Automobile steering wheel frame assembly detection flow line

Abstract

The present application relates to a kind of automobile steering wheel frame assembly detection assembly lines, including touch screen control end integrated PLC for system control, and loading area carries the tooling to be processed.The flow line is transmitted automobile steering wheel frame by input line, and is provided with no detection sensor detection steering wheel frame at the end.The multi-axis robot is responsible for handling and welding work, and welding station executes welding task.The turntable mechanism is configured four stations: input bit, CCD detection station, label station and output station.The sorting mechanism operates between the turntable mechanism and output line, and is handled to qualified product output line or waste box according to the detection result.The output line starting end is provided with code scanning module, for obtaining and confirming product label information, to ensure that qualified steering wheel frame is accurately outputed.The automatic processing inspection can be realized, and the processing efficiency and product quality are significantly improved.

Description

Technical Field

[0001] This invention relates to the field of mechanical automation technology, specifically to an assembly and testing production line for automotive steering wheel frames. Background Technology

[0002] With the rapid development of modern manufacturing towards automation and intelligence, the market demand for efficient, precise, and multifunctional welding equipment is increasing. Traditional welding processes are usually carried out independently, lacking integrated material handling, precision welding, real-time monitoring, and automatic quality inspection functions, resulting in low production efficiency, frequent manual intervention, and an inability to ensure product consistency and quality stability.

[0003] In recent years, although some welding equipment with automated production lines, visual inspection, and data statistics functions has emerged, these devices still face some technical bottlenecks in practical applications. For example, existing welding equipment often focuses only on single welding operations, neglecting seamless integration with other production processes such as labeling, barcode scanning, and finished product sorting, resulting in limited flexibility and adaptability of the overall production line. Furthermore, existing control systems often fail to achieve accurate product quality judgment and automatic sorting, affecting the intelligent decision-making and self-optimization capabilities of the entire production system.

[0004] In view of this, the present invention aims to propose an SA3F high-configuration welding equipment that integrates feeding conveying, multi-station precision welding, CCD online detection, automatic labeling, material output scanning and intelligent data analysis, in order to solve the problems of low integration, process flow segmentation, lack of real-time monitoring and insufficient automation in the existing technology, thereby improving the overall production line efficiency, product quality control capability and intelligent manufacturing level. Summary of the Invention

[0005] The purpose of this invention is to address the aforementioned problems in the prior art by providing an assembly and testing line for automotive steering wheel frames.

[0006] To achieve the above-mentioned objectives, the present invention adopts the following technical solution: a car steering wheel frame assembly and testing production line comprising:

[0007] The touchscreen control terminal has a built-in PLC that communicates with various components.

[0008] The loading area is used for loading materials.

[0009] An input line is used to transport the car steering wheel frame from the beginning to the end, and the end is equipped with a presence or absence detection sensor to detect the presence or absence of the car steering wheel frame.

[0010] Multi-axis robot, with a range of motion covering the loading area, input line, welding station and turntable mechanism, is used to transport car steering wheel frames;

[0011] The welding station, located between the input line and the turntable mechanism, is used to weld the parts of the car steering wheel frame that need to be welded.

[0012] Welding fixtures, located at the welding station, are used to position and fix the car steering wheel frame.

[0013] The turntable mechanism has four stations along the circumference, including an input station, a CCD detection station, a labeling station, and an output station. Each station is equipped with a positioning structure for installing the car steering wheel frame.

[0014] The CCD inspection module, located at the CCD inspection station, is used to visually inspect the welded parts of the automotive steering wheel frame after welding to determine whether they meet the preset quality standards.

[0015] The labeling mechanism, located at the labeling station, is used to label the inspected car steering wheel frame. The labeling information includes at least the labeling time, part name, and part number.

[0016] The sorting mechanism is located between the turntable mechanism and the output line, and its range of motion covers the labeling station, the output station, the waste box and the beginning of the output line. It is used to transport the car steering wheel frame after inspection.

[0017] Waste bins, located below the sorting mechanism, are used to hold defective car steering wheel frames;

[0018] The output line is used to output qualified car steering wheel frames, and a barcode scanning module is provided at one end of the output line to scan the labels on the car steering wheel frames to obtain label information.

[0019] Furthermore, the touchscreen control unit also has a built-in alarm module. When a set number of defective car steering wheel frames are produced consecutively, the alarm module will sound an alarm through a combination of an external alarm and push notifications. This aims to promptly detect and respond to batch quality issues, effectively prevent the accumulation of defective products and potential quality crises, and improve the control efficiency and quality management level of the entire production process.

[0020] Furthermore, the touchscreen control unit features both automatic and manual modes. In manual mode, operators can individually control the start / stop of each controllable component and adjust various parameters via tap operations on the touchscreen. Manual mode allows operators to precisely control the start / stop status and parameter adjustments of each component directly through the touchscreen interface, greatly enhancing the production line's flexibility and emergency response capabilities, ensuring rapid adaptation to non-standardized processes or troubleshooting needs when necessary.

[0021] Furthermore, the touchscreen control unit is equipped with a shielding module to block unauthorized components or workstations. This enables access control and flexible scheduling of certain parts of the production line, avoiding unnecessary process execution, optimizing the production flow, and improving the overall safety and rationality of equipment use. For example, if a dual welding workstation is adjusted to a single welding workstation, or if labeling and scanning operations are not required, labeling and scanning can be directly stopped.

[0022] Furthermore, the CCD inspection module is driven by a Y-axis linear module, the labeling mechanism by a two-axis XZ linear module, and the sorting mechanism by a three-axis XYZ linear module. This improves the space utilization efficiency and motion accuracy of the entire production line, enhances the flexibility and dynamic adaptability of the automated production line, and helps to achieve a more efficient and accurate assembly and inspection process.

[0023] Furthermore, the output end of the multi-axis robot is equipped with a rotary gripper. Each of the four corners of this gripper has a gripper jaw, and this gripper can rotate under the drive of the multi-axis robot to simultaneously grip two car steering wheel frames and perform position switching operations. Through the rotary gripper, the robot can grip and process two car steering wheel frames at once, significantly increasing the number of frames processed per unit time compared to single-frame processing, thereby improving the overall production line output efficiency. The rotary gripper, combined with the multi-directional motion capability of the multi-axis robot, allows for simultaneous position changes of the two frames when switching between different workstations, saving a significant amount of time spent changing between workstations and optimizing the production line cycle time.

[0024] Furthermore, the front and rear ends of the rotating clamp are inclined relative to the middle section. This allows for better targeting of the unique shape of the car steering wheel frame, enabling precise and rapid clamping of the car steering wheel frame.

[0025] Furthermore, the welding station is a dual-station facility, significantly improving welding efficiency.

[0026] Furthermore, the welding station is equipped with a processing table at its bottom and a horizontal drive for moving the processing table back and forth between the waiting position for receiving the automotive steering wheel frame and the processing position of the welding station. The processing table is also equipped with welding fixtures. These fixtures ensure that the automotive steering wheel frame can be quickly and accurately positioned at the preset welding position when transferred to the welding station, thereby improving the precision and consistency of the welding operation. The horizontal drive allows the processing table to automatically move from the waiting position to below the welding station for processing, then return to its original position to prepare for the next cycle, achieving continuous automated flow of the automotive steering wheel frame and improving production efficiency.

[0027] Furthermore, after acquiring the barcode information, the scanning module checks for missing, incorrect, or duplicate codes. This ensures that the labeling information on each car steering wheel frame is complete and meets the preset format and content requirements, effectively preventing quality traceability problems caused by missing labels or incomplete information. Real-time verification of the scanned information allows for the timely detection and interception of incorrectly labeled products, preventing them from entering subsequent stages or the market, thus improving overall product quality. Regarding duplicate codes, the scanning module effectively avoids the reuse of the same serial number or part number, ensuring that each steering wheel frame has a unique identifier, facilitating accurate quality management and supply chain tracking. Most importantly, it enhances the accuracy of production line data collection, ensuring the reliability of information recorded in the database, which is beneficial for statistical analysis and continuous improvement of production processes.

[0028] Compared with the prior art, the present invention demonstrates the following technological advancements and beneficial effects:

[0029] 1. Integration of automation and intelligence: By combining a touch screen control terminal with a PLC control system, a high degree of automation and precise control of the production line operation is achieved, which improves the overall operating efficiency and reliability of the production line.

[0030] 2. Highly Efficient and Precise Welding and Inspection Process: The welding fixture design ensures precise positioning and secure fixation of the steering wheel frame during the welding process, which is beneficial to improving welding quality. The application of multi-axis robots allows for flexible and efficient handling and welding operations, greatly reducing errors and instability caused by manual operation. The CCD inspection module enables real-time visual inspection of the welded areas, ensuring that the welding quality meets preset standards and enhancing the real-time nature and accuracy of quality control.

[0031] 3. Integrated Quality Tracking and Management: The turntable mechanism is equipped with workstations of different functions, realizing an integrated assembly, inspection, and labeling process, reducing changeover time and material turnover costs between processes. The labeling mechanism automatically marks the labeling time, part name, and part number of each product, facilitating batch traceability and quality management. The barcode scanning module further strengthens product quality control, ensuring that every product leaving the factory undergoes rigorous quality inspection and is recorded through real-time reading of labeling information.

[0032] 4. Intelligent sorting and waste disposal: The sorting mechanism can automatically send qualified products to the output line based on the results of CCD detection, while placing unqualified products into the waste box, which significantly improves the yield rate and overall production efficiency, while reducing the risk of defective products entering the market. Attached Figure Description

[0033] Figure 1 This is a top view of the present invention;

[0034] Figure 2This invention relates to the feeding area and input line;

[0035] Figure 3 This is a schematic diagram of the welding station of the present invention;

[0036] Figure 4 This is a schematic diagram of the welding fixture of the present invention;

[0037] Figure 5 This is a schematic diagram of the rotating gripper on the multi-axis robot of the present invention;

[0038] Figure 6 This is a schematic diagram of the structure of the turntable mechanism of the present invention;

[0039] Figure 7 This is a schematic diagram of the output line of the present invention;

[0040] Figure 8 This is a screenshot of the manual mode settings interface on the touchscreen control panel.

[0041] In the diagram, 1. Car steering wheel frame; 2. Touch screen control terminal; 3. Loading area; 4. Input line; 5. Multi-axis robot; 6. Welding station; 7. Turntable mechanism; 8. CCD detection module; 9. Labeling mechanism; 10. Sorting mechanism; 11. Waste box; 12. Output line; 13. Barcode scanning module; 51. Rotary fixture; 61. Processing table; 62. Horizontal driver; 63. Welding fixture; 81. Y-axis linear module; 91. XZ two-axis linear module; 101. XYZ three-axis linear module. Detailed Implementation

[0042] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0043] Those skilled in the art should understand that, in the disclosure of this invention, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," 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, the above terms should not be construed as limiting this invention.

[0044] like Figure 1-7As shown, this automotive steering wheel frame assembly and testing production line mainly includes a touch screen control terminal 2, welding fixture 63, loading area 3, input line 4, multi-axis robot 5, welding station 6, turntable mechanism 7, CCD detection module 8, labeling mechanism 9, sorting mechanism 10, waste box 11, output line 12, and barcode scanning module 13.

[0045] In this embodiment, the touchscreen control terminal 2 embeds a PLC controller, maintaining real-time communication with various components on the production line via a communication interface. The touchscreen control terminal 2 also integrates an alarm module. When a preset number of defective products are continuously detected, an external alarm is triggered, and a notification is sent to relevant personnel to promptly identify and address batch quality issues, improving the overall production process control efficiency and quality management level. For example, the production line of this invention uses an Omron CP1 series PLC for system control. The touchscreen control terminal 2 displays the equipment's operating status and the production data and operating status of each workstation online. During equipment operation, the upper computer system can collect output data and welding head temperature from each workstation for detection. The CCD detection module 8 records the product qualification mark data and transmits it to the PLC, thereby achieving the function of sorting qualified and unqualified products. Each process is tightly integrated through a data chain, thereby realizing automatic welding, labeling, and inspection functions for the products.

[0046] Preferably, the touchscreen control terminal 2 has both automatic and manual modes. In manual mode, the operator can intuitively control the start, pause, and parameter fine-tuning of each adjustable component through the touchscreen interface, giving the production line a high degree of flexibility and the ability to respond to emergencies. Figure 8 As shown, various parameter settings can be configured.

[0047] Preferably, the touch screen control terminal 2 is also equipped with a shielding module, which can enable or disable certain components or workstations according to actual production needs. For example, when only one welding workstation 6 needs to operate, another welding workstation 6 can be turned off; when labeling and scanning operations are not required, the relevant equipment can be turned off directly, thereby optimizing the production process and improving the safety and rationality of equipment use.

[0048] On this production line, the CCD detection module 8 is driven by the Y-axis linear module 81 to achieve precise detection, the labeling mechanism 9 is driven by the XZ two-axis linear module 91 to achieve flexible labeling in a two-dimensional plane, and the sorting mechanism 10 is driven by the XYZ three-axis linear module 101 to achieve free movement in three-dimensional space. These designs together improve the space utilization and motion accuracy of the production line, and enhance the flexibility and dynamic adaptability of the production line.

[0049] In this embodiment, the output end of the multi-axis robot 5 is equipped with a rotating gripper 51. The gripper has independent grippers at each of its four corners and can rotate under the robot's drive to simultaneously grip and switch between two car steering wheel frames 1, which greatly improves the processing efficiency per unit time, saves the time for switching between workstations, and optimizes the overall rhythm of the production line.

[0050] Preferably, the rotating clamp 51 is designed with the front and rear ends and the middle section inclined, which allows the clamp to better adapt to the unique shape of the car steering wheel frame 1 and achieve fast and accurate clamping and positioning.

[0051] In this embodiment, welding station 6 adopts a dual-station design, significantly improving welding efficiency. A processing table 61, driven by a horizontal actuator 62 (cylinder or electric cylinder), is located at the bottom of welding station 6. Welding fixture 63 is mounted on the processing table 61, and the welding fixture 63 has a positioning structure. After the processing table 61 automatically moves from its waiting position to below welding station 6 for processing, it returns to its original position to receive the next frame to be processed. This method achieves continuous and precise automated flow, effectively improving production efficiency and welding accuracy. In this embodiment, the welding part of the automotive steering wheel frame 1 is a foot bracket, which allows the automotive steering wheel frame 1 to be inserted and installed on the vehicle via a snap-fit ​​mechanism. Of course, other components can also be used; this is not limited to these specific components.

[0052] The welding equipment at welding station 6 is not limited; different welding equipment can be selected for different welding parts. In this embodiment, the welding is mainly carried out by pressure heating.

[0053] In this embodiment, the turntable mechanism 7 has four stations along the circumference: an input station, a CCD detection station, a labeling station, and an output station. Each station has a positioning structure for mounting the automotive steering wheel frame 1. The turntable mechanism 7 rotates primarily by using a servo motor to drive the turntable.

[0054] Finally, after acquiring the scanned information, the barcode scanning module 13 verifies the information to check for missing, incorrect, or duplicate codes. This not only ensures that the labeling information on each car steering wheel frame 1 is complete and conforms to preset specifications, but also promptly intercepts erroneous products, preventing them from entering subsequent stages and ensuring product quality. Furthermore, the barcode scanning module 13 prevents the reuse of the same serial number or part number, providing a unique identifier for each steering wheel frame, facilitating refined quality management and supply chain tracking. Simultaneously, rigorous barcode information verification greatly enhances the accuracy and reliability of production line data collection, enabling statistical analysis and process improvement based on real data.

[0055] Preferably, the technical parameters of the production line of the present invention are as follows:

[0056] ① Power supply: AC 380V, 50Hz, power 12kW.

[0057] ② System driving air source pressure: 0.4-0.6MPa. For example, welding station 6 uses a cylinder to drive the downward pressure for welding.

[0058] ③ System startup waiting time: not less than 60 seconds.

[0059] ④ Equipment insulation resistance: ≥10MΩ.

[0060] In this embodiment, the multi-axis robot, CCD detection module 8, input line 4 and output line 12 (both input line 4 and output line 12 are common synchronous belt devices, and a positioning structure for placing the car steering wheel frame 1, such as a rectangular groove, can be installed on the input line 4) and labeling mechanism 9 (mainly a combination of label printer and suction cup, the suction cup combination is driven by XZ two-axis linear module 91) are existing products, which can be selected or customized according to needs, and are not limited here.

[0061] In this embodiment, the positioning structure used to position the car steering wheel frame 1 is not limited, and is basically a single or combination of positioning holes, positioning grooves and positioning posts. Different combinations are used for the car steering wheel frame 1 of different car models.

[0062] Preferably, the production line of the present invention can further incorporate more intelligent and automated elements, such as:

[0063] Data analysis module: Collects data from various workstations, such as welding quality parameters, labeling time, and barcode scanning results. Through big data analysis and AI algorithms, it predicts potential quality problems, performs preventative maintenance in advance, and provides a scientific basis for process optimization.

[0064] Adaptive adjustment function: The system can automatically adjust welding temperature, pressure and other parameters according to the actual production situation to meet the welding requirements of automotive steering wheel frames 1 of different materials or specifications. At the same time, the labeling mechanism 9 can also automatically adjust the labeling strategy according to different label sizes and positions.

[0065] Integration with intelligent warehousing system: It works in conjunction with the warehouse management system to automatically allocate raw material supply based on production plans and actual output, and update inventory information in real time to ensure stable operation of the production line.

[0066] Remote monitoring and diagnostics: Supports remote access and monitoring of the production line's operating status. Through the network platform, technicians can view various indicators in real time, promptly identify and resolve potential problems, and effectively shorten troubleshooting time.

[0067] Preventive maintenance reminders: Based on equipment operating time and workload, the system can proactively remind users to perform preventive maintenance, extend equipment life, reduce failure rate, and improve overall equipment uptime.

[0068] Environmental monitoring and adaptation: Equipped with environmental monitoring devices such as temperature and humidity sensors, it monitors changes in the working environment in real time and automatically adjusts the equipment's operating parameters to adapt to environmental changes, ensuring that product quality is not affected by the environment.

[0069] Deep integration with MES / ERP systems: Achieve deep integration with Manufacturing Execution System (MES) or Enterprise Resource Planning (ERP) systems to realize full-process information management from order, production, quality inspection to outbound delivery, and improve the level of factory intelligence.

[0070] The parts of this invention not described in detail are prior art, therefore they are not described in detail here.

[0071] It is understood that the term "a" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element can be one, while in another embodiment, the number of the element can be multiple, and the term "a" should not be understood as a limitation on the number.

[0072] Although this paper frequently uses terms such as 1. automotive steering wheel frame, 2. touchscreen control terminal, 3. loading area, 4. input line, 5. multi-axis robot, 6. welding station, 7. turntable mechanism, 8. CCD detection module, 9. labeling mechanism, 10. sorting mechanism, 11. waste box, 12. output line, 13. barcode scanning module, 51. rotary fixture, 61. processing table, 62. horizontal actuator, 63. welding fixture, 81. Y-axis linear module, 91. XZ two-axis linear module, and 101. XYZ three-axis linear module, the possibility of using other terms is not excluded. The use of these terms is merely for the convenience of describing and explaining the essence of this invention; interpreting them as any additional limitation would contradict the spirit of this invention.

[0073] This invention is not limited to the preferred embodiments described above. Anyone can derive other products in various forms under the guidance of this invention. However, regardless of any changes made to their shape or structure, any technical solution that is the same as or similar to this invention falls within the protection scope of this invention.

Claims

1. A production line for assembling and inspecting automotive steering wheel frames, characterized in that, include: The touchscreen control terminal has a built-in PLC that communicates with various components. The loading area is used for loading materials. An input line is used to transport the car steering wheel frame from the beginning to the end, and the end is equipped with a presence or absence detection sensor to detect the presence or absence of the car steering wheel frame. A multi-axis robot, whose range of motion covers the loading area, the input line, the welding station, and the turntable mechanism, is used to transport car steering wheel frames. The output end of the multi-axis robot is equipped with a rotating gripper, which has a gripper at each of its four corners. The rotating gripper can rotate under the drive of the multi-axis robot to simultaneously grip two car steering wheel frames and perform position switching operations. A welding station, located between the input line and the turntable mechanism, is used to weld the parts of the car steering wheel frame that need to be welded; the bottom of the welding station is equipped with a processing table and a horizontal drive for driving the processing table back and forth between the position waiting to receive the car steering wheel frame and the processing position of the welding station; the welding station is a dual-station. Welding fixtures, set on the processing table of the welding station, are used to position and fix the car steering wheel frame. The turntable mechanism has four stations along the circumference, including an input station, a CCD detection station, a labeling station, and an output station. Each station is equipped with a positioning structure for installing the car steering wheel frame. The CCD inspection module, located at the CCD inspection station, is used for visual inspection of the welded parts of the welded automotive steering wheel frame to determine whether they meet preset quality standards; the CCD inspection module is driven by a Y-axis linear module. A labeling mechanism, located at the labeling station, is used to label the inspected automotive steering wheel frame. The labeling information includes at least the labeling time, part name, and part number. The labeling mechanism is driven by an XZ two-axis linear module. The sorting mechanism is located between the turntable mechanism and the output line, and its range of motion covers the labeling station, the output station, the waste box, and the beginning of the output line. It is used to transport the inspected car steering wheel frame. The sorting mechanism is driven by an XYZ three-axis linear module. A waste box, located below the sorting mechanism, is used to place defective car steering wheel frames. The output line is used to output a qualified car steering wheel frame, and a scanning module is provided at one end of the output line to scan the label on the car steering wheel frame to obtain label information; after obtaining the scanning information, the scanning module checks whether there are any missing codes, incorrect codes or duplicate codes.

2. The automotive steering wheel frame assembly and testing production line according to claim 1, characterized in that, The touchscreen control terminal also has a built-in alarm module. When a set number of defective car steering wheel frames are found in succession, the alarm module will sound an alarm through a combination of an external alarm and information notification push.

3. The automotive steering wheel frame assembly and testing production line according to claim 1, characterized in that, The touchscreen control terminal has an automatic mode and a manual mode. In the manual mode, the start / stop of each controllable component and the adjustment of various parameters can be individually controlled by tapping on the touchscreen control terminal.

4. The automotive steering wheel frame assembly and testing production line according to claim 1, characterized in that, The touch screen control terminal is equipped with a shielding module, which is used to shield unauthorized components or workstations.

5. The automotive steering wheel frame assembly and testing production line according to claim 1, characterized in that, The front and rear ends and the middle section of the rotating clamp are inclined.

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