Instrument panel switch disassembly mistake proofing method and system

Abstract

The application provides an instrument panel switch disassembly mistake proofing method and system, the method comprises the following steps: S1: pre-configure the position corresponding relationship of each switch storage box and switch rack; S2: based on the identification information in each switch storage box, obtain the switch material list; S3: in response to at least one work task indicated by the system, generate switch assembly planning; S4: based on the switch assembly planning, detect whether the assembly process of the switch assembly planning is correct; if correct, then proceed with switch assembly; if incorrect, then issue an alarm prompt. Compared with the prior art, the application avoids the situation that the employee incorrectly or omits to assemble the switch during the assembly process, reduces the repair cost, and improves the production efficiency.

Description

Technical Field

[0001] This application relates to the field of instrument panel switch assembly technology, and more specifically, to a method and system for preventing errors in the separate assembly of instrument panel switches. Background Technology

[0002] There are dozens of types of electrical switches used in the interior trim of existing truck cabs. Depending on the overall vehicle configuration, these switches need to be combined during the assembly process, resulting in hundreds of different instrument switch assemblies. Due to the flexible co-production of various vehicle models on the production line, operators assemble the switches according to the production sequence. Because the shapes of the various electrical switches are not easily distinguishable, incorrect or missing installations are prone to occur during on-site assembly. This leads to replacements and repairs after the products come off the production line, which seriously affects the user experience. Summary of the Invention

[0003] The purpose of this application is to provide a method and system for preventing errors in the assembly of dashboard switches, thereby avoiding the situation where employees incorrectly install or omit switches during the assembly process, reducing rework costs, and improving production efficiency; the specific solution is as follows:

[0004] A method for error-proofing the assembly of dashboard switches, the method comprising the following steps:

[0005] S1: Pre-configure the positional correspondence between each switch storage box and the switch rack;

[0006] S2: Based on the switch components in each switch storage box, obtain the switch bill of materials;

[0007] S3: In response to at least one work task indicated by the system, generate a switch assembly plan;

[0008] S4: Based on the switch assembly plan, check whether the assembly process of the switch assembly is correct;

[0009] If correct, proceed with the switch assembly assembly;

[0010] If an error occurs, an alarm will be issued.

[0011] Furthermore, step S1 includes:

[0012] The system pre-configures the correspondence between the identification information of the switch storage box and the location information of the switch rack; wherein, the identification information includes the identification mark of the switch storage box, the model information and quantity information of the switch components; the location information includes the storage location information of the switch rack; and the storage location information uniquely corresponds to the identification mark.

[0013] In response to storage bit information, trigger the corresponding warning information.

[0014] Furthermore, in step S4, based on the switch assembly plan, the correctness of the switch assembly process is checked, specifically including:

[0015] Based on the switch assembly plan, generate a list of information instructions;

[0016] Based on the information instruction list, complete the assembly of the switch assembly.

[0017] Furthermore, the assembly of the switch assembly based on the information indication list specifically includes:

[0018] Check whether the assembly process of the switch assembly is correct;

[0019] If correct, issue the first prompt message;

[0020] Based on the initial prompt, issue an instruction;

[0021] If an error occurs, a second prompt message will be issued;

[0022] An alarm is issued based on the second prompt information.

[0023] Furthermore, it also includes step S5; step S5 includes:

[0024] Based on the task at hand, acquire the three-dimensional data of the switch assembly;

[0025] Based on 3D data, a general diagram of the switch assembly is generated; the general diagram includes: the image areas of each switch component;

[0026] In response to the assembly process of the switch assembly plan, an image area color indicator list is generated; wherein, the image area color indicator list is synchronously associated with the information indicator list.

[0027] Furthermore, the assembly process in response to the switch assembly plan generates an image area color indicator list, specifically including:

[0028] Switch assembly is performed based on a list of color indicators for image regions;

[0029] If the assembly process is correct, an image information indication will be generated;

[0030] In response to image information indication, adjust the color of the corresponding switch component image area;

[0031] If an assembly process is incorrect, an image alert will be generated.

[0032] In response to the image alarm, the corresponding switch component image area is prominently displayed.

[0033] A dashboard switch reassembly error prevention system, employing the aforementioned dashboard switch reassembly error prevention method; the dashboard switch reassembly error prevention system includes:

[0034] At least one assembly table, the surface of which is provided with tooling fixtures for installing switch components;

[0035] A switch material rack is fixedly installed on the assembly table;

[0036] The switch rack has at least two sets of storage compartments arranged in parallel; each set of storage compartments is divided into several storage cavities by a partition.

[0037] Each storage compartment contains a switch storage box for storing switch components;

[0038] LED indicator lights are provided at the front and rear ends of the switch rack, corresponding to the positions of the switch storage box.

[0039] Both sides of the switch rack are equipped with switch hangers for storing switch panels.

[0040] Furthermore, a warning light buzzer is provided at the upper end of the switch rack; an image display is provided at the lower front side of the switch rack to show the image area of ​​each switch component; the image display and the LED ambient light are electrically connected to the warning light buzzer.

[0041] Furthermore, the switch rack is also equipped with a vision module; the vision module includes: an image detection device for acquiring image information of the switch assembly and a supplementary light for providing a light source to the switch assembly; a printer for printing labels on the switch assembly is provided on one side of the assembly table.

[0042] Furthermore, an industrial control computer is installed at the lower part of the assembly table; the industrial control computer is electrically connected to the image display, the vision module and the printer respectively;

[0043] The lower part of the assembly table is also equipped with a storage cabinet for storing tools.

[0044] Compared with the prior art, the beneficial effects of the present invention are:

[0045] This invention provides a method and system for preventing errors in the assembly of dashboard switches. It pre-configures the positional correspondence between each switch storage box and switch rack; determines the positional information of each switch component; and ensures process monitoring of each switch component during actual assembly to avoid incorrect assembly. Based on the switch bill of materials, the system generates a switch assembly list according to the work tasks indicated by the system, and assembles the switch according to the switch assembly plan generated by the work tasks. It checks whether the assembly process of the switch assembly plan is correct; if correct, it proceeds with the switch assembly; if incorrect, it issues an alarm. This method avoids the problem of numerous parts and on-site assembly errors, and can efficiently and quickly complete the switch assembly task, reducing rework costs. Attached Figure Description

[0046] Figure 1 A flowchart illustrating the error-proofing method for disassembling instrument panel switches;

[0047] Figure 2 A front structural diagram of the error-proofing system for instrument panel switches;

[0048] Figure 3 A side view diagram of the error-proofing system for instrument panel switches;

[0049] Figure 4 and Figure 5 This is a schematic diagram of the tooling fixtures for two different switch assemblies mounted on the assembly table.

[0050] In the picture:

[0051] 1. Assembly table;

[0052] 2. Tooling and fixtures;

[0053] 3. Switch rack; 31. Switch storage box; 32. LED indicator light;

[0054] 4. Switch bracket;

[0055] 5. Warning light and buzzer;

[0056] 6. Image display;

[0057] 7. Visual module;

[0058] 71. Fill light; 72. Image detection equipment;

[0059] 8. Printer;

[0060] 9. Lockers. Detailed Implementation

[0061] To make the purpose, technical solution, and advantages of this application clearer, the following will be described in conjunction with the appendix. Figure 1-5This application will be described in further detail. It is obvious that the described embodiments are merely some, not all, of the embodiments described herein. All other embodiments obtained by those skilled in the art based on the embodiments described herein without inventive effort are within the scope of protection of this application.

[0062] It should be understood that although the terms first, second, third, etc., may be used in the embodiments of this application, these descriptions should not be limited to these terms. These terms are only used to distinguish the descriptions. For example, first may also be referred to as second without departing from the scope of the embodiments of this application, and similarly, second may also be referred to as first.

[0063] To facilitate understanding of the instrument panel switch assembly error prevention method provided by this invention, its application scenario is first explained. Existing truck cab interior electrical switches involve dozens of types, and depending on the vehicle's functional configuration, they need to be combined during assembly, resulting in hundreds of different instrument panel switch assemblies. Therefore, current assembly is based on manual labor. While experienced employees have a relatively low error rate, new employees need to be guided by experienced workers to assemble the switch assemblies, leading to low efficiency. Furthermore, because the switches have similar appearances, incorrect assembly is difficult to detect. Therefore, this application provides an instrument panel switch assembly error prevention method. By implementing error detection and reporting during the assembly process, the probability of incorrect switch assembly is reduced. Moreover, by statistically analyzing the parts list and establishing the positional relationships of the parts through the system, the assembly of the switch assembly can be completed quickly, improving production efficiency.

[0064] It should be explained that the switch components and the switch storage box 31 are pre-assembled at the factory; the switch assembly includes switch components of different models; during field installation, switch components of the same model need to be assembled onto the switch panel to form the switch assembly components.

[0065] like Figure 1 As shown, a method for error-proofing the assembly of dashboard switches includes the following steps:

[0066] S1: Pre-configure the positional correspondence between each switch storage box and the switch rack;

[0067] S2: Obtain the switch material list based on the identification information in each switch storage box;

[0068] S3 responds to at least one work task indicated by the system, obtains the switch assembly list, and assembles the switch assembly based on the switch assembly plan;

[0069] It is understandable that, based on the work tasks indicated by the MOM system, the information of the switches to be assembled in the BOM list is transmitted to the material rack, the indicator light at the corresponding switch storage cavity of the material rack lights up, the corresponding switch assembly plan is generated, and the switch assembly list is generated according to the switch material list.

[0070] S4: Based on the switch assembly plan, check whether the assembly process of the switch assembly is correct;

[0071] If correct, proceed with the switch assembly assembly;

[0072] If an error occurs, an alarm will be issued.

[0073] Specifically, this application maps the information in the switch storage box 31 to the position of the switch rack, enabling accurate acquisition of the position information of the switch components to be assembled during assembly, thus preventing employees from picking up the wrong switch components. Furthermore, the application obtains the switch material list through the identification information in the switch storage box 31 and assembles the switch assembly according to the switch assembly plan. By detecting whether the assembly process of the switch assembly plan is correct, supervision is achieved at each stage of the switch assembly, thereby reducing the probability of incorrect assembly of the switch assembly.

[0074] Optionally, step S1 includes:

[0075] The correspondence between the identification information of the switch storage box 31 and the position information of the switch rack is pre-configured; wherein, the identification information includes the identification mark of the switch storage box 31, the model information and quantity information of the switch components; the position information includes the storage position information of the switch rack; the storage position information uniquely corresponds to the identification mark;

[0076] In response to storage bit information, trigger the corresponding warning information.

[0077] It is understood that this application scans and identifies a mark, such as a QR code; sends the QR code information to the system, and the system obtains the corresponding storage location information based on the obtained QR code information, triggers the indicator light at the corresponding position on the switch rack to light up, thereby storing the switch storage box 31 in the corresponding position of the switch rack.

[0078] In step S4, based on the switch assembly plan, the correctness of the switch assembly process is checked, specifically including:

[0079] Based on the switch assembly plan, generate a list of information instructions;

[0080] Based on the information instruction list, complete the assembly of the switch assembly.

[0081] Specifically, the switch assembly is completed according to the switch assembly planning steps. During the assembly process, the information instruction list instructs employees to complete the assembly steps. It can be understood that each assembly process of the switch assembly in this application is prompted by information instructions. For example, after each assembly process is completed, the indicator light corresponding to the completion of the assembly process goes out, and the indicator light for the next assembly process lights up. It can be understood that if the operator does not pick up the parts in the order of the information instruction list, an alarm will be issued. In this embodiment, a light curtain sensor is arranged at the opening of each switch storage box. The light curtain sensor determines whether the part picking operation is correct and sends a signal to the indicator light, which instructs the operator.

[0082] Optionally, the step of completing the switch assembly assembly based on the information indication list specifically includes:

[0083] Check if the assembly process of the switch assembly is correct; if correct, issue the first warning message.

[0084] Based on the initial prompt, issue an instruction;

[0085] If an error occurs, a second prompt message is issued; based on the second prompt message, an alarm is issued.

[0086] Specifically, during the assembly of the switch assembly, if the operator follows the correct assembly steps, an information indication will be issued according to the first prompt information, such as the indicator light turning green; if the assembly steps are incorrect, an alarm will be issued according to the second prompt information, such as the indicator light turning red, and an audible alarm will be issued through the warning light buzzer.

[0087] Optionally, this application further includes step S5; step S5 includes:

[0088] Based on the task at hand, acquire the three-dimensional data of the switch assembly;

[0089] Based on 3D data, a general diagram of the switch assembly is generated; the general diagram includes: the image areas of each switch component;

[0090] In response to the assembly process of the switch assembly plan, an image area color indicator list is generated; wherein, the image area color indicator list is synchronously associated with the information indicator list.

[0091] According to the work task, this application obtains the diagram of the switch assembly to be assembled and displays it on the interface through the image display 6; at the same time, according to the assembly process of the switch assembly plan, the corresponding switch component image area effect display is triggered; it can be understood that if the switch component in the current assembly step does not match the image area displayed on the interface, it indicates that the switch assembly process is incorrect, and at this time, the buzzer will sound an alarm.

[0092] Specifically, the assembly process in response to the switch assembly plan, generating an image area color indicator list, specifically includes:

[0093] Switch assembly is performed based on a list of color indicators for image regions;

[0094] If the assembly process is correct, an image information indication will be generated;

[0095] In response to image information indication, adjust the color of the corresponding switch component image area;

[0096] If an assembly process is incorrect, an image alert will be generated.

[0097] In response to the image alarm, the corresponding switch component image area is prominently displayed.

[0098] It is understood that this application further prevents errors in the assembly process of the switch assembly by guiding operators to assemble the switch through an image area color indicator list. If the assembly process is correct, the color of the corresponding switch component image area is adjusted, for example, the image color of the switch component changes from lit to gray. If the assembly process is incorrect, the image color of the switch component changes from lit to a bright red indicator, and the warning light buzzer 5 is triggered to issue an audible error.

[0099] It is understood that this application uses the image area color indicator list and information indicator list to coordinate with the assembly of the indicator switch assembly. Compared with the existing technology that uses manual assembly, this greatly reduces the situation of incorrect or missing switch assembly, and significantly improves assembly efficiency.

[0100] This application also includes step S6, which includes:

[0101] In response to the work task indicated by the system, determine the tooling fixture 2 that matches the switch assembly;

[0102] Pre-associate the indicator light position information and switch assembly plan with the tooling fixture 2;

[0103] In response to the switch assembly plan, the corresponding indicator light on tooling fixture 2 is triggered.

[0104] Specific examples are provided based on the above content;

[0105] The first step is to scan the QR code on the switch storage box 31 and send the QR code information to the PLC. Then, the PLC obtains the storage location information of the switch storage box 31 on the switch rack 3 and lights up the indicator light of the storage location. The switch storage box 31 is then stored in the corresponding location. After storage is completed, the indicator light goes out.

[0106] The second step is that the MOM system transmits the switch information to be assembled from the BOM list to the switch rack according to the work task. The indicator light at the corresponding switch storage cavity of the switch rack lights up, and a switch assembly plan is generated. The switch assembly plan includes the assembly steps of the switch assembly and the switch assembly list.

[0107] The third step is to activate the dashboard assembly error prevention system and obtain the MES switch assembly plan through the industrial control computer. In this example, two assembly lines are used to assemble two types of switch assemblies. For ease of understanding, they are divided into the first switch assembly and the second switch assembly. The assembly images of the first switch assembly and the second switch assembly are displayed alternately on the display. For example, every 10 switch assemblies are divided into batches, and assembly instructions are given on the display.

[0108] The fourth step is to assemble the switch assembly according to the assembly process of the switch assembly plan. The indicator lights on the switch rack 3 are initially green, and the alarm indicator light is red. A light curtain sensor is installed at the opening of each switch storage box 31. When the operator correctly retrieves the part, the light curtain sensor will transmit the retrieval information to the PLC, and then to the indicator light, which will turn off. If the wrong part is retrieved, the light curtain sensor will transmit the retrieval information to the alarm light and buzzer through the PLC. The operator completes the assembly according to the switch assembly plan and the retrieval sequence.

[0109] Fifth, each assembly line has a switch fixture 2 on the assembly table 1. Indicator lights are set at the assembly positions of the switches on the fixture 2. The PLC acquires the switch assembly image of the corresponding vehicle model and displays the switch assembly image on the monitor. The switch storage box and the indicator light information of the fixture 2 are interconnected. When the operator takes the part from the switch storage box 31, the indicator light at the corresponding assembly position of the fixture 2 flashes. The operator assembles the switch according to the flashing position of the indicator light. After each switch is installed, the corresponding indicator light of the fixture 2 goes out, and the corresponding switch image area on the monitor changes color. The timer for each switch starts from when it is taken out and ends when the installation is completed. If the time is exceeded, the photoelectric switch transmits the information to the warning light buzzer 5 through the PLC to trigger an alarm.

[0110] Step 6: According to the product assembly requirements, the instrument switch assembly needs to be assembled with wire harnesses. Each assembly table 1 is equipped with a wire harness assembly positioning fixture. After the switch is assembled on the switch panel, flip the switch panel and install it on the wire harness assembly positioning fixture. Connect the wire harness to the corresponding switch according to the color code.

[0111] Step 7: After the instrument switch assembly is assembled, the supplementary light 71 of the vision module 7 is turned on. The image of the switch assembly is acquired through the image detection device 72, and the image is compared with the instrument switch assembly device image obtained from the basic database. If there is an error, the system will automatically prompt through the PLC. The incorrectly installed switch assembly will be displayed in blue on the display, and the warning light buzzer 5 will sound an alarm to prompt the operator to correct it. The system will automatically save the detection results to achieve traceability of records.

[0112] Step 8: The correct switch assembly is detected and transmitted to printer 8 via PLC. The printed label is then affixed to the corresponding position on the switch panel.

[0113] In one embodiment, this application provides a fault-prevention device for disassembling dashboard switches, comprising:

[0114] The configuration module is used to pre-configure the positional correspondence between each switch storage box and the switch rack;

[0115] The switch bill of materials acquisition module is configured to acquire the switch bill of materials based on the switch components in each switch storage box;

[0116] A switch assembly planning generation module is configured to generate a switch assembly plan in response to at least one work task indicated by the system.

[0117] The switch assembly testing module is configured to detect whether the assembly process of the switch assembly plan is correct;

[0118] If correct, proceed with the switch assembly assembly;

[0119] If an error occurs, an alarm will be issued.

[0120] In one embodiment, this application provides a dashboard switch reassembly error prevention system, such as... Figures 2-5 As shown, the instrument panel switch reassembly error prevention method described above is adopted; the instrument panel switch reassembly error prevention system includes:

[0121] Two assembly tables 1, each of which has a tooling fixture 2 for installing switch components on its upper surface;

[0122] A switch rack 3 is fixedly installed on the assembly table 1;

[0123] At least two sets of storage compartments are arranged in parallel on the switch rack 3; each set of storage compartments is divided into several storage cavities by a partition.

[0124] Each storage compartment is equipped with a switch storage box 31 for storing switch components;

[0125] LED indicator lights 33 are provided on the front and rear sides of the switch rack 3, corresponding to the upper position of the switch storage box 31.

[0126] Both sides of the switch rack 3 are provided with switch hangers 4 for storing switch panels.

[0127] Optionally, a warning light buzzer 5 is provided at the upper end of the switch rack 3; an image display 6 for displaying the image area of ​​each switch component is provided at the lower front side of the switch rack 3; the image display 6 and the LED ambient light are electrically connected to the warning light buzzer 5 respectively; the image display 6 is a display screen.

[0128] Optionally, the switch rack 3 is further provided with a vision module 7; the vision module 7 includes: an image detection device 72 for collecting image information of the switch assembly and a supplementary light 71 for providing a light source to the switch assembly; wherein, the image detection device 72 is a camera; a printer 8 for printing labels on the switch assembly is provided on one side of the assembly table 1.

[0129] Optionally, an industrial control computer is provided at the lower part of the assembly table 1; wherein, the industrial control computer is equipped with a PLC.

[0130] The industrial control computer is electrically connected to the switch rack 3, the image display 6, the vision module 7 and the printer 8 respectively;

[0131] The lower part of the assembly table 1 is also equipped with a storage cabinet 9 for storing tools.

[0132] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

Claims

1. A method for preventing errors in the assembly of instrument panel switches, characterized in that, The method includes the following steps: S1: Pre-configure the positional correspondence between each switch storage box and the switch rack; S2: Obtain the switch material list based on the identification information in each switch storage box; S3: In response to at least one work task indicated by the system, generate a switch assembly plan; S4: Based on the switch assembly plan, check whether the assembly process of the switch assembly is correct; If correct, proceed with the switch assembly assembly; If an error occurs, an alarm will be issued; Step S1 includes: The system pre-configures the correspondence between the identification information of the switch storage box and the location information of the switch rack; wherein, the identification information includes the identification mark of the switch storage box, the model information and quantity information of the switch components; the location information includes the storage location information of the switch rack; and the storage location information uniquely corresponds to the identification mark. In response to storage bit information, trigger an alert message corresponding to the storage bit information; In step S4, based on the switch assembly plan, the correctness of the switch assembly process is checked, specifically including: Based on the switch assembly plan, generate a list of information instructions; Based on the information instruction list, complete the assembly of the switch assembly; The assembly of the switch assembly based on the information indication list specifically includes: Check whether the assembly process of the switch assembly is correct; If correct, issue the first prompt message; Based on the initial prompt, issue an instruction; If an error occurs, a second prompt message will be issued; Based on the second prompt information, an alarm is issued; It also includes step S5; step S5 includes: Based on the task at hand, acquire the three-dimensional data of the switch assembly; Based on 3D data, a general diagram of the switch assembly is generated; the general diagram includes: the image areas of each switch component; In response to the assembly process of the switch assembly plan, an image area color indicator list is generated; wherein, the image area color indicator list is synchronously associated with the information indicator list.

2. The error-proofing method for instrument panel switch assembly according to claim 1, characterized in that, The assembly process in response to the switch assembly plan generates an image area color indicator list, specifically including: Switch assembly is performed based on a list of color indicators for image regions; If the assembly process is correct, an image information indication will be generated; In response to image information indication, adjust the color of the corresponding switch component image area; If an assembly process is incorrect, an image alert will be generated. In response to the image alarm, the corresponding switch component image area is prominently displayed.

3. A fault-prevention system for instrument panel switch reassembly, characterized in that, The instrument panel switch reassembly error prevention method according to any one of claims 1-2 is adopted; the instrument panel switch reassembly error prevention system includes: At least one assembly table (1), the surface of which is provided with a tooling fixture (2) for installing switch components; A switch rack (3) is fixedly installed on the assembly table (1); At least two sets of several storage compartments are arranged in parallel on the switch rack (3); each set of storage compartments is divided into several storage cavities by a partition. Each storage compartment is equipped with a switch storage box (31) for storing switch components. LED indicator lights (33) are provided at the front and rear ends of the switch rack (3) corresponding to the switch storage box (31). The switch rack (3) has switch hangers (4) on both sides for storing switch panels.

4. The instrument panel switch reassembly error prevention system according to claim 3, characterized in that, The upper end of the switch rack (3) is provided with a warning light buzzer (5); the lower front end of the switch rack (3) is provided with an image display (6) for displaying the image area of ​​each switch component; the image display (6) and the LED ambient light are electrically connected to the warning light buzzer (5).

5. The instrument panel switch reassembly error prevention system according to claim 4, characterized in that, The switch rack (3) is also equipped with a vision module (7); the vision module (7) includes: an image detection device (72) for collecting image information of the switch assembly and a supplementary light (71) for providing a light source to the switch assembly; a printer (8) for printing labels on the switch assembly is provided on one side of the assembly table (1).

6. The instrument panel switch reassembly error prevention system according to claim 5, characterized in that, An industrial control computer is installed at the lower part of the assembly table (1); the industrial control computer is electrically connected to the image display (6), the vision module (7) and the printer (8) respectively; The lower part of the assembly table (1) is also provided with a storage cabinet (9) for storing tools.

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