A discrete assembly automation system and method of operation adapted to vehicle light manufacturing iterations

Abstract

The application discloses a kind of discrete assembly automation systems and working methods suitable for car light manufacturing iteration, the discrete assembly automation systems suitable for car light manufacturing iteration include X unit module, AGV dolly, flexible production line module rack, intelligent tooling and X unit module management workstation;The X unit module is used to control the production equipment and measuring instrument on lamp product production line to execute action;The AGV dolly is used to flow between X unit module management workstation and flexible production line module rack with X unit module transport;The intelligent tooling is used to position clamping lamp product and store lamp product detection information.The application provides a kind of discrete assembly automation systems and working methods suitable for car light manufacturing iteration, realize that production line is in minimum range Structural modification is carried out, with optimal quality guarantee, least manual intervention and minimum upgrade iteration cost and development cycle simultaneously.

Description

Technical Field

[0001] This invention relates to a discrete assembly automation system and working method adapted to the iterative manufacturing of automotive lights, belonging to the field of automotive parts assembly technology. Background Technology

[0002] Currently, with increasingly fierce market competition, customers have higher and higher demands for products. In this environment, manufacturing companies face unprecedented challenges in achieving success. Take the automotive lighting industry as an example: to capture user traffic, automakers constantly launch new models to maintain brand competitiveness. New models iterate rapidly in the market, undergoing model upgrades every year or even every six months. Correspondingly, the headlights also need to be upgraded. Headlights pursue novel appearances, and their internal structures are divided into high, medium, and low configurations, incorporating multiple functions and communication methods.

[0003] Therefore, traditional automated assembly lines designed for large-volume customization are no longer sufficient to meet the demands of today's market characterized by small-batch, diversified, and personalized production. Dedicated automated production lines for single products need to be completely redesigned to adapt to product flexibility and technological iteration.

[0004] The hardware equipment integrated into the racks of an old production line has almost no recycling value for a new production line. However, the electrical control components for control, detection, and process parameters on the old production line represent the best accumulated production technology and quality assurance for automotive lighting assembly. For highly integrated traditional automated production lines, completely overhauling the old line and developing a new one requires redeveloping and upgrading the electrical control components, which increases development difficulty and risk, resulting in wasted manpower, time, and resources. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a discrete assembly automation system and working method that adapts to the iterative manufacturing of automotive lights, so as to realize the structural transformation of the production line within a minimal scope, while having the best quality assurance, the least amount of manual intervention, and the lowest upgrade and iteration costs and development cycle.

[0006] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows:

[0007] This invention provides a discrete assembly automation system adapted to the iterative manufacturing of automotive lights, which includes an X-unit module, an AGV trolley, a flexible production line module frame, intelligent tooling, and an X-unit module management workstation.

[0008] The X unit module is used to control the production equipment and measuring instruments on the lighting product production line to perform actions.

[0009] The AGV is used to transport the X-unit module between the X-unit module management workstation and the flexible production line module rack.

[0010] The intelligent tooling is used to position and clamp the lighting products and store the lighting product testing information;

[0011] The flexible production line module frame is used to install intelligent tooling and X-unit modules, and communicates and interacts with intelligent tooling and X-unit modules respectively. In the working state, it monitors and extracts the lamp product testing information on the intelligent tooling in real time.

[0012] The X-unit module management workstation is used to centrally manage and adaptively iteratively upgrade and maintain different types of X-unit modules according to the characteristics and requirements of different lighting products.

[0013] Furthermore, the X-unit module management workstation includes an X-unit module technical management room, a robot vision appearance inspection system control cabinet, a connecting lifting platform, an intelligent warehousing system control screen, a shelf transfer robot, a robot vision appearance inspection system, and an intelligent storage rack;

[0014] The X-unit module performs updates to lighting product assembly processes, iterates lighting product testing procedures, and matches general interface definitions in the X-unit module technical management room.

[0015] The connecting lifting platform is used to load and unload the X unit module on the AGV and lift it to the visual inspection area of ​​the robot visual appearance inspection system.

[0016] The robot vision appearance inspection system is used to perform appearance inspection on the X unit module on the docking lifting platform.

[0017] The robot vision appearance inspection system control cabinet is used to send control commands to the robot vision appearance inspection system and control the robot vision appearance inspection system.

[0018] The shelf transfer robot is used to transfer intact X-unit modules to various storage partitions of the smart warehouse rack.

[0019] The intelligent storage rack is equipped with multiple storage partitions for storing X-unit modules transported by the rack transfer robot;

[0020] The intelligent warehousing system control panel is used to display the name, type, quantity, and status information of the X unit modules on the intelligent storage rack.

[0021] Furthermore, the X unit module has a built-in lighting product assembly process program, lighting product testing program, and data storage module.

[0022] Furthermore, multiple AGV vehicles are installed.

[0023] Furthermore, the X unit module is configured in multiple ways.

[0024] Furthermore, the flexible production line module frame, along with the X-unit modules and intelligent tooling installed on the flexible production line module frame, together constitute a unit workstation.

[0025] Furthermore, the unit workstation is provided in two units, which are spliced ​​together, with one unit workstation as the main workstation and the other unit workstation as the backup workstation.

[0026] Another aspect of the present invention provides a method for operating a discrete assembly automation system adapted to the iterative manufacturing of automotive lights, comprising:

[0027] Step S1: Based on the type of lighting product, the X Unit Module Technical Management Office sends the corresponding X Unit Module call command;

[0028] Step S2: The shelf transfer robot places the X unit module on the smart storage shelf onto the connecting lifting platform. The connecting lifting platform loads the X unit module onto the AGV trolley, and then the AGV trolley transports the X unit module to the X unit module technical management room.

[0029] Step S3: Perform corresponding technical management on the X unit module in the X unit module technical management room. The technical management includes updating the lighting product assembly process, iterating the lighting product testing program, and matching the general interface definition.

[0030] Step S4: The AGV trolley transports the X unit module that has completed technical management to the connecting lifting platform. The connecting lifting platform lifts the X unit module on the AGV trolley to the visual inspection area of ​​the robot visual appearance inspection system, and the robot visual appearance inspection system performs appearance inspection on the X unit module.

[0031] Step S5: The connecting lifting platform transports the intact X-unit module to the AGV trolley, and the AGV trolley transports the X-unit module to the flexible production line module rack.

[0032] Step S6: After the X unit module is installed in place, the X unit module controls the production equipment and measuring instruments on the lighting product production line to perform actions.

[0033] By adopting the above technical solution, the present invention has the following beneficial effects:

[0034] 1. This invention transforms a company's production methods by comprehensively planning and dividing traditional automated production lines into several modular standard units. These standardized modules are endowed with the technical attribute of independent iterative upgrades. Standardized communication interfaces are implemented to enable the combination and assembly of X-unit modules with flexible production line module frames, allowing for the reusability of the X-unit modules. This helps companies quickly adapt to the current volatile and uncertain market environment, flexibly adapting to multi-variety, small-batch, make-to-order production tasks.

[0035] 2. This invention employs information management to centrally manage these X-unit modules, allocate process formula programs, and distribute them to the workstations of each production line automation unit. The X-unit modules undergo technical optimization, innovation, and iteration at the X-unit module management workstation, enabling recycling, X-unit upgrades, and real-time traceability of TPM history.

[0036] 3. This invention uses the X-unit module as a link between the new production line and the old production line, and inherits the process technology in a modular way, effectively reducing the design risk and development difficulty of the new production line, achieving the best quality assurance, the lowest replacement and upgrade cost, and an efficient production line manufacturing cycle.

[0037] 4. This invention can ensure high-quality and rapid product delivery. At the same time, the X-unit module and flexible production line module frame, which are universal on automated production lines, can be modularly and independently upgraded and iterated. With technological innovation, the X-unit module and flexible production line module frame can be recycled and reused, helping enterprises to maintain their competitive advantage in the industry.

[0038] 5. This invention is suitable for large-scale customization, small-batch production, and make-to-order production models. It adapts to changes in customer demand to formulate production plans, enabling rapid model changeover and make-to-order production with high flexibility. The X-unit module continuously links the old and new production line processes, representing a sustainable development technology that combines inheritance and reference. Automated production lines based on this concept can shorten development cycles when upgrading products, switching characteristics, or changing states, achieving optimal quality assurance, minimal structural modifications, minimal human intervention, and the lowest upgrade and iteration costs and development cycles. It also offers stronger human-machine collaboration, safer operation, lower development and iteration costs for both new and old production lines, and rational architectural space management. Attached Figure Description

[0039] Figure 1 This is a diagram of the equipment architecture of a discrete assembly automation system adapted to the iterative manufacturing of automotive lights according to the present invention.

[0040] Figure 2 This is a device architecture diagram of the X-unit module management workstation of the present invention. Detailed Implementation

[0041] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0042] Example 1

[0043] like Figure 1 As shown, this embodiment provides a discrete assembly automation system adapted to the iterative manufacturing of automotive lights, which includes an X-unit module 1, an AGV trolley 2, a flexible production line module frame 3, intelligent tooling 4, and an X-unit module management workstation 5.

[0044] X-Unit Module 1 is a control and testing module divided according to the assembly processes and testing requirements of different types of lighting products. X-Unit Module 1 contains built-in lighting product assembly process programs, lighting product testing programs, and data storage modules. It is used to control the production equipment and measuring instruments on the lighting product production line to perform actions, such as: sealing testing module, brightness testing module, and execution control module. Multiple X-Unit Modules are available, the specific number depending on the needs of the lighting production line. The X-Modular Unit acts as a link between new and old production lines, transferring process technology in a modular way, effectively reducing the design risks and development difficulties of new production lines, achieving optimal quality assurance, lowest upgrade costs, and efficient production line manufacturing cycles.

[0045] Multiple AGV carts 2 are set up to transport X-unit modules 1 between the X-unit module management workstation 5 and the flexible production line module frame 3, replacing manual labor and realizing the automatic flow of X-unit modules 1.

[0046] The intelligent tooling 4 is used to position and clamp lighting products and store lighting product testing information. It also has an interface for communication and interaction with the flexible production line module frame 3.

[0047] The flexible production line module frame 3 is used to install the intelligent tooling 4 and the X-unit module 1, and communicates and interacts with both. During operation, it monitors and extracts real-time testing information of the lighting products on the intelligent tooling 4. The flexible production line module frame 3 features a three-station, two-operation-face design, opening up more space and allowing more personnel to participate in simultaneous assembly and collaborative work on large-sized product workpieces. The multi-process integrated flexible production line module frame 3 enables parallel assembly, simplifying complex processes and simplifying large-scale production.

[0048] The flexible production line module frame 3, along with the X-unit modules 1 and intelligent tooling 4 mounted on it, together constitute a unit workstation. For excessively long lighting products, two flexible production line module frames 3 can be combined and assembled, similar to connecting train carriages in series. One unit workstation serves as the primary workstation, while the other acts as a backup, allowing the other to be started even if one malfunctions. By disassembling the equipment into flexible production line module frames 3 and individual X-unit modules 1, and assembling them into unit workstations according to the assembly process requirements of the lighting products, in conjunction with the intelligent tooling 4, the production line design and development can save half the processing cycle and production line costs, making it more suitable for the current discrete assembly of products.

[0049] X-unit module management workstation 5 is used to centrally manage and adaptively iteratively upgrade and maintain different types of X-unit modules 1 according to the characteristics and requirements of different lighting products.

[0050] like Figure 2 As shown, the X-unit module management workstation 5 in this embodiment includes an X-unit module technical management room 51, a robot vision appearance inspection system control cabinet 52, a connecting lifting platform 53, an intelligent warehousing system control screen 54, a shelf transfer robot 55, a robot vision appearance inspection system 56, and an intelligent storage rack 57.

[0051] The X-unit module technical management room 51 is managed by professional technicians. Within the X-unit module technical management room 51, X-unit module 1 undergoes updates to lighting product assembly processes, iterations to lighting product testing procedures, and matching of universal interface definitions. By establishing the X-unit module technical management room 51, professional technicians perform daily maintenance, technological innovation, and centralized management of the X-module units, enabling the recycling of X-module units.

[0052] The purpose of establishing the X-Module Unit Technology Management Office is to fully involve personnel in the upgrade process of automated and flexible production line systems. This involves improving the skills of professional personnel and iterating the technology of the X-Module Units in sync with daily TPM maintenance. This new concept goes beyond simply copying traditional production methods to automate a few product processes; it's about continuous improvement through lean manufacturing, enabling the sustainable recycling of value from each X-Module Unit.

[0053] The connecting lifting platform 53 is used to load and unload the X unit module 1 on the AGV trolley 2 and lift it to the visual inspection area of ​​the robot visual appearance inspection system 56.

[0054] The robot vision appearance inspection system 56 is used to perform appearance inspection on the X unit module 1 on the docking lifting platform 53. The robot vision appearance inspection system 56 performs a full appearance inspection of the X unit module 1 to prevent damaged X unit module 1 chassis from being mixed into the intelligent storage rack 57 during transportation by the AGV trolley 2. The robot vision appearance inspection system control cabinet 52 is used to send control commands to the robot vision appearance inspection system 56 to control the robot vision appearance inspection system 56.

[0055] The intelligent storage rack 57 is equipped with multiple storage partitions, and the rack transfer robot 55 is used to transfer the intact X unit module 1 to each storage partition of the intelligent storage rack 57.

[0056] The intelligent warehousing system control panel 54 is used to display the name, type, quantity, and status information of the X unit module 1 on the intelligent storage rack 57.

[0057] Example 2

[0058] This embodiment provides a working method for the discrete assembly automation system adapted to the iterative manufacturing of automotive lights, as described in Embodiment 1. It includes:

[0059] Step S1: Based on the type of lighting product, the X-unit module technical management room 51 sends the corresponding X-unit module 1 call command and selects the required X-unit module 1, such as the sealing detection module, brightness detection module, and execution control module.

[0060] Step S2: After selecting the required X-unit module 1, the shelf transfer robot 55 places the X-unit module 1 on the intelligent storage rack 57 onto the connecting lifting platform 53. The connecting lifting platform 53 loads the X-unit module 1 onto the AGV trolley 2, and then the AGV trolley 2 transports the X-unit module 1 to the X-unit module technical management room 51.

[0061] Step S3: Professional technicians in the X Unit Module Technical Management Room 51 perform corresponding technical management for each X Unit Module 1. Technical management includes updating the assembly process of lighting products, iterating the testing procedures for lighting products, and matching the definition of general interfaces.

[0062] Step S4: The AGV trolley 2 transports the X unit module 1, which has completed technical management, to the connecting lifting platform 53. The connecting lifting platform 53 lifts the X unit module 1 on the AGV trolley 2 to the visual inspection area of ​​the robot visual appearance inspection system 56, and the robot visual appearance inspection system 56 performs a full appearance inspection on the X unit module 1.

[0063] Step S5: The connecting lifting platform 53 transports the intact X unit module 1 to the AGV trolley 2, and the AGV trolley 2 transports the X unit module 1 to the flexible production line module frame 3.

[0064] Step S6: After the X unit module 1 is installed in place, the X unit module 1 controls the production equipment and measuring instruments on the lighting product production line to perform actions.

[0065] The automated production system utilizing this invention is a preferred solution for manufacturing enterprises exploring innovation. Its philosophy emphasizes simplification over detail, breaking down complex tasks into easily achievable steps. It primarily restructures production assembly patterns through the following five methods:

[0066] 1. Breakdown: Decompose the product according to size and function;

[0067] 2. Cutting: The assembly process is divided into steps;

[0068] 3. Separation: Separate the integrated communication cabling using standard quick-connect interfaces;

[0069] 4. Dispersed: Dispersed and centralized management of X unit module 1;

[0070] 5. Chain: The X unit module 1 and the equipment are connected in series or parallel to form a production line through system scheduling.

[0071] By redesigning the production line through the above steps, we can improve lean manufacturing and rapid product delivery capabilities, reduce costs, and build a digital operating system to achieve seamless flow of production information.

[0072] The specific embodiments described above further illustrate the technical problems, technical solutions, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A discrete assembly automation system adapted to iterative automotive lighting manufacturing, characterized in that: It includes an X-unit module (1), an AGV trolley (2), a flexible production line module frame (3), intelligent tooling (4), and an X-unit module management workstation (5); The X unit module (1) is used to control the production equipment and measuring instruments on the lighting product production line to perform actions; The AGV (2) is used to transport the X unit module (1) between the X unit module management workstation (5) and the flexible production line module frame (3); The intelligent tooling (4) is used to position and clamp the lighting products and store the lighting product testing information; The flexible production line module frame (3) is used to install the intelligent tooling (4) and the X unit module (1), and communicates with the intelligent tooling (4) and the X unit module (1) respectively, and monitors and extracts the lamp product testing information on the intelligent tooling (4) in real time during operation. The X-unit module management workstation (5) is used to centrally manage and adaptively iteratively upgrade and maintain different types of X-unit modules (1) according to the characteristics and requirements of different lighting products.

2. The discrete assembly automation system adapted to the iterative manufacturing of automotive lights according to claim 1, characterized in that: The X-unit module management workstation (5) includes an X-unit module technical management room (51), a robot vision appearance inspection system control cabinet (52), a connecting lifting platform (53), an intelligent warehousing system control screen (54), a shelf transfer robot (55), a robot vision appearance inspection system (56), and an intelligent storage rack (57). The X unit module (1) performs updates on lighting product assembly processes, iterates on lighting product testing procedures, and matches general interface definitions in the X unit module technical management room (51). The connecting lifting platform (53) is used to load and unload the X unit module (1) on the AGV trolley (2) and lift it to the visual inspection area of ​​the robot visual appearance inspection system (56); The robot visual appearance inspection system (56) is used to perform appearance inspection on the X unit module (1) on the docking lifting platform (53); The robot visual appearance inspection system control cabinet (52) is used to send control commands to the robot visual appearance inspection system (56) and control the robot visual appearance inspection system (56); The shelf transfer robot (55) is used to transfer the intact X unit module (1) to each storage partition of the smart storage rack (57); The intelligent storage rack (57) is equipped with multiple storage partitions for storing the X unit modules (1) transported by the rack transfer robot (55); The intelligent warehousing system control panel (54) is used to display the name, type, quantity and status information of the X unit module (1) on the intelligent storage rack (57).

3. The discrete assembly automation system adapted to the iterative manufacturing of automotive lights according to claim 1, characterized in that: The X unit module (1) has a built-in lamp product assembly process program, lamp product testing program and data storage module.

4. The discrete assembly automation system adapted to the iterative manufacturing of automotive lights according to claim 1, characterized in that: The AGV (2) is equipped with multiple units.

5. The discrete assembly automation system adapted to the iterative manufacturing of automotive lights according to claim 1, characterized in that: The X unit module (1) is provided in multiple ways.

6. The discrete assembly automation system adapted to the iterative manufacturing of automotive lights according to claim 1, characterized in that: The flexible production line module frame (3) and the X unit module (1) and intelligent tooling (4) installed on the flexible production line module frame (3) together constitute a unit workstation.

7. The discrete assembly automation system adapted to the iterative manufacturing of automotive lights according to claim 6, characterized in that: The unit workstation is provided with two units, which are spliced ​​together. One unit workstation is the main workstation, and the other unit workstation is the backup workstation.

8. A method for operating a discrete assembly automation system adapted to the iterative manufacturing of automotive lamps as described in any one of claims 1 to 7, characterized in that, It includes: Step S1: Based on the type of lighting product, the X Unit Module Technical Management Office (51) sends the corresponding X Unit Module (1) call instruction; Step S2: The shelf transfer robot (55) places the X unit module (1) on the smart storage rack (57) onto the connecting lifting platform (53), the connecting lifting platform (53) loads the X unit module (1) onto the AGV trolley (2), and then the AGV trolley (2) transports the X unit module (1) to the X unit module technical management room (51). Step S3: Perform corresponding technical management on the X unit module (1) in the X unit module technical management room (51). The technical management includes updating the assembly process of lighting products, iterating the testing program of lighting products, and matching the definition of general interfaces. Step S4: The AGV (2) transports the X unit module (1) that has completed technical management to the connecting lifting platform (53). The connecting lifting platform (53) lifts the X unit module (1) on the AGV (2) to the visual inspection area of ​​the robot visual appearance inspection system (56), and the robot visual appearance inspection system (56) performs appearance inspection on the X unit module (1). Step S5: The connecting lifting platform (53) transports the intact X unit module (1) to the AGV trolley (2), and the AGV trolley (2) transports the X unit module (1) to the flexible production line module frame (3); Step S6: After the X unit module (1) is installed in place, the X unit module (1) controls the production equipment and measuring instruments on the lighting product production line to perform actions.

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