A fully automated assembly line for front brake modules

Abstract

This invention provides a fully automated front brake module assembly line, relating to the automotive manufacturing field, including an assembly device, a conveying device, and a unloading device. The assembly device includes assembly units, each comprising a first assembly unit, a second assembly unit, a fastening unit, and a third assembly unit. The conveying device is configured to transfer workpieces between the workstations of each assembly unit. The first assembly unit is configured to assemble a wheel hub bearing and a brake disc from a workpiece into a first sub-assembly assembly. The second assembly unit is configured to assemble a steering knuckle and a dust cover from a workpiece into a second sub-assembly assembly. The fastening unit is configured to form a third sub-assembly assembly. The third assembly unit is configured to assemble a brake caliper onto the third sub-assembly assembly to form a fourth sub-assembly assembly. The unloading device includes an assembly trolley, configured to pick up the fourth sub-assembly assembly and place it onto the assembly trolley. This invention provides a fully automated front brake module assembly line with high production efficiency.

Description

Technical Field

[0001] This invention relates to the field of automobile manufacturing technology, and in particular to a fully automated assembly line for front brake modules. Background Technology

[0002] The complexity of automobile assembly processes and the diversity of parts make automation development extremely difficult and its scalability low. Only a few typical single-station automation practices have been achieved in automotive assembly workshops, such as automated windshield adhesive application and installation, and automated seat deployment.

[0003] Currently, most front brake module production lines are manual assembly lines. Since the front brake module consists of multiple parts, the assembly process is broken down into several steps. Under high-speed production conditions, this requires multiple people to work together to complete the assembly. Manual assembly lines mainly consist of conveying devices, suspended assisted robotic arms, and pneumatic positioning mechanisms, and require various tooling and assisted robotic arms to complete the assembly.

[0004] However, this traditional manual assembly line is highly dependent on human labor, resulting in low production efficiency. Summary of the Invention

[0005] This application provides a fully automated assembly line for front brake modules, which has a high degree of automation and high production efficiency.

[0006] This application provides a fully automated front brake module assembly line, including an assembly device, a conveying device, and a unloading device. The assembly device includes multiple assembly units, each including a first assembly unit, a second assembly unit, a fastening unit, and a third assembly unit. The conveying device is sequentially connected between the first assembly unit, the second assembly unit, the fastening unit, and the third assembly unit, and is configured to convey workpieces between the workstations of each assembly unit along a preset assembly direction. The first assembly unit is configured to assemble a wheel hub bearing and a brake disc from a workpiece into a first sub-assembly assembly. The second assembly unit is configured to assemble a steering knuckle and a dust cover from a workpiece into a second sub-assembly assembly. The fastening unit is configured to connect the first sub-assembly assembly and the second sub-assembly assembly to form a third sub-assembly assembly. The third assembly unit is configured to assemble a brake caliper from a workpiece into the third sub-assembly assembly to form a fourth sub-assembly assembly. The unloading device includes an assembly trolley and is configured to pick up the fourth sub-assembly assembly onto the assembly trolley.

[0007] As described above, the fully automated front brake module assembly line may optionally include a double-speed chain and workstations set on the double-speed chain, with each workstation corresponding to a specific assembly unit. The first, second, third, and fourth assembly assemblies are all assembled at their respective workstations.

[0008] As described above, in the fully automated front brake module assembly line, the first assembly unit may optionally include a first gripping component and a second gripping component. The first gripping component is used to grip the wheel hub bearing, and the second gripping component is used to grip the brake disc.

[0009] As described above in the fully automated front brake module assembly line, optionally, the first gripping assembly includes a first base and a first gripper movably connected to the first base. The first gripper includes two opposing gripper members, with a clamping portion on the facing side of each gripper member. The shape of the clamping portion matches the outer ring shape of the wheel hub bearing. The two gripper members are configured to move closer to or further away from each other to allow the first gripper to grip the wheel hub bearing; and / or,

[0010] The second gripping component includes a second base, a first suction cup, and a detection module. The detection module includes a telescopic rod, a position sensor, and a controller. The telescopic rod is telescopically connected to the second base and is configured to retract when it abuts against the end face of the brake disc. The position sensor and the controller are electrically connected, and the controller is used to control the first suction cup to adsorb the brake disc when the position sensor detects that the telescopic rod has retracted.

[0011] As described above, in the fully automated assembly line for the front brake module, the second assembly unit may optionally include a rotary assembly table, a third gripping component, and a fourth gripping component. The third gripping component and the fourth gripping component are respectively disposed on the periphery of the rotary assembly table. The rotary assembly table is rotatable around a vertical axis and has multiple rotating positions in its circumferential direction. The rotary assembly table is configured to move the workpiece to different rotating positions by its own rotation.

[0012] The multiple rotary stations include a first rotary station corresponding to the third gripping assembly and a second rotary station corresponding to the fourth gripping assembly. The third gripping assembly is used to pick up the steering knuckle to the first rotary station, and the fourth gripping assembly is used to pick up the dust cover to the second rotary station and assemble it onto the steering knuckle on the second rotary station.

[0013] As described above, in the fully automated front brake module assembly line, the rotary assembly table may optionally include a first positioning post, a suction cup, and a clamping assembly. The first positioning post is used for fitting the steering knuckle, the clamping assembly is used to tighten the steering knuckle fitted on the first positioning post, and the suction cup is used to fix the dust cover.

[0014] As described above in the fully automated front brake module assembly line, optionally, the third gripping assembly includes a third base, a second positioning post, a clamping member, and a flipping hook. The second positioning post, clamping member, and flipping hook are all connected to the third base. The second positioning post is used for fitting the steering knuckle. The clamping member is movably arranged relative to the second positioning post to clamp the steering knuckle fitted onto the second positioning post. The flipping hook is used to flip open the partition located on the material rack as the third base moves, so that the third gripping assembly can pick up the next layer of steering knuckles from the material rack. The material rack is used to store the steering knuckles to be assembled.

[0015] As described above, in the fully automated assembly line for the front brake module, the third assembly unit may optionally include a fifth gripping component. The fifth gripping component includes a fourth base and at least two second grippers connected to the fourth base. The at least two second grippers are arranged side by side and spaced apart on the fourth base, and each second gripper has a different gripping space.

[0016] As described above, in the fully automated front brake module assembly line, the first assembly unit may optionally include a straightening mechanism configured to straighten holes in the first assembly assembly.

[0017] As described above, in the fully automated assembly line for the front brake module, optionally, at least one assembly unit is equipped with a machine vision component. The machine vision component is used to determine the relative pose of the assembly unit and the workpiece so that the assembly unit can adjust its position according to the relative pose.

[0018] This application provides a fully automated front brake module assembly line, including an assembly device, a conveying device, and a unloading device. The assembly device includes multiple assembly units, each comprising a first assembly unit, a second assembly unit, a fastening unit, and a third assembly unit. The conveying device is sequentially connected between the first, second, fastening, and third assembly units and is configured to convey workpieces between the workstations of each assembly unit along a preset assembly direction. The first assembly unit is configured to assemble a wheel hub bearing and a brake disc from a workpiece into a first sub-assembly assembly. The second assembly unit is configured to assemble a steering knuckle and a dust cover from a workpiece into a second sub-assembly assembly. The fastening unit is configured to connect the first and second sub-assembly assemblies to form a third sub-assembly assembly. The third assembly unit is configured to assemble a brake caliper from a workpiece into the third sub-assembly assembly to form a fourth sub-assembly assembly. The unloading device includes an assembly trolley and is configured to pick up the fourth sub-assembly assembly and place it onto the assembly trolley. This application provides a fully automated front brake module assembly line with a high degree of automation and high production efficiency.

[0019] The structure of the fully automated front brake module assembly line provided in this application, as well as its other inventive objectives and beneficial effects, will become more apparent and understandable through the description of the preferred embodiments in conjunction with the accompanying drawings. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of a fully automated assembly line for a front brake module provided in an embodiment of this application;

[0021] Figure 2 This is a schematic diagram of the structure of the first gripping component in a fully automated front brake module assembly line provided in an embodiment of this application;

[0022] Figure 3 This is a schematic diagram of the structure of the second gripping component in a fully automated front brake module assembly line provided in this application embodiment;

[0023] Figure 4 This is a schematic diagram of the center straightening hole mechanism of a fully automated front brake module assembly line provided in this application embodiment;

[0024] Figure 5 This is a schematic diagram of the structure of the third gripping component in a fully automated front brake module assembly line provided in an embodiment of this application;

[0025] Figure 6 This is a schematic diagram of the structure of the fifth gripping component in a fully automated front brake module assembly line provided in this application embodiment;

[0026] Figure 7 This is a schematic diagram of the structure of the rotating assembly table in a fully automated front brake module assembly line provided in this application embodiment;

[0027] Figure 8 This is a schematic diagram of the sixth gripping component in a fully automated front brake module assembly line provided in this application embodiment.

[0028] Explanation of reference numerals in the attached figures:

[0029] 10 - Fully automated assembly line for front brake modules;

[0030] 100 - Assembly device;

[0031] 110 - First assembly unit;

[0032] 111 - First fetching component;

[0033] 1111 - First Plinth;

[0034] 1112 - First gripper;

[0035] 112 - Second grabbing component;

[0036] 1121 - Second base;

[0037] 1122 - First suction cup;

[0038] 1123 - Telescopic pole;

[0039] 1124 - Position sensor;

[0040] 113 - Hole straightening mechanism;

[0041] 1131 - Pin;

[0042] 114 - Testing equipment;

[0043] 120 - Second assembly unit;

[0044] 1210 - Rotary dispensing stage;

[0045] 1211 - Rotary station;

[0046] 1212 - First positioning post;

[0047] 1213 - Suction Cup;

[0048] 1214 - Clamping assembly;

[0049] 1220 - Third Crawling Component;

[0050] 1221 - Third Plinth;

[0051] 1222 - Second positioning post;

[0052] 1223 - Clamping component;

[0053] 1224-Layer flipping hook;

[0054] 1230 - Fourth Crawling Component;

[0055] 130 - Fastening unit;

[0056] 140 - Third Assembly Unit;

[0057] 141 - Fifth grabbing component;

[0058] 1411 - Fourth Plinth;

[0059] 1412 - Second gripper;

[0060] 142-Brake caliper holder;

[0061] 200 - Conveying device;

[0062] 210-speed chain;

[0063] 220-workstation;

[0064] 300 - Feeding device;

[0065] 310 - Assembly Cart;

[0066] 320 - Sixth Grabbing Component;

[0067] 321 - Fifth Plinth;

[0068] 400 - Machine Vision Components. Detailed Implementation

[0069] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0070] The complexity of automobile assembly processes and the diversity of parts make automation development extremely difficult and its scalability low. Only a few typical single-station automation practices have been achieved in automotive assembly workshops, such as automated windshield adhesive application and installation, and automated seat deployment.

[0071] Currently, most front brake module production lines are manual assembly lines. Since the front brake module consists of multiple parts, the assembly process is broken down into several steps. Under high-speed production conditions, this requires multiple people to work together to complete the assembly. Manual assembly lines mainly consist of conveying devices, suspended assisted robotic arms, and pneumatic positioning mechanisms, and require various tooling and assisted robotic arms to complete the assembly.

[0072] However, this traditional manual assembly line is highly dependent on human labor, resulting in low production efficiency.

[0073] To address this, this application provides a fully automated front brake module assembly line. It utilizes a conveyor system to transfer workpieces to different workstations; an adjustable mechanical gripper combined with a vision system precisely completes different assembly processes; inspection equipment is used to test the assembled wheel bearings and brake discs; finally, the assembled front brake module assembly is transported to an assembly trolley. Compared to traditional manual assembly lines, this production line boasts a high degree of automation and high production efficiency.

[0074] The following section further elaborates on a fully automated assembly line for a front brake module in this embodiment.

[0075] Figure 1 This is a schematic diagram of a fully automated assembly line for a front brake module provided in an embodiment of this application; Figure 2 This is a schematic diagram of the structure of the first gripping component in a fully automated front brake module assembly line provided in an embodiment of this application; Figure 3 This is a schematic diagram of the structure of the second gripping component in a fully automated front brake module assembly line provided in this application embodiment; Figure 4 This is a schematic diagram of the center straightening hole mechanism of a fully automated front brake module assembly line provided in this application embodiment; Figure 5 This is a schematic diagram of the structure of the third gripping component in a fully automated front brake module assembly line provided in an embodiment of this application; Figure 6 This is a schematic diagram of the structure of the fifth gripping component in a fully automated front brake module assembly line provided in this application embodiment;

[0076] Figure 7 This is a schematic diagram of the structure of the rotating assembly table in a fully automated front brake module assembly line provided in this application embodiment; Figure 8 This is a schematic diagram of the sixth gripping component in a fully automated front brake module assembly line provided in this application embodiment.

[0077] like Figure 1 As shown, this application embodiment provides a fully automated assembly line for front brake modules. From Figure 1 As can be seen from the diagram, the fully automated front brake module assembly line 10 includes an assembly device 100, a conveying device 200, and a unloading device 300. The assembly device 100 includes multiple assembly units, namely a first assembly unit 110, a second assembly unit 120, a fastening unit 130, and a third assembly unit 140. The conveying device 200 is sequentially connected between the first assembly unit 110, the second assembly unit 120, the fastening unit 130, and the third assembly unit 140, and is configured to transfer workpieces between the workstations 220 of each assembly unit along a preset assembly direction. The first assembly unit 110 is configured to assemble the hub bearing and brake disc in the workpiece into a first sub-assembly assembly; the second assembly unit 120 is configured to assemble the steering knuckle and dust cover in the workpiece into a second sub-assembly assembly; the fastening unit 130 is configured to connect the first sub-assembly assembly and the second sub-assembly assembly to form a third sub-assembly assembly; the third assembly unit 140 is configured to assemble the brake caliper in the workpiece into the third sub-assembly assembly to form a fourth sub-assembly assembly; the unloading device 300 includes an assembly cart 310 and is configured to pick up the fourth sub-assembly assembly onto the assembly cart 310.

[0078] This production line uses a conveyor device 200 to transfer workpieces to different workstations 220; and an adjustable mechanical gripper combined with a vision system precisely completes different sub-assembly processes of the workpieces; an inspection device 114 inspects the sub-assembled wheel hub bearings and brake discs; finally, the assembled front brake module assembly is transported to the assembly trolley. Compared to traditional manual assembly lines, this production line has a high degree of automation and high production efficiency.

[0079] The conveying device 200 also includes a lift, which drives the pallet located on the workstation 220 to be conveyed on the double-speed chain 210.

[0080] The unloading device 300 also includes a sixth gripping component 320, which is connected to the robot via a fifth base 321. Figure 8 As shown, the sixth gripping component 320 can be compatible with parts of different sizes to a certain extent and can keep the parts stable during gripping and placement. During operation, the robot grips the assembly and places it into the corresponding empty position on the rack. The robot feeds back the gripping completion signal to the programmable logic controller (PLC). After the photoelectric sensor feeds back the signal that the workpiece is not in place, the lifting mechanism of the double-speed chain 210 lowers the pallet and the pallet returns.

[0081] In some embodiments, the conveying device 200 includes a double-speed chain 210 and a station 220 disposed on the double-speed chain 210. The station 220 corresponds one-to-one with each assembly unit, wherein the first sub-assembly assembly, the second sub-assembly assembly, the third sub-assembly assembly and the fourth sub-assembly assembly are all assembled on the corresponding station 220.

[0082] Based on the actual application needs of the project, the conveying device 200 has both manual and automatic control capabilities. When on-site equipment malfunctions or during installation and commissioning, individual button operations can be performed on each part of the transfer mechanism. In case of an emergency during operation, the machine can be stopped using the emergency stop button. Specifically, the conveying device 200 utilizes a combination of magnetic limit switches and mechanical stops to ensure high positioning accuracy during operation.

[0083] In some embodiments, the first assembly unit 110 includes a first gripping component 111 and a second gripping component 112, wherein the first gripping component 111 is used to grip the wheel hub bearing and the second gripping component 112 is used to grip the brake disc.

[0084] The first assembly unit 110 also includes a testing device 114. The first gripping component 111 positions the wheel hub bearing on the testing device 114, and the second gripping component 112 positions the brake disc on the testing device 114 and assembles it with the positioned wheel hub bearing to form the first sub-assembly assembly.

[0085] Among these factors, surface vibration generated after the assembly of the automotive brake disc assembly is a critical cause of braking torque fluctuations. Key causes of surface vibration in the brake disc assembly include: non-compliance with manufacturing standards for the brake disc itself, non-compliance with manufacturing standards for the wheel hub, non-compliance with manufacturing standards for the steering knuckle, errors during brake disc assembly, and the influence of ambient temperature. A surface vibration detection system needs to establish a detection model to effectively control the quality of the brake disc assembly.

[0086] Specifically, the testing equipment 114 is used to detect parameters such as thickness, circumferential difference, radial difference, runout, and flatness difference of the first sub-assembly, and to transfer qualified workpieces to the next station 220 and reject unqualified workpieces. When the start button is pressed, the test data will be displayed on the screen of the testing equipment 114.

[0087] In some embodiments, the first gripping assembly 111 includes a first base 1111 and a first gripper 1112 movably connected to the first base 1111. The first gripper 1112 includes two opposing gripper members, and the opposing sides of the gripper members have a clamping portion. The shape of the clamping portion matches the shape of the outer ring of the wheel hub bearing. The two gripper members are configured to move closer to or further away from each other so that the first gripper 1112 can grip the wheel hub bearing; and / or,

[0088] The second gripping component 112 includes a second base 1121, a first suction cup 1122, and a detection module. The detection module includes a telescopic rod 1123, a position sensor 1124, and a controller. The telescopic rod 1123 is telescopically connected to the second base 1121 and is configured to retract when it abuts against the end face of the brake disc. The position sensor 1124 is electrically connected to the controller, which controls the first suction cup 1122 to adsorb the brake disc when the position sensor 1124 detects that the telescopic rod 1123 has retracted.

[0089] The first gripping component 111 is connected to the robot's sixth axis via the first base 1111, such as... Figure 2 As shown, a sliding groove is provided on the first base 1111, and a protrusion matching the shape of the sliding groove is provided on the top of the first gripper 1112. The first gripper 1112 can slide inside the sliding groove to grip wheel hub bearings of different sizes. Specifically, the first gripper 1112 can be compatible with different configuration parts with a diameter difference of ±10mm or more.

[0090] Specifically, during operation, the robot, with its second gripping component 112, approaches the surface of the brake disc. When the telescopic rod 1123 touches the brake disc surface, it rebounds upwards, triggering a signal from the position sensor 1124 to the robot. The robot then slows down and continues to travel a predetermined distance downwards. The first workpiece suction cup 1122 is powered on and picks up the workpiece. After moving it to a safe position, the brake disc is rotated to the correct angle and placed on the rotary dispensing table 1210. After demagnetization, the workpiece is released and the robot returns to the safe area. After removing one layer of parts, the robot, with its gripper, approaches the partition. The partition suction cup picks up the partition and places it in the designated position.

[0091] In some embodiments, the second assembly unit 120 includes a rotary assembly table 1210, a third gripping component 1220 and a fourth gripping component 1230. The third gripping component 1220 and the fourth gripping component 1230 are respectively disposed on the periphery of the rotary assembly table 1210. The rotary assembly table 1210 is rotatably disposed about a vertical axis of rotation, and the rotary assembly table 1210 has a plurality of rotating stations 1211 in its circumferential direction. The rotary assembly table 1210 is configured to move the workpiece to different rotating stations 1211 by its own rotation.

[0092] The plurality of rotary stations 1211 include a first rotary station corresponding to the third gripping component 1220 and a second rotary station corresponding to the fourth gripping component 1230. The third gripping component 1220 is used to pick up the steering knuckle to the first rotary station, and the fourth gripping component 1230 is used to pick up the dust cover to the second rotary station and assemble it onto the steering knuckle on the second rotary station.

[0093] Among them, such as Figure 7 As shown, the rotary assembly table 1210 has four rotating stations 1211, and each rotating station 1211 is arranged in a fan shape, which makes the overall structure of the rotary assembly table 1210 compact and occupies a small area. Specifically, a pneumatic slip ring mechanism is provided below the rotary assembly table 1210 to provide power to the rotary assembly table 1210 so that it can rotate continuously.

[0094] In some embodiments, the rotary dispensing table 1210 includes a first positioning post 1212, a suction cup 1213 and a clamping assembly 1214. The first positioning post 1212 is used for fitting a steering knuckle, the clamping assembly 1214 is used to clamp the steering knuckle fitted on the first positioning post 1212, and the suction cup 1213 is used to fix the dust cover.

[0095] The first positioning post 1212 is used to restrict the horizontal movement of the steering knuckle, and the clamping assembly 1214 is used to restrict the vertical rotation of the steering knuckle. The first positioning post 1212 and the clamping assembly 1214 work together to position the steering knuckle. Specifically, the rotating assembly table 1210 rotates 90° to reach the second rotating station. The robot places the dust cover on the steering knuckle through the vision component 400 and uses the suction cup 1213 to fix the left and right dust covers respectively. The rotating assembly table 1210 rotates another 90° to reach the third rotating station, and the dust cover is tightened by the tightening shaft carried by the servo module. The rotating assembly table 1210 rotates another 90° to reach the fourth rotating station. At this time, the clamping assembly 1214 is released, the robot takes away the sub-assembly and places it on the double-speed chain tray for positioning. In this way, the four rotating stations work in a cycle with a compact cycle, which is suitable for the sub-assembly of a small number of parts.

[0096] In some embodiments, the third gripping assembly 1220 includes a third base 1221, a second positioning post 1222, a clamping member 1223, and a flipping hook 1224. The second positioning post 1222, clamping member 1223, and flipping hook 1224 are all connected to the third base 1221. The second positioning post 1222 is used for mounting steering knuckles. The clamping member 1223 is movably disposed relative to the second positioning post 1222 to clamp the steering knuckle mounted on the second positioning post 1222. The flipping hook 1224 is used to flip open the partition located on the material rack as the third base 1221 moves, so that the third gripping assembly 1220 picks up the next layer of steering knuckles from the material rack. The material rack is used to store steering knuckles to be assembled, such as... Figure 5 As shown.

[0097] The third gripping component 1220 is connected to the robot via the third base 1221. The robot brings the third gripping component 1220 close to the steering knuckle. Using the guiding structure of the second positioning post 1222, it adaptively positions itself with the steering knuckle. The clamping member 1223 rotates from its idle position to its working position and simultaneously clamps the steering knuckle. The robot then places the steering knuckle onto the rotary dispensing table 1210. After each layer of steering knuckles is removed, the robot automatically completes the flipping operation using the flipping hook 1224 to continue removing the next layer. The third gripping component 1220 can adaptively match and position itself with the steering knuckle, reducing the accuracy requirements for placing the steering knuckles on the rack and allowing for layer flipping of the rack as needed.

[0098] In some embodiments, the third assembly unit 140 includes a fifth gripping assembly 141, which includes a fourth base 1411 and at least two second grippers 1412 connected to the fourth base 1411. The at least two second grippers 1412 are arranged side-by-side and spaced apart on the fourth base 1411, and each second gripper 1412 has a different gripping space, such as... Figure 6 As shown.

[0099] The second gripper 1412, which can be of different sizes depending on the vehicle model, can be selected to grip the brake caliper, providing high flexibility.

[0100] In some embodiments, the first assembly unit 110 further includes a straightening mechanism 113, which is configured to straighten holes in the first sub-assembly assembly, such as... Figure 4 As shown.

[0101] The hole straightening mechanism 113 includes a vision component 400 and a pin 1131. Specifically, during hole straightening, the vision component 400 first locates the threaded hole inside the wheel hub bearing, and then transmits the coordinates of the threaded hole to the robot. At this time, the robot rotates with the gripper until the pin 1131 is aligned with the bolt hole. Then, the pin 1131 is inserted into the threaded hole, adjusting the threaded hole at any angle to a fixed angle for later assembly.

[0102] In some embodiments, at least one assembly unit is provided with a machine vision component 400, which is used to determine the relative pose of the assembly unit and the workpiece so that the assembly unit can adjust its position according to the relative pose.

[0103] Specifically, when the assembly unit is working, the vision component 400 first reaches the preset position, accurately obtains the position and deflection angle of the part, and transmits the position and angle offset values ​​to the robot. The robot, carrying a gripper, accurately grasps the part through the gripper and rotates it to the required angle, and places it on the workstation tray.

[0104] The vision component 400 includes an image acquisition unit, which uses a camera and lens to capture images of the object being inspected. The accuracy of object recognition is adjusted by changing the camera's pixel count, and the field of view is controlled by adjusting the lens's focal length, facilitating subsequent image processing. Specifically, the vision component 400 is also equipped with a safety controller and collision detection function, enabling safety control during the grasping process to prevent accidents and providing a high level of safety.

[0105] The working process of the fully automated front brake module assembly line 10 will be described below.

[0106] Figure 1 This is a schematic diagram of a fully automated assembly line for a front brake module provided in an embodiment of this application, as shown below. Figure 1As shown, the first gripping assembly 111 picks up a wheel hub bearing from the wheel hub bearing rack and places it on the sub-assembly table of the testing equipment 114 for positioning. The second gripping assembly 112 picks up a brake disc from the brake disc rack and places it on the sub-assembly table of the testing equipment 114, assembling it with the positioned wheel hub bearing to form a first sub-assembly assembly. The testing equipment 114 tests the first sub-assembly assembly. After passing the test, the first sub-assembly assembly is positioned at the first station of the double-speed chain 210 and then conveyed to the second station of the double-speed chain 210. The straightening mechanism 113 straightens the first sub-assembly assembly to fix the bolt holes of the wheel hub bearing at the required angle. The third gripping component 1220 takes the steering knuckle from the steering knuckle rack and places it on the first rotary station of the rotary assembly table 1210 and positions it. The rotary assembly table 1210 rotates 90° to reach the second rotary station. The fourth gripping component 1230 takes the dust cover from the dust cover rack and places it on the second rotary station, positioning it with the steering knuckle. The rotary assembly table 1210 rotates 90° to reach the third rotary station. The fastening unit 130 tightens the dust cover and the steering knuckle to form the second sub-assembly assembly. The rotary assembly table 1210 rotates 90° to reach the fourth rotary station. The robot transports the second sub-assembly assembly to the second station of the double-speed chain 210 and positions it with the second sub-assembly assembly that has been straightened. The double-speed chain 210 transports the first and second sub-assembly assemblies to the third station. The fastening unit 130 takes bolts to connect the first and second sub-assembly assemblies to form the third sub-assembly assembly. Then, the double-speed chain 210 transports the third sub-assembly assembly to the fourth station of the double-speed chain 210. The fifth gripper assembly 141 takes the brake caliper from the brake caliper rack 142 and installs it on the third sub-assembly assembly to form the fourth sub-assembly assembly. Then, the double-speed chain 210 transports the fourth sub-assembly assembly to the fifth station of the double-speed chain 210. The sixth gripping assembly 320 grips the fourth sub-assembly assembly and places it on the assembly trolley 310.

[0107] The fully automated front brake module assembly line 10 in this embodiment includes an assembly device 100, a conveying device 200, and a unloading device 300. The assembly device 100 includes multiple assembly units, including a first assembly unit 110, a second assembly unit 120, a fastening unit 130, and a third assembly unit 140. The conveying device 200 is sequentially connected between the first assembly unit 110, the second assembly unit 120, the fastening unit 130, and the third assembly unit 140, and is configured to transfer workpieces between the workstations 220 of each assembly unit along a preset assembly direction. The process involves several steps: a first assembly unit 110 is configured to assemble the wheel hub bearing and brake disc from the workpiece into a first sub-assembly; a second assembly unit 120 is configured to assemble the steering knuckle and dust cover from the workpiece into a second sub-assembly; a fastening unit 130 is configured to connect the first and second sub-assembly assemblies to form a third sub-assembly; a third assembly unit 140 is configured to assemble the brake caliper from the workpiece into the third sub-assembly to form a fourth sub-assembly; and a material unloading device 300 includes an assembly cart 310 and is configured to pick up the fourth sub-assembly assembly onto the assembly cart 310. The workpiece is then conveyed to different workstations 220 using a conveying device 200; an adjustable mechanical gripper combined with a vision system is used to precisely complete the different sub-assembly processes of the workpiece; an inspection device 114 is used to inspect the assembled wheel hub bearing and brake disc; and finally, the assembled front brake module assembly is transported to the assembly cart. Compared to traditional manual assembly lines, this production line has a high degree of automation and high production efficiency.

[0108] The terms "first," "second," etc., used in the embodiments of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this application described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion.

[0109] In the embodiments of this application, the terms "upper," "lower," "inner," "middle," "outer," "front," and "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for better description of this application and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation. Furthermore, some of the above terms may be used to indicate other meanings besides orientation or positional relationship; for example, the term "upper" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in the embodiments of this application according to the specific circumstances.

[0110] Furthermore, the terms "set up," "connect," and "fix" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this disclosure according to the specific circumstances.

[0111] It should be noted that the embodiments referred to in the specification, such as "one embodiment," "embodiment," "exemplary embodiment," and "some embodiments," may include specific features, structures, or characteristics, but not every embodiment necessarily includes that specific feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same embodiment. Moreover, when a specific feature, structure, or characteristic is described in connection with an embodiment, implementing such a feature, structure, or characteristic in conjunction with other embodiments, whether explicitly described or not, is within the knowledge scope of those skilled in the art.

[0112] Generally speaking, terms should be understood at least in part by their use in context. For example, at least in part by context, the term "one or more" as used in the text can be used to describe any feature, structure, or characteristic of the singular meaning, or a combination of features, structures, or characteristics of the plural meaning. Similarly, at least in part by context, terms such as "one" can be understood to convey either singular or plural usage.

[0113] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A fully automated assembly line for front brake modules, characterized in that, It includes an assembly device, a conveying device, and a material unloading device; the assembly device includes multiple assembly units, each of which includes a first assembly unit, a second assembly unit, a fastening unit, and a third assembly unit; the conveying device is sequentially connected between the first assembly unit, the second assembly unit, the fastening unit, and the third assembly unit, and is configured to convey workpieces between the workstations of each assembly unit along a preset assembly direction. The first assembly unit is configured to combine the wheel hub bearing and brake disc in the workpiece into a first sub-assembly; the second assembly unit is configured to combine the steering knuckle and dust cover in the workpiece into a second sub-assembly; the fastening unit is configured to connect the first sub-assembly and the second sub-assembly to form a third sub-assembly. The third assembly unit is configured to assemble the brake caliper in the workpiece to the third sub-assembly to form the fourth sub-assembly. The unloading device includes an assembly cart and is configured to pick up the fourth sub-assembly assembly into the assembly cart; The second assembly unit includes a rotary assembly table, a third gripping component, and a fourth gripping component. The third gripping component and the fourth gripping component are respectively disposed on the periphery of the rotary assembly table. The rotary assembly table is rotatable about a vertical axis and has multiple rotating stations in its circumferential direction. The rotary assembly table is configured to move the workpiece to different rotating stations by its own rotation. The plurality of rotating stations include a first rotating station corresponding to the third gripping component and a second rotating station corresponding to the fourth gripping component. The third gripping component is used to pick up the steering knuckle to the first rotating station, and the fourth gripping component is used to pick up the dust cover to the second rotating station and assemble it onto the steering knuckle on the second rotating station. The third gripping assembly includes a third base, a second positioning post, a clamping member, and a flipping hook. The second positioning post, the clamping member, and the flipping hook are all connected to the third base. The second positioning post is used for mounting the steering knuckle. The clamping member is movably disposed relative to the second positioning post to clamp the steering knuckle mounted on the second positioning post. The flipping hook is used to flip open the partition located on the material rack as the third base moves, so that the third gripping assembly can pick up the next layer of steering knuckles from the material rack. The material rack is used to store the steering knuckles to be assembled.

2. The fully automated assembly line for the front brake module according to claim 1, characterized in that, The conveying device includes a double-speed chain and workstations disposed on the double-speed chain. Each workstation corresponds to one of the assembly units, wherein the first sub-assembly assembly, the second sub-assembly assembly, the third sub-assembly assembly, and the fourth sub-assembly assembly are all assembled at their respective workstations.

3. The fully automated assembly line for the front brake module according to claim 2, characterized in that, The first assembly unit includes a first gripping component and a second gripping component, wherein the first gripping component is used to grip the wheel hub bearing and the second gripping component is used to grip the brake disc.

4. The fully automated assembly line for the front brake module according to claim 3, characterized in that, The first gripping assembly includes a first base and a first gripper movably connected to the first base. The first gripper includes two opposing gripper members, each with a clamping portion on its facing side. The shape of the clamping portion matches the shape of the outer ring of the wheel hub bearing. The two gripper members are configured to move closer to or further away from each other to allow the first gripper to grip the wheel hub bearing; and / or, The second gripping component includes a second base, a first suction cup, and a detection module. The detection module includes a telescopic rod, a position sensor, and a controller. The telescopic rod is telescopically connected to the second base and is configured to retract when it abuts against the end face of the brake disc. The position sensor and the controller are electrically connected. The controller is used to control the first suction cup to adsorb the brake disc when the position sensor detects that the telescopic rod has retracted.

5. The fully automated assembly line for the front brake module according to claim 1, characterized in that, The rotary dispensing stage includes a first positioning post, a suction cup, and a clamping assembly. The first positioning post is used for mounting the steering knuckle, the clamping assembly is used for clamping the steering knuckle mounted on the first positioning post, and the suction cup is used for fixing the dust cover.

6. The fully automated assembly line for the front brake module according to claim 1, characterized in that, The third assembly unit includes a fifth gripping component, which includes a fourth base and at least two second grippers connected to the fourth base. The at least two second grippers are arranged side by side and spaced apart on the fourth base, and each second gripper has a different gripping space.

7. The fully automated assembly line for the front brake module according to any one of claims 1-4, characterized in that, The first assembly unit further includes a straightening mechanism configured to straighten holes in the first sub-assembly assembly.

8. The fully automated assembly line for the front brake module according to any one of claims 1-4, characterized in that, At least one of the assembly units is provided with a machine vision component for determining the relative pose of the assembly unit and the workpiece, so that the assembly unit can adjust its position according to the relative pose.

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