the image processor processes image A to obtain the contour line B1 of the positioning line 111;

[0089] Step 1.2.2: The first camera acquires the initial image of the active template 5; the image processor processes the initial image to obtain the outline B2 of the active module 5;

[0090] Step 1.2.3: Calculate the distance h1 between contour line B1 and contour line B2, and obtain the maximum value of the distance h, denoted as h1a;

[0091] Step 1.2.4: Compare h1a with the set first offset threshold Z1. If h1a is not greater than Z1, it is determined that the placement position of the active template 5 has not shifted. If h1a is greater than Z1, it is determined that the placement position of the active template 5 has shifted.

[0092] The specific steps for determining whether the placement position of substrate 42 is offset in step 1.4 are as follows:

[0093] Step 1.4.1: The first camera acquires an initial image of the active template 5, whose position has not shifted; the image processor processes the initial image to obtain the outline B3 of the active module 5;

[0094] Step 1.4.2: The first camera acquires a first image of the substrate 42; the image processor processes the first image to obtain the outline B4 of the substrate 42;

[0095] Step 1.4.3: Calculate the spacing h2 between contour line B3 and contour line B4, and obtain the maximum value of spacing h2, denoted as h2a;

[0096] Step 1.4.4: Compare h2a with the set second offset threshold Z2. If h2a is not greater than Z2, it is determined that the placement position of the substrate 42 has not shifted. If h2a is greater than Z2, it is determined that the placement position of the substrate 42 has shifted.

[0097] Step 3, which involves placing the surface layer 41 at the designated position on the substrate 42, is as follows:

[0098] Step 3.1: The first camera acquires a first image of the substrate 42 with its position unchanged; the image processor processes the first image to obtain the outline B5 of the substrate 42;

[0099] Step 3.2: The first camera acquires a second image of the surface layer 41; the image processor processes the second image to obtain the outline B6 of the surface layer 41;

[0100] Step 3.3: Calculate the spacing h3 between contour line B5 and contour line B6, and obtain the maximum value of spacing h3, denoted as h3a;

[0101] Step 3.4: Compare h3a with the set third offset threshold Z3. If h3a is not greater than Z3, it is determined that the placement position of the surface layer 41 is in the set position. If h3a is greater than Z3, it is determined that the placement position of the surface layer 41 has shifted. Adjust the placement position of the surface layer 41 and execute step 3.1.

[0102] The specific steps for determining whether the placement position of the second integrated component is the set position in step 4 are as follows:

[0103] Step 4.1: The second camera acquires image C of the positioning device 3, and the image processor processes image C to obtain the outline B7 of the positioning device 3;

[0104] Step 4.2: The second camera acquires a third image of the second integrated module; the image processor processes the third image to obtain the outline B8 of the active module 5 in the second integrated module;

[0105] Step 4.3: Calculate the spacing h4 between contour line B7 and contour line B8, and obtain the maximum value of spacing h4, denoted as h4a;

[0106] Step 4.4: Compare h4a with the set fourth offset threshold Z4. If h4a is not greater than Z4, determine that the placement position of the second integrated body is at the set position. If h4a is greater than Z4, determine that the placement position of the second integrated body has shifted.

[0107] The steps in step 6 to determine whether the semi-finished anti-slip mat is located in the cut edge area are as follows:

[0108] Step 6.1: Load the preprocessing onto the third camera so that the center of the cutting area captured by the third camera coincides with the center of the two sets of cutters;

[0109] Step 6.2: The third camera captures the fourth image of the semi-finished anti-slip mat, and the vision processing module processes the fourth image to obtain the outline B9 of the surface layer in the fourth image;

[0110] Step 6.3: Obtain the center point O1 of the fourth image; connect the diagonals of the contour line B9 to obtain the center point O2 of the surface layer;

[0111] Step 6.4: Obtain the distance H between center point O1 and center point O2, compare H with the set threshold Z5. If H is not greater than Z5, the center of the semi-finished anti-slip mat coincides with the center of the cutting edge area, and it is determined that the semi-finished anti-slip mat is located in the cutting edge area. Proceed to step 7. If H is greater than Z5, the center of the semi-finished anti-slip mat does not coincide with the center of the cutting edge area, and it is determined that the semi-finished anti-slip mat is not in the cutting edge area. Proceed to step 6.5, and increment the cumulative number of misalignments n of the semi-finished anti-slip mat by 1.

[0112] Step 6.5: Calculate the actual distance H0 between center point O1 and center point O2; H0 = S x H; S is the magnification of the image acquired by the third camera; H is the distance between center point O1 and center point O2 on the image, and H is a known parameter; The conveyor on the edge trimming machine moves the semi-finished anti-slip mat by H0, and execute step 6.2;

[0113] The limiting plate in this embodiment effectively prevents the semi-finished anti-slip mat from tilting, so only the straight-line distance between the center point O1 and the center point O2 needs to be considered;

[0114] Step 6.6: Determine whether the number of times n of the semi-finished anti-slip mat is misaligned is greater than the set threshold. If yes, determine that the conveyor belt mechanism and / or the conveyor belt of the edge trimming machine are malfunctioning. The controller will stop the conveyor belt mechanism and / or the conveyor belt of the edge trimming machine and activate the alarm. If no, proceed to step 7.

[0115] The specific steps for step 7 are as follows:

[0116] Step 7.1: The third camera captures a fourth image of the semi-finished anti-slip mat, and the image processor processes the fourth image to obtain the outline B10 and center point O of the surface layer 41;

[0117] Step 7.2: Obtain the distances H1 and H2 between the outline B10 in the length and width directions and the center point O in the fourth image;

[0118] Step 7.3: Calculate the actual spacing. Set the actual spacing between the contour line B10 in the length direction and the center point O as L, and the actual spacing between the contour line B10 in the width direction and the center point O as W. The magnification of the image acquired by the third camera is S.

[0119] L = H1XS; W = H2XS;

[0120] Step 7.4: Calculate the distance the cutter moves along the length of surface layer 41;

[0121] In this embodiment, the two sets of cutters are symmetrically distributed around the center of the slicing area. The distance between the cutter and the center of the slicing area is a set value Q. The center point O of the surface layer 41 coincides with the center of the slicing area. The distance the cutter moves in the length direction of the surface layer 41 is set as L1, where L1 = LQ.

[0122] Step 7.5: The cutter displacement mechanism controls the cutter to move L1 to the line to be cut along the length of the surface layer 41;

[0123] Step 7.6: The cutting drive mechanism controls the cutter to move downwards and cut along the line to be cut;

[0124] Step 7.7: The cutting rotation mechanism controls the cutter to rotate 90°;

[0125] Step 7.8: Calculate the distance the cutter moves in the width direction of surface layer 41;

[0126] The distance the cutter moves in the width direction of surface layer 41 is set as W1, where W1 = WQ;

[0127] Step 7.9: The cutter displacement mechanism controls the cutter to move L1 to the line to be cut in the width direction of surface layer 41;

[0128] Step 7.10: The cutting drive mechanism controls the cutter to move down and cut along the line to be cut.

[0129] Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

Claims

1. A production system for anti-slip mats, used for producing anti-slip mats, the anti-slip mats comprising a surface layer, a base material, and suction cups, characterized in that: The system includes a hot-melt device, a pressing device, and a positioning device. The hot-melt device is connected to the pressing device. The hot-melt device includes a hot-melt fusion device and a hot-melt table. The hot-melt fusion device melts the substrate. The hot-melt table has a movable template on which the substrate is placed. The positioning device positions and installs suction cups. The surface layer and suction cups are located on both sides of the molten substrate. The pressing device presses the surface layer and suction cups together, simultaneously hot-melting and welding them to the substrate to form an anti-slip mat. The movable template has perforations, and the positioning device has several suction cup positioning holes for mounting suction cups. The perforations of the movable template correspond one-to-one with the suction cup positioning holes. The pressing device includes a cylinder, a frame, a pressure plate, and a pressure table. The cylinder is fixed to the frame, the pressure plate is fixed to the output end of the cylinder, and the pressure table is located below the pressure plate. The cylinder drives the pressure plate to move vertically up and down above the pressure table. The positioning device is located on the pressure table. The system also includes a vision device, which includes a controller and... The system includes a first camera, a second camera, an image processor, and an alarm connected to a controller. The first and second cameras are respectively connected to the image processor. The controller controls the first and second cameras to capture images. The first and second cameras acquire images and generate corresponding image signals, which are then sent to the image processor. The image processor processes the images and outputs a processing signal to the controller. The controller outputs a trigger signal to the alarm based on the processing signal to activate the alarm. The first camera captures an initial image of the movable template on the hot melt table surface, a first image of the first integrated body formed by the movable template and the substrate, and a second image of the second integrated body formed by the surface layer being attached to the first integrated body. It determines whether the placement of the movable template, the substrate, and the surface layer is correct. The second camera captures a third image of the second integrated body on the positioning device to determine whether the placement of the second integrated body is correct.

2. The anti-slip mat production system according to claim 1, characterized in that: It also includes a cooling mechanism that cools the semi-finished anti-slip mat.

3. The anti-slip mat production system according to claim 1, characterized in that: It also includes a trimming mechanism, which comprises a conveyor belt mechanism, a limiting plate, a third camera, a vision processing module, and a trimming machine. The conveyor belt mechanism is located between the pressing device and the trimming machine, and is connected to both the pressing device and the trimming machine respectively. The limiting plate is located on both sides of the conveyor belt mechanism to limit the movement of the semi-finished anti-slip mat during the conveying process. The third camera is set above the trimming area to capture a fourth image of the semi-finished anti-slip mat located on the trimming machine and transmit the image to the vision processing module. The vision processing module is connected to the controller. The vision processing module receives the image and processes the fourth image to determine whether the semi-finished anti-slip mat is located in the trimming area and the cutting line. The center of the trimming area coincides with the center of the two sets of cutters. When the semi-finished anti-slip mat is located in the trimming area, the centers of the two coincide.

4. A method for producing an anti-slip mat, characterized in that: Includes the following steps: Step 1: Place the movable template and base material in the designated positions on the hot melt table; Step 1.1: Place the movable template on the hot melt table; Step 1.2: The first camera captures the initial image of the active template and determines whether the placement position of the active template is offset. If yes, the alarm is activated and step 1.1 is executed; otherwise, step 1.3 is executed. Step 1.3: Place the substrate on the movable template; Step 1.4: The first camera captures the first image of the substrate and determines whether the placement of the substrate is off-center. If yes, the alarm is activated and step 1.3 is executed; otherwise, step 2 is executed. Step 2: The hot melt table transports the movable template and substrate to the hot melt machine for hot melting until the substrate reaches a molten state and is then removed. Step 3: Place the top layer in the designated position on the substrate; Step 4: Move the second integrated body, consisting of the movable template, base material and surface layer, onto the positioning device with the suction cups already loaded. Determine whether the placement position of the second integrated body is the set position. If yes, proceed to step 5. If no, adjust the placement position of the second integrated body. Step 4.1: The second camera acquires image C of the positioning device, and the image processor processes image C to obtain the outline B7 of the positioning device; Step 4.2: The second camera acquires a third image of the second integrated module; the image processor processes the third image to obtain the outline B8 of the active module in the second integrated module; Step 5: The cylinder controls the pressure plate to press down, pressing the second integrated body tightly, so that the surface layer and suction cup are thermally welded to the molten base material to obtain a semi-finished anti-slip mat; Step 6: The cooling mechanism cools down the semi-finished anti-slip mat, the semi-finished anti-slip mat is demolded, the conveyor belt mechanism transports the semi-finished anti-slip mat from the pressing device to the edge cutting machine, and limits it by the limiting plate. The edge cutting machine moves the semi-finished anti-slip mat to the edge cutting area. Step 7: The edge trimming machine trims off the excess base material along the cutting line to obtain the finished anti-slip mat; Step 8: End of steps.

5. A method for producing an anti-slip mat according to claim 4, characterized in that: The step in step 1.2 to determine whether the placement position of the active template is offset is as follows: Step 1.2.1: The first camera acquires image A of the hot melt table surface, and the image processor processes image A to obtain the outline B1 of the positioning line; Step 1.2.2: The first camera acquires the initial image of the active template (5); the image processor processes the initial image to obtain the outline B2 of the active module; Step 1.2.3: Calculate the distance h1 between contour line B1 and contour line B2, and obtain the maximum value of the distance h, denoted as h1a; Step 1.2.4: Compare h1a with the set first offset threshold Z1. If h1a is not greater than Z1, it is determined that the placement position of the active template 5 has not shifted. If h1a is greater than Z1, it is determined that the placement position of the active template (5) has shifted.

6. The method for producing an anti-slip mat according to claim 4, characterized in that: The steps in step 6 to determine whether the semi-finished anti-slip mat is located in the cut edge area are as follows: Step 6.1: Load the preprocessing onto the third camera so that the center of the cutting area captured by the third camera coincides with the center of the two sets of cutters; Step 6.2: The third camera captures a fourth image of the semi-finished anti-slip mat, and the vision processing module processes the fourth image to obtain the outline B9 of the surface layer in the fourth image; Step 6.3: Obtain the center point O1 of the fourth image; connect the diagonals of the contour line B9 to obtain the center point O2 of the surface layer; Step 6.4: Obtain the distance H between center point O1 and center point O2, compare H with the set threshold Z5. If H is not greater than Z5, the center of the semi-finished anti-slip mat coincides with the center of the cutting edge area, and the semi-finished anti-slip mat is determined to be located in the cutting edge area. Proceed to step 7. If H is greater than Z5, the center of the semi-finished anti-slip mat does not coincide with the center of the cutting edge area, and the semi-finished anti-slip mat is determined to be not in the cutting edge area. Proceed to step 6.5, and increment the cumulative number of misalignments n of the semi-finished anti-slip mat by 1. Step 6.5: Calculate the actual distance H0 between center point O1 and center point O2; H0 = S x H; S is the magnification of the image acquired by the third camera; H is the distance between center point O1 and center point O2 on the image, and H is a known parameter; The conveyor on the edge trimming machine moves the semi-finished anti-slip mat by H0, and execute step 6.2; Step 6.6: Determine whether the number of times n of the semi-finished anti-slip mat is misaligned is greater than the set threshold. If yes, determine that the conveyor belt mechanism and / or the conveyor belt of the edge trimming machine are malfunctioning. The controller will pause the conveyor belt mechanism and / or the conveyor belt of the edge trimming machine and activate the alarm. If no, proceed to step 7.

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