An integrated molding and foaming production process for landfilling sub-components within a mold

Abstract

The present application relates to the production process field, specifically relates to a kind of integral forming foaming production process for filling sub-class components in mould, comprising the following steps: setting mould, taking material, lifting transfer, pre-embedded part installation seam identification, fixed pre-embedded part, fastening pre-embedded part and foaming etc.Step;Through the above steps, the present application solves the production process that same type product needs to be glued to connect pillow core body and sub-class components, improves environmental protection and appearance, greatly improves production efficiency, saves cost;Also eliminate the possibility of pillow core body and sub-class components separation after long time use, need after-sales maintenance.

Description

Technical Field

[0001] This invention relates to the field of manufacturing processes, specifically to an integral molding foaming manufacturing process for embedding sub-components within a mold. Background Technology

[0002] When additional sub-components are needed in molded foam pillow cores on the market, a process of gluing the pillow core body with adhesive is often used. This process is complex, inefficient, and results in high costs and is also environmentally unfriendly.

[0003] like Figures 10-13 The sub-components installed inside the pillow core mainly provide support for the cervical spine, increasing the comfort of the product and the body's feel. Since the material properties of the sub-components are different from those of the pillow core body, it is technically difficult to foam them simultaneously in the same mold. Therefore, they are generally foamed separately and then assembled. Currently, the common process is to glue a whole piece of sponge with the sub-components attached to the pillow core body.

[0004] like Figure 8-9 As shown, another common process involves pre-embedding and fixing the sub-components within the main product mold. Because the sub-components affect the flow rate and direction of the polyether during foaming, and the polyether also impacts the position of the sub-components, causing them to deviate from their intended location, a certain number of fixing components are typically added to the upper and lower covers of the mold (if the number is small, the polyether will impact the sub-components during foaming, causing them to deviate from their intended position), such as iron needles. Using iron needles will create... Figure 14 The holes and air bubbles left at the corresponding positions of the fixing parts on the finished pillow core shown will affect the appearance and function of the finished product. Summary of the Invention

[0005] This invention solves the problems in the background technology and provides an integrated molding foaming production process for embedding sub-components in a mold; it overcomes the shortcomings of the prior art and aims to solve the problems of the production process of using glue to bond the pillow core body and sub-components for similar products, as well as the problems of external physical and chemical factors impacting the sub-components during the foaming reaction, causing them to deviate from their predetermined positions.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution: An integrated foaming production process for embedding sub-components within a mold, using a traceless foaming mold and a pre-embedded part transfer mechanism for positioning and assembling the embedded pre-embedded parts before foaming, specifically includes the following steps: S1, Set up the mold: Set up a pre-embedded steel shaft in the non-marking foaming mold for positioning the pre-embedded part before the pillow core is foamed; S2, Material Retrieval: The pre-embedded part with the installation seam is cut and shaped and placed into the center, and then the pre-embedded part is removed by the automated pre-embedded part installation device; S3, Lifting and Transfer: The embedded part is transferred from the feeding mechanism to the top of the non-marking foaming mold through the translation mechanism, lifting mechanism and gripping mechanism in the embedded part transfer mechanism; S4, Embedded part rotation recognition: The embedded part rotation mechanism starts and controls the embedded part to rotate at a constant speed, and the embedded part installation joint recognition mechanism is started in turn. The camera continuously captures and identifies the position of the embedded part installation joint, and controls the embedded part installation joint to be aligned with the steel shaft. S5, Fix the embedded parts, and install the embedded parts identified in step 4 onto the corresponding steel shafts by controlling the gripping mechanism; S6, Tighten the embedded parts. After the step of fixing the embedded parts is completed, the embedded parts rotation mechanism works again to rotate the embedded parts slightly, thereby tightening the embedded parts. S7, Foaming: After completing step 6, close the base and cover plate, then inject polyurethane foam material into the foaming cavity through the holes. After standing for a period of time, take out the pillow core after the foaming is completed.

[0007] The embedded parts in this case are the sub-type components in the background technology.

[0008] The specific identification method for the embedded part installation seam identification step includes the following steps: Step 1, Pre-embedded part rotates at a constant speed: Start the pre-embedded part rotation mechanism to control the pre-embedded part to rotate at a constant speed; Step 2, image processing: The camera is used to continuously capture images of the embedded part at a constant frequency f. The images are then cropped to extract a dot matrix of the embedded part with a size range of n×m. The images are then binarized by setting a threshold to obtain a stage image a containing only black and white. Step 3, assign pixel information: assign and record each pixel of stage image a in step 1 as (x, y, c), where x is the horizontal coordinate of the pixel, y is the vertical coordinate of the pixel, 0 < x ≤ n, 0 < y ≤ m, and c is the pixel color, c = 1 or 0, where 1 represents black and 0 represents white. Step 4, image edge processing: Set non-calculated regions Δx and Δy at the edge positions in stage image a to obtain stage detection image b. The coordinate range of stage detection image b is (Δx, Δy) ~ (n-Δx, m-Δy). Step 5, Seam Recognition: In the traversal phase, detect all pixels in image b, find the coordinates of pixels with a c value of 1, and record them in set A {a1, a2, ..., a}. i}, verify the c value of each pixel's coordinates in set A relative to its x-axis neighbors. If c is 0, discard the coordinate; if c is 1, record the coordinate a.i For b i Recorded in set B {b1, b2, ..., b} j} Where j≤i, read the ordinates of all pixels in set B, take out the maximum and minimum values, and record them as m1 and m2. Calculate the current ordinate value of the installation seam yp=(m1+m2) / 2. Transform the pixels in set A into points in set B by checking them. This eliminates discrete interference coordinates and obtains the continuous installation seam position. Step six, installation seam position positioning: set the installation seam positioning coordinates yt=m / 2, compare yp and yt, until yp=yt, then it is determined that the installation seam has reached the positioning target position. The target position is the installation seam facing upward and centered. At this time, stop the embedded part rotation mechanism. Step 7: Once the installation seam is in place, restart the embedded part rotation mechanism and control the rotation motor to rotate n times, reversing the embedded part by 180° so that the embedded part installation seam is directly opposite the steel shaft; where n = D / 2d, where d is the diameter of the roller and D is the diameter of the embedded part.

[0009] The automated embedded part installation device includes an embedded part transfer mechanism, a feeding mechanism, a non-marking foaming mold, and a fixed base. The feeding mechanism and the non-marking foaming mold are located at both ends above the fixed base. The embedded part transfer mechanism transfers the embedded part in the feeding mechanism to the steel shaft of the non-marking foaming mold through a translation structure.

[0010] The embedded part transfer mechanism includes: a translation mechanism, a lifting mechanism, a gripping mechanism, an embedded part rotation mechanism, and an embedded part installation seam identification mechanism. The lifting mechanism is slidably mounted on the translation mechanism, the gripping mechanism is mounted at the bottom end of the lifting mechanism, and the embedded part rotation mechanism and the embedded part installation seam identification mechanism are mounted on the lifting mechanism.

[0011] Preferably, the feeding mechanism includes a storage box, a discharge baffle, and a feeding port. The discharge baffle is disposed between the storage box and the feeding port. As the motor rotates, the motor drives the discharge baffle to rotate. The motor can control the discharge baffle to open and close left and right, so that the embedded parts can fall from the storage box to the feeding port one by one, making it easier for the embedded part transfer mechanism to grab the removed embedded parts.

[0012] Preferably, the translation mechanism includes: a vertical support, a slide rail, and a translation slider. The vertical support is disposed above the fixed base, the slide rail is disposed at the upper end of the vertical support, and the translation slider is provided with a translation motor and a translation drive wheel. The translation slider moves on the slide rail by means of the translation motor and the translation drive wheel. The translation mechanism, through the combination of the translation motor and the translation drive wheel, allows the translation slider to move on the slide rail, facilitating the adjustment of the translation position of the embedded part.

[0013] Preferably, the lifting mechanism includes a lifting driver and a rack. The lifting driver is fixed on the translation slider and includes a lifting motor and a lifting gear. The rack meshes with the lifting gear. Through the interaction between the lifting driver and the rack, the lifting mechanism can freely adjust the height of the embedded part to a position above the non-marking foaming mold.

[0014] Preferably, the gripping mechanism includes: a gripping mounting base, gripping fingers, a gripping control cylinder, a control linkage, and a drag-reducing roller; the gripping mechanism is fixed to the bottom of the rack via the gripping mounting base, the middle of the gripping fingers is hinged to the gripping mounting base, the top of the gripping fingers is hinged to one end of the control linkage, the bottom of the gripping control cylinder is fixed to the upper end of the gripping mounting base, and the top of the gripping control cylinder is hinged to the other end of the control linkage; the gripping mechanism expands the gripping fingers through the operation of the control linkage, thereby making it easier for the gripping fingers to grip the embedded part, and the cooperation of the two sets of gripping mechanisms makes the embedded part more stable in the entire transfer mechanism.

[0015] The drag-reducing roller is located on the inner side of the gripper finger, and the surface of the drag-reducing roller is covered with a sponge sleeve; the drag-reducing roller can reduce the friction generated when the embedded part rotates, so that the embedded part can rotate more flexibly.

[0016] Preferably, the embedded part installation seam identification mechanism includes a camera, which is connected to a host computer via a signal line. The camera, connected to the host computer, calculates the location of the embedded part's installation seam using a series of algorithms, ensuring that the installation seam precisely aligns with the steel shaft. This identification mechanism makes the installation of the embedded part and the steel shaft more accurate.

[0017] Preferably, the embedded part rotation mechanism includes: a lifting cylinder, a rotating motor, and a roller. The lifting cylinder is installed at the bottom of the rack, the top of the rotating motor is fixed to the bottom of the lifting cylinder, and the roller is connected to the rotating shaft of the rotating motor. The rotating motor can automatically adjust the roller according to the identified embedded part installation seam position, thereby achieving the effect of self-fine adjustment of the equipment.

[0018] Preferably, the traceless foaming mold includes: a base, a cover plate, and a steel shaft. The upper side plate of the base is hinged to the cover plate. The base is provided with a foaming cavity with an upper opening. The steel shaft is disposed in the foaming cavity. Two detachable steel shafts are disposed in the foaming cavity. The steel shafts can be detached by opening holes on both sides of the base, which facilitates the removal of the steel needles after foaming and can achieve a traceless effect on the pillow core.

[0019] In summary, the beneficial effects of this invention are as follows: 1. The production process described in this invention includes the following steps: installing steel needles, taking materials, lifting and transferring, identifying the installation seam of the embedded part, fixing the embedded part, tightening the embedded part, and foaming, etc. Through the above steps, during the installation seam identification process, the corresponding installation seam position of the embedded part can be more effectively determined through the superposition of algorithms, making the process more accurate. 2. The process described in this invention differs from general foaming processes in that it is traceless. After foaming, because the steel needles are installed on both sides of the base, only small holes are left on the side of the pillow core, and no holes or air bubble marks are left on the pillow core. Therefore, the appearance quality is improved and the product qualification rate is increased. 3. This invention solves the production process problem of using glue to bond the pillow core body and sub-components in similar products, improving environmental protection and appearance, greatly increasing production efficiency, and saving costs; at the same time, it also eliminates the possibility of the pillow core body and sub-components separating after long-term use, requiring after-sales maintenance. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall production process of the present invention; Figure 2 This is a schematic diagram of the automated pre-embedded component installation device of the present invention; Figure 3 This is a schematic diagram of the embedded part transfer mechanism of the present invention; Figure 4 This is a schematic diagram of the gripping mechanism of the present invention; Figure 5 This is a schematic diagram of the structure of the embedded part rotation mechanism of the present invention; Figure 6 This is a schematic diagram of the structure of the traceless foaming mold of the present invention; Figure 7 This is a schematic diagram of the feeding mechanism of the present invention; Figure 8 It is a mold with a steel shaft added in the background technology; Figure 9 This is a schematic diagram of the installation of embedded parts in the background technology; Figure 10 This is a side view of the pillow core; Figure 11 This is a top view of the bottom of the pillow core; Figure 12 This is a side view diagram showing the pillow core after the embedded parts have been installed. Figure 13 This is a rear view of the finished pillow insert; Figure 14 This is a diagram of holes formed on a finished steel shaft in the background art; Figure 15 This is a schematic diagram of the steel shaft in the non-marking foaming mill of this embodiment; Figure 16 This is a detailed drawing of the pre-embedded parts fixing in this embodiment; Figure 17 This is a picture of the finished product after the embedded parts have been installed; In the diagram, the markings are: 1-Embedded part transfer mechanism, 2-Feeding mechanism, 3-Seamless foaming mold, 4-Fixed base, 11-Translation mechanism, 12-Lifting mechanism, 13-Gripping mechanism, 14-Embedded part rotation mechanism, 15-Embedded part installation seam identification mechanism, 31-Base, 32-Cover plate, 33-Steel shaft, 34-First steel needle, 35-Second steel needle, 311-Foaming cavity, 111-Vertical support, 112 - Slide rail, 113- Translation slider, 121- Lifting driver, 122- Rack, 131- Gripper mounting base, 132- Gripper finger, 133- Gripper control cylinder, 134- Control linkage, 1311- Resistance reducing roller, 146- Lifting cylinder, 147- Rotary motor, 148- Roller, 21- Storage box, 22- Discharge baffle, 23- Feed port, 151- Camera, 16- Embedded part. Detailed Implementation

[0021] The following specific embodiments are merely illustrative of the present invention and are not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to these embodiments without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of the present invention.

[0022] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. Example

[0023] according to Figure 1 As shown, an integrated molding foaming production process for embedding sub-components within a mold is described. This process utilizes a seamless foaming mold 3, and after positioning and assembling the embedded pre-embedded parts using a pre-embedded part transfer mechanism 1, foaming is performed. The specific steps include: S1, Set mold: Set the embedded steel shaft 33 in the non-marking foaming mold 3 for positioning the embedded part 16 before the pillow core is foamed; S2, Material Removal: Place the pre-embedded part 16, which has been cut and has an installation seam, into 2, and then remove the pre-embedded part 16 through the automated pre-embedded part installation device; S3, Lifting and Transfer: The embedded part 16 is transferred from the feeding mechanism 2 to the top of the non-marking foaming mold 3 through the translation mechanism 11, lifting mechanism 12 and gripping mechanism 13 in the embedded part transfer mechanism 1. S4, Embedded part rotation recognition: The embedded part rotation mechanism 14 starts and controls the embedded part 16 to rotate at a constant speed, and the embedded part installation seam recognition mechanism 15 is started in succession. The camera 151 continuously captures and identifies the installation seam position of the embedded part 16, and controls the installation seam of the embedded part 16 to be aligned with the steel shaft 33. S5, Fix the embedded part, and install the embedded part 16 identified in step 4 onto the corresponding steel shaft 33 by controlling the gripping mechanism 13; S6, Tighten the embedded part. After the step of fixing the embedded part is completed, the embedded part rotation mechanism 14 works again to rotate the embedded part 16 slightly, thereby tightening the embedded part 16. S7, Foaming: After completing step 6, close the base 31 and the cover plate 32, then inject polyurethane foam material into the foaming cavity 311 through the holes. After standing for a period of time, take out the pillow core after the foaming is completed.

[0024] The specific identification method for the embedded part installation seam identification step includes the following steps: Step 1, Embedded part 16 rotates at a constant speed: Start the embedded part rotation mechanism 14 to control the embedded part 16 to rotate at a constant speed; Step 2, image processing: The camera 151 continuously captures images of the embedded part 16 at a frequency f, then the images are cropped to extract a dot matrix of the embedded part 16 with a size range of n×m. The images are then binarized by setting a threshold to obtain a stage image a containing only black and white. Step 3, assign pixel information: assign and record each pixel of stage image a in step 1 as (x, y, c), where x is the horizontal coordinate of the pixel, y is the vertical coordinate of the pixel, 0 < x ≤ n, 0 < y ≤ m, and c is the pixel color, c = 1 or 0, where 1 represents black and 0 represents white. Step 4, image edge processing: Set non-calculated regions Δx and Δy at the edge positions in stage image a to obtain stage detection image b. The coordinate range of stage detection image b is (Δx, Δy) ~ (n-Δx, m-Δy). Step 5, Seam Recognition: In the traversal phase, detect all pixels in image b, find the coordinates of pixels with a c value of 1, and record them in set A {a1, a2, ..., a}. i}, verify the c value of each pixel's coordinates in set A relative to its x-axis neighbors. If c is 0, discard the coordinate; if c is 1, record the coordinate a. i For b i Recorded in set B {b1, b2, ..., b} j} Where j≤i, read the ordinate of all pixels in set B, take out the maximum and minimum values, record them as m1 and m2, and calculate the current installation seam ordinate value yp=(m1+m2) / 2; Step 6: Positioning the installation seam. Set the positioning coordinates of the installation seam to yt=m / 2. Compare yp with yt. When yp=yt, it is determined that the installation seam has reached the positioning target position. The target position is the installation seam facing upward and centered. At this time, stop the embedded part rotation mechanism 14. Step 7: Once the installation seam is in place, restart the embedded part rotation mechanism 14 and control the rotation motor 147 to rotate n times, reversing the embedded part 16 by 180° so that the installation seam of the embedded part 16 is aligned with the steel shaft 33; where n = D / 2d, and d is the diameter of the roller 148 and D is the diameter of the embedded part 16.

[0025] according to Figure 2 As shown, the automated embedded part installation device includes an embedded part transfer mechanism 1, a feeding mechanism 2, a non-marking foaming mold 3, and a fixed base 4. The feeding mechanism 2 and the non-marking foaming mold 3 are located at both ends above the fixed base 4. The embedded part transfer mechanism 1 transfers the embedded part 16 in the feeding mechanism 2 into the interior of the non-marking foaming mold 3 by translation and lifting.

[0026] according to Figure 1 As shown, the embedded part transfer mechanism 1 includes: a translation mechanism 11, a lifting mechanism 12, a gripping mechanism 13, an embedded part rotation mechanism 14, and an embedded part installation seam identification mechanism 15. The lifting mechanism 12 is slidably mounted on the translation mechanism 11, the gripping mechanism 13 is mounted at the bottom end of the lifting mechanism 12, and the embedded part rotation mechanism 14 and the embedded part installation seam identification mechanism 15 are mounted on the lifting mechanism 12.

[0027] according to Figure 3 As shown, the translation mechanism 11 includes: a vertical support 111, a slide rail 112, and a translation slider 113. The vertical support 111 is disposed above the fixed base 4, the slide rail 112 is disposed at the upper end of the vertical support 111, and the translation slider 113 is provided with a translation motor and a translation drive wheel. The translation slider 113 moves on the slide rail 112 by means of the translation motor and the translation drive wheel.

[0028] according to Figure 3 As shown, the lifting mechanism 12 includes a lifting driver 121 and a rack 122. The lifting driver 121 is fixed on the translation slider 113. The lifting driver 121 includes a lifting motor and a lifting gear. The rack 122 meshes with the lifting gear.

[0029] according to Figure 4 As shown, the gripping mechanism 13 includes: a gripping mounting base 131, a gripping finger 132, a gripping control cylinder 133, a control link 134, and a drag-reducing roller 1311; the gripping mechanism 13 is fixed to the bottom of the rack 122 via the gripping mounting base 131, the middle of the gripping finger 132 is hinged to the gripping mounting base 131, the top of the gripping finger 132 is hinged to one end of the control link 134, the bottom of the gripping control cylinder 133 is fixed to the upper end of the gripping mounting base 131, and the top of the gripping control cylinder 133 is hinged to the other end of the control link 134; the drag-reducing roller 1311 is disposed inside the gripping finger 132, and the surface of the drag-reducing roller 1311 is provided with a sponge sleeve.

[0030] according to Figure 3 As shown, the embedded part installation seam identification mechanism 15 includes: a camera 151, and a host computer that is connected to the camera 151 via a signal line.

[0031] according to Figure 5 As shown, the embedded part rotation mechanism 14 includes: a lifting cylinder 146, a rotating motor 147 and a roller 148. The lifting cylinder 146 is installed at the bottom of the rack 122, the top of the rotating motor 147 is fixed to the bottom of the lifting cylinder 146, and the roller 148 is connected to the rotating shaft of the rotating motor 147.

[0032] according to Figure 6 As shown, the traceless foaming mold 3 includes: a base 31, a cover plate 32, and a steel shaft 33. The upper side plate of the base 31 is hinged to the cover plate 32. The base 31 is provided with a foaming cavity 311 with an upper opening. The steel shaft 33 is disposed in the foaming cavity 311. Two steel shafts 33 are disposed in the foaming cavity 311. The steel shaft 33 includes a first steel needle 34 and a second steel needle 35. The first steel needle 34 and the second steel needle 35 are detachable structures. The steel shaft can be detachable by opening holes on both sides of the base.

[0033] Working principle: according to Figure 1-17 As shown, firstly, the automated embedded part installation device is powered on. Then, the first steel needle 34 and the second steel needle 35 are inserted into the foaming cavity 311. After the first steel needle 34 and the second steel needle 35 are inserted into the foaming cavity 311, they are wrapped and fixed at the connection between the first steel needle 34 and the second steel needle 35 and the base 31, so that the two steel needles will not be displaced during the foaming process. Next, the motor is started, and the motor drives the discharge baffle 22 to rotate. The motor controls the discharge baffle 22 to open and close left and right, so that the embedded parts 16 fall one by one from the storage box 21 onto the feeding port 23. Then the embedded part transfer mechanism 1 is started. Through the interaction of the translation motor and the translation drive wheel, the translation slider 113 moves horizontally from left to right along the slide rail 112. Since the lifting drive 121 is fixed on the translation slider 113, the lifting motor drives the lifting gear to rotate. Through the interaction of the lifting drive and the rack, the lifting mechanism 12 is adjusted. The gripping mechanism 13 is fixed at the bottom of the lifting mechanism 12. While the lifting mechanism 12 is descending, it drives the gripping mechanism 13 to adjust downward. When the gripping mechanism 13 is adjusted to above the embedded part 16, the gripping control cylinder 133 drives the control link 134 to move. The control link 134 adjusts the expansion and contraction of the gripping finger 132, thereby gripping the embedded part 16. The embedded part transfer mechanism 1 transfers the embedded part 16 to above the non-marking foaming mold 3. The embedded part rotation mechanism 14 starts and controls the embedded part 16 to rotate at a constant speed. The embedded part installation seam recognition mechanism 15 is then activated. The camera 151 continuously captures images to identify the installation seam position of the embedded part 16 and controls the installation seam of the embedded part 16 to be aligned with the steel shaft 33. Then, the gripping mechanism 13 grips the embedded part 16 and fills it into the steel needle. Subsequently, the push rod end of the lifting cylinder 146 is slightly adjusted and lowered again, so that the roller 148 is in close contact with the sponge embedded part. Then, the rotating motor 147 drives the roller 148 to rotate slightly to secure the embedded part 16. After the gripping mechanism 13 fills the embedded part into the steel needle, the gripping control cylinder 133 is adjusted to open the gripping fingers 132. The embedded part transfer mechanism 1 is then activated. The lifting motor drives the lifting gear to rotate, raising the gripping mechanism 13 to a certain position above the non-marking foam mold 3. Then, the foam pillow core internal filling part installation device automatically stops operating. At this time, the base 31 and the cover plate 32 are closed by human activity. The cover plate 32 has holes. Polyurethane foam material is injected into the foaming cavity 311 through the holes. After standing for a period of time, the pillow core after foaming is taken out and the edges are trimmed.

[0034] Finally, it should be noted that in the description of this invention, the terms "vertical," "upper," "lower," "horizontal," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0035] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0036] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. 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 one-piece molding foaming production process for embedding sub-components within a mold, characterized in that, Using a non-marking foaming mold (3), and in conjunction with the embedded part transfer mechanism (1), the embedded part is positioned and assembled before foaming. The specific steps include: S1, Set mold: Set a pre-embedded steel shaft (33) in the non-marking foaming mold (3) for positioning the pre-embedded part (16) before the pillow core is foamed; S2, material handling: The pre-embedded part (16) with the installation seam is cut and shaped and placed into the feeding mechanism (2), and then the pre-embedded part (16) is taken out by the automated pre-embedded part installation device. S3, Lifting and Transfer: The embedded part (16) is transferred from the feeding mechanism (2) to the top of the non-marking foaming mold (3) by the translation mechanism (11), lifting mechanism (12) and gripping mechanism (13) in the embedded part transfer mechanism (1); S4, Embedded part rotation identification: The embedded part rotation mechanism (14) starts and controls the embedded part (16) to rotate at a constant speed, and the embedded part installation seam identification mechanism (15) is started in succession. The camera (151) continuously captures and identifies the installation seam position of the embedded part (16), and controls the installation seam of the embedded part (16) to be aligned with the steel shaft (33). S5, Fix the embedded part, and install the embedded part (16) identified in step 4 onto the corresponding steel shaft (33) by controlling the gripping mechanism (13); S6, Tighten the embedded part. After the embedded part is fixed, the embedded part rotation mechanism (14) works again to rotate the embedded part (16) slightly, thereby tightening the embedded part (16). S7, Foaming: After step 6 is completed, the base (31) and cover plate (32) are closed, and then polyurethane foam material is injected into the foaming cavity (311) through the hole. After standing for a period of time, the pillow core after foaming is taken out. The specific identification method for the embedded part installation seam identification step includes the following steps: Step 1, the embedded part (16) rotates at a constant speed: start the embedded part rotation mechanism (14) to control the embedded part (16) to rotate at a constant speed; Step 2, image processing: The camera (151) is used to continuously capture images of the embedded part (16) at a frequency f. The images are then cropped to extract a dot matrix of the embedded part (16) with a size range of n×m. The images are then binarized by setting a threshold to obtain a stage image a containing only black and white colors. Step 3, assign pixel information: assign and record each pixel of stage image a in step 1 as (x, y, c), where x is the horizontal coordinate of the pixel, y is the vertical coordinate of the pixel, 0 < x ≤ n, 0 < y ≤ m, and c is the pixel color, c = 1 or 0, where 1 represents black and 0 represents white. Step 4, image edge processing: Set non-calculated regions Δx and Δy at the edge positions in stage image a to obtain stage detection image b. The coordinate range of stage detection image b is (Δx, Δy) ~ (n-Δx, m-Δy). Step 5, Seam Recognition: In the traversal phase, detect all pixels in image b, find the coordinates of pixels with a c value of 1, and record them in set A {a1, a2, ..., a}. i }, verify the c value of each pixel's coordinates in set A relative to its x-axis neighbors. If c is 0, discard the coordinate; if c is 1, record the coordinate a. i For b i Recorded in set B {b1, b2, ..., b} j } Where j≤i, read the ordinate of all pixels in set B, take out the maximum and minimum values, record them as m1 and m2, and calculate the current installation seam ordinate value yp=(m1+m2) / 2; Step 6: Positioning of the installation seam. Set the positioning coordinates of the installation seam to yt=m / 2. Compare yp with yt. When yp=yt, it is determined that the installation seam has reached the positioning target position. The target position is the installation seam facing upward and centered. At this time, stop the embedded part rotation mechanism (14). Step 7: Once the installation seam is in place, restart the embedded part rotation mechanism (14) and control the rotation motor (147) to rotate n times, reverse the embedded part (16) by 180°, so that the installation seam of the embedded part (16) is aligned with the steel shaft (33); where n = D / 2d, where d is the diameter of the roller (148) and D is the diameter of the embedded part (16).

2. The integral molding foaming production process for embedding sub-components within a mold according to claim 1, characterized in that, The automated embedded part installation device includes an embedded part transfer mechanism (1), a feeding mechanism (2), a non-marking foaming mold (3), and a fixed base (4). The feeding mechanism (2) and the non-marking foaming mold (3) are located at both ends above the fixed base (4). The embedded part transfer mechanism (1) transfers the embedded part (16) in the feeding mechanism (2) to the inside of the non-marking foaming mold (3) by translation and lifting.

3. The integral molding foaming production process for embedding sub-components within a mold according to claim 2, characterized in that, The embedded part transfer mechanism (1) includes: a translation mechanism (11), a lifting mechanism (12), a gripping mechanism (13), an embedded part rotation mechanism (14), and an embedded part installation seam identification mechanism (15). The lifting mechanism (12) is slidably disposed on the translation mechanism (11), the gripping mechanism (13) is disposed at the bottom end of the lifting mechanism (12), and the embedded part rotation mechanism (14) and the embedded part installation seam identification mechanism (15) are disposed on the lifting mechanism (12).

4. The integral molding foaming production process for embedding sub-components within a mold according to claim 3, characterized in that, The translation mechanism (11) includes: a vertical support (111), a slide rail (112), and a translation slider (113). The vertical support (111) is located above the fixed base (4). The slide rail (112) is located at the upper end of the vertical support (111). The translation slider (113) is equipped with a translation motor and a translation drive wheel. The translation slider (113) moves on the slide rail (112) through the translation motor and the translation drive wheel.

5. The integral molding foaming production process for embedding sub-components within a mold according to claim 4, characterized in that, The lifting mechanism (12) includes a lifting driver (121) and a rack (122). The lifting driver (121) is fixed on the translation slider (113). The lifting driver (121) includes a lifting motor and a lifting gear. The rack (122) meshes with the lifting gear.

6. The integral molding foaming production process for embedding sub-components within a mold according to claim 5, characterized in that, The gripping mechanism (13) includes: a gripping mounting base (131), a gripping finger (132), a gripping control cylinder (133), a control link (134), and a drag-reducing roller (1311); the gripping mechanism (13) is fixed to the bottom of the rack (122) through the gripping mounting base (131), the middle part of the gripping finger (132) is hinged to the gripping mounting base (131), the top of the gripping finger (132) is hinged to one end of the control link (134), the bottom of the gripping control cylinder (133) is fixed to the upper end of the gripping mounting base (131), and the top of the gripping control cylinder (133) is hinged to the other end of the control link (134); the drag-reducing roller (1311) is located inside the gripping finger (132), and the surface of the drag-reducing roller (1311) is provided with a sponge sleeve.

7. The integral molding foaming production process for embedding sub-components within a mold according to claim 6, characterized in that, The embedded part installation seam identification mechanism (15) includes: a camera (151), which is connected to a host computer via a signal line.

8. The integral molding foaming production process for embedding sub-components within a mold according to claim 7, characterized in that, The embedded part rotation mechanism (14) includes: a lifting cylinder (146), a rotating motor (147), and a roller (148). The lifting cylinder (146) is installed at the bottom of the rack (122), the top of the rotating motor (147) is fixed at the bottom of the lifting cylinder (146), and the roller (148) is connected to the rotating shaft of the rotating motor (147).

9. The integral molding foaming production process for embedding sub-components within a mold according to claim 8, characterized in that, The traceless foaming mold (3) includes: a base (31), a cover plate (32), and a steel shaft (33). The upper side plate of the base (31) is hinged to the cover plate (32). The base (31) is provided with a foaming cavity (311) with an upper opening. The steel shaft (33) is located inside the foaming cavity (311).

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