An assembly processing system and processing method for automobile lamp production

Abstract

The present invention relates to the field of automobile processing technology. The present invention provides an assembly processing system and a processing method for automobile lamp production. The assembly processing system includes a server, a processing table, a robotic arm, a conveying module, a limiting module, a welding module, a quality assessment module, and a robotic arm control module. The conveying module transports a first assembly and a second assembly to the processing table. The limiting module limits the first assembly and the second assembly transported by the conveying module. The welding module welds the first assembly and the second assembly that abut against each other. The robotic arm control module controls the moving path of the welding module to cooperate with the welding module to weld the first assembly and the second assembly that abut against each other. The quality assessment module collects the welding position of the welding module, and evaluates the collected welding data to form an evaluation result, and feeds the evaluation result back to the welding module to trigger the welding module to adjust the welding parameters.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile processing, and in particular to an assembly processing system and a processing method thereof for automobile lamp production. Background Art

[0002] Some automobile lamp assembly and processing systems generally have problems such as low automation, low efficiency, and insufficient assembly precision, which leads to high production costs and difficulty in ensuring product quality.

[0003] For example, Chinese patent CN104476509A discloses an auxiliary device for an automobile lamp assembly table, which uses a conveyor plate on the assembly table and arranged on a frame for transportation, making the transportation efficiency and convenience more convenient than manual placement. However, it still relies on manual participation, which greatly limits the production efficiency, and the quality of welding cannot be verified online.

[0004] In addition, there are still several problems in the prior art:

[0005] 1. Low degree of automation: The existing assembly and processing system mainly relies on manual operation, with a low level of automation, resulting in low production efficiency and unable to meet the needs of large-scale production;

[0006] 2. Insufficient assembly precision: Due to the limitations of manual operation, the precision in the assembly process is difficult to guarantee, and problems such as component misalignment and poor contact are prone to occur, affecting the overall quality of the automotive lamp;

[0007] 3. Unstable welding quality: Welding is a key link in the assembly process of automotive lights. Traditional welding processes are difficult to ensure the accuracy and strength of welding points, and the welding quality is unstable, which can easily lead to product failure during use;

[0008] 4. Insufficient testing methods: Existing testing methods mainly rely on manual testing, which is inefficient, easy to miss, and difficult to ensure the quality of each product.

[0009] The present invention is made to solve the common problems in the field, such as lack of online calibration, reliance on manual participation, low production efficiency, low degree of automation, poor intelligence, poor welding assembly accuracy, unadjustable assembly angle, lack of calibration means, etc. Summary of the invention

[0010] The purpose of the present invention is to address the existing deficiencies and propose an assembly processing system and a processing method for automobile lamp production.

[0011] In order to overcome the shortcomings of the prior art, the present invention adopts the following technical solutions:

[0012] An assembly processing system for automobile lamp production, the assembly processing system comprising a server, a processing table, and a robotic arm, the assembly processing system further comprising a conveying module, a limit module, a welding module, a quality assessment module, and a robotic arm control module, the server being connected to the conveying module, the limit module, the welding module, the quality assessment module, and the robotic arm control module respectively;

[0013] The conveying module transports the first assembly and the second assembly to the processing table, the limiting module limits the first assembly and the second assembly transported by the conveying module, and abuts the first assembly and the second assembly to be assembled, the welding module welds the abutting first assembly and the second assembly, the robot arm control module controls the moving path of the welding module to cooperate with the welding module to weld the abutting first assembly and the second assembly, the quality assessment module collects the welding position of the welding module, and evaluates the collected welding data to form an evaluation result, and feeds the evaluation result back to the welding module to trigger the welding module to adjust the welding parameters;

[0014] The limiting module is arranged on the processing table, and the limiting module includes a limiting unit and a supporting unit. The limiting unit limits the first assembly and the second assembly to be transported, and the supporting unit adjusts the posture of the limiting unit so that the first assembly to be assembled and the second assembly can be close to each other.

[0015] Optionally, the limiting unit includes an α adsorption component, a β adsorption component, and a posture adjustment component, wherein the α adsorption component performs adsorption and limiting on the first assembly, the β adsorption component performs position limiting adsorption on the second assembly, and the posture adjustment component finely adjusts the postures of the α adsorption component and the β adsorption component, respectively, so that the spacing between the first assembly adsorbed by the α adsorption component and the second assembly adsorbed by the β adsorption component is equal;

[0016] The α adsorption member and the β adsorption member are independently connected to the posture adjustment member to form an α adsorption portion and a β adsorption portion, respectively, and finely adjust the postures of the first assembly adsorbed by the α adsorption member and the second assembly adsorbed by the β adsorption member.

[0017] Optional,

[0018] The posture adjustment component includes a steering subcomponent and a tilt adjustment subcomponent, wherein the steering subcomponent is used to steer the position of the tilt adjustment subcomponent, and the tilt adjustment subcomponent is used to adjust the postures of the α adsorption component and the β adsorption component;

[0019] Among them, the steering sub-component includes a fixed seat, a steering seat, a steering drive mechanism, an identification probe, and at least two positioning marking parts. The fixed seat is used to support the steering seat. One side end face of the steering seat is hinged to the one side end face of the steering seat to form a steering part, and the steering drive mechanism is arranged on the fixed seat and drives the steering seat to rotate along the axis of the hinge position. At least two positioning marking parts are arranged on the fixed seat and are evenly distributed along the circumference of the steering part. The identification probe is arranged on the steering seat and is arranged opposite to at least two positioning marking parts.

[0020] Optionally, the welding module includes a welding unit, a positioning unit, and a welding parameter adjustment unit, the welding unit welds the first assembly and the second assembly that are close to each other with hot melt adhesive, the positioning unit positions the welding unit so that the welding unit welds at the welding position, and the welding parameter adjustment unit calculates new welding parameters according to the evaluation result of the evaluation module, and adjusts and controls the welding process according to the new welding parameters;

[0021] Wherein, the welding module is arranged on the execution end of the robot arm.

[0022] Optionally, the quality assessment module includes a collection unit and an assessment unit, the collection unit collects status data of the welding position of the welding module, and the assessment unit assesses the welding position according to the status data collected by the collection unit to form an assessment result;

[0023] The acquisition unit includes an image acquisition component and a detection component. The image acquisition component acquires image data of the welding position. The detection component detects the welding position and acquires detection data of the welding position.

[0024] Optionally, the conveying module includes a transport unit and a correction unit, the transport unit transports the first assembly and the second assembly to be assembled, and the correction unit corrects the postures of the transported first assembly and the second assembly so that the first assembly and the second assembly fall into the limiting unit;

[0025] The transport unit comprises at least two transport belts and a transport driving mechanism, wherein the at least two transport driving mechanisms independently drive the at least two transport belts to form a γ transport part and a λ transport part;

[0026] The γ transport part and the λ transport part transport the first assembly to be welded and the second assembly to be welded respectively and independently.

[0027] Optionally, the evaluation unit obtains the pre-processed state data and calculates the weld state index Weld according to the following formula:

[0028]

[0029] Wherein, W' is the width coefficient of the weld at the welding position, S' is the surface quality coefficient of the weld at the welding position, E' is the uniformity coefficient of the weld at the welding position, and D' is the internal defect coefficient of the welding position;

[0030] If the weld state index Weld does not fall within the set monitoring threshold range [QC1, QC2], the welding parameter adjustment unit is triggered to adjust the welding parameters.

[0031] In addition, the present invention also provides an assembly processing method for automobile lamp production, the assembly processing method comprising the following steps:

[0032] S1, transporting the first assembly part and the second assembly part to be assembled to the assembly station through the conveying module;

[0033] S2, the limiting module limits and absorbs the first assembly and the second assembly transported into the processing table, and makes the first assembly and the second assembly to be assembled abut against each other to form a welding posture;

[0034] S3, controlling the robotic arm to carry the welding module to weld the first assembly and the second assembly that are in a welding posture through the robotic arm control module, so that the hot melt adhesive is adhered between the first assembly and the second assembly to be assembled to form a welding position;

[0035] S4, the quality assessment module collects the status data of the welding position, and evaluates the welding status index Weld of the welding position according to the collected status data to form an evaluation result;

[0036] S5. The welding module dynamically triggers adjustment and control of welding parameters according to the evaluation results.

[0037] Optionally, the assembly processing method also includes: in step S5, when the trigger condition is met, the welding module determines new welding parameters according to the welding state index and the monitoring threshold QC set by the system, and triggers the welding module to adjust and control the welding process according to the new welding parameters.

[0038] Optionally, the assembly processing method further includes: in step S2, during the welding process, the limiting module adjusts the postures of the first assembly part and the second assembly part to cooperate with the welding module for welding.

[0039] The beneficial effects achieved by the present invention are:

[0040] 1. Through the coordinated use of the quality assessment module and the welding module, the quality control capability of the assembly process is made more accurate, ensuring that the entire system has the advantages of good assembly quality, high processing efficiency, high intelligence, strong quality monitoring capability, and good real-time dynamic adjustment;

[0041] 2. Through the cooperation between the evaluation unit and the acquisition unit, the quality of the welding process is evaluated, ensuring that the entire system has the advantages of strong online verification capability, good automatic operation capability, high production efficiency, high intelligence, and reliable assembly accuracy;

[0042] 3. The first assembly and the second assembly are transported by the transport module, which improves the efficiency of transportation and ensures that the entire system can be assembled quickly, so that the entire system has the advantages of high assembly efficiency and strong automatic operation capability;

[0043] 4. Through the cooperation between the limit unit and the abutment unit, the assembly parts can be assembled without manual participation, which greatly reduces the labor intensity and ensures that the whole system has the advantages of high assembly angle adjustment accuracy, strong welding assembly ability and high intelligence;

[0044] 5. Through the coordination among the α adsorption component, the β adsorption component, and the posture adjustment component, the assembly can be installed without damage, thus maximizing the appearance quality of the assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The present invention can be further understood from the following description in conjunction with the accompanying drawings. The components in the figures are not necessarily drawn to scale, but the emphasis is placed on illustrating the principles of the embodiments. In different views, the same reference numerals designate the same parts.

[0046] Figure 1 It is an overall block diagram of the present invention.

[0047] Figure 2 It is a schematic block diagram of the limiting unit, the abutting unit, the first assembly part and the second assembly part of the present invention.

[0048] Figure 3 It is a block diagram of a welding parameter adjustment unit, a welding unit, a positioning unit, a first assembly unit and a second assembly unit of the present invention.

[0049] Figure 4 It is a partial structural schematic diagram of the conveying module, robotic arm, welding module and workbench of the present invention.

[0050] Figure 5 for Figure 4 A magnified schematic diagram of center A.

[0051] Figure 6 for Figure 4A magnified schematic diagram of point B in the middle.

[0052] Figure 7 It is a schematic structural diagram of the first assembly part and the limiting unit of the present invention.

[0053] Figure 8 It is a schematic structural diagram of the second assembly and the limiting unit of the present invention.

[0054] Fig. 9 It is a side view schematic diagram of the conveying module of the present invention transporting the first assembly.

[0055] Fig.10 for Fig. 9 Enlarged schematic diagram of point C in the middle.

[0056] Fig.11 It is a schematic diagram of the layout positions of the first assembly part, the second assembly part and the welding position of the present invention.

[0057] Fig.12 It is a schematic diagram of the structure of the robot arm and welding module of the present invention.

[0058] Explanation of the reference numerals in the accompanying drawings: 1. workbench; 2. conveying module; 3. robotic arm; 4. welding nozzle; 5. abutment rod; 6. fixing rod; 7. hinged portion; 8. movable rod; 9. fixing seat; 10. inflatable airbag; 11. first assembly part; 12. first hidden cavity; 13. conveyor belt; 14. correction rod; 15. correction plate; 16. actuator; 17. second assembly part; 18. welding position; 19. placement seat; 20. first extension rod; 21. first suction nozzle; 22. positioning marking member; 23. steering gear; 24. steering drive mechanism; 25. steering seat; 26. identification probe; 27. electronic deflation valve; 28. second extension rod; 29. ​​second suction nozzle; 30. telescopic rod; 31. positioning rod; 32. sensing component. DETAILED DESCRIPTION

[0059] The following is an explanation of the embodiments of the present invention through specific embodiments. Those skilled in the art can understand the advantages and effects of the present invention from the contents disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and the details in this specification can also be modified and changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. In addition, the drawings of the present invention are only simple schematic illustrations and are not depicted according to actual sizes. It is stated in advance. The following embodiments will further explain the relevant technical contents of the present invention in detail, but the disclosed contents are not intended to limit the scope of protection of the present invention.

[0060] Embodiment 1: According to Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Fig. 9 , Fig.10 , Fig.11 and Fig.12 As shown, this embodiment provides an assembly processing system for automobile lamp production, the assembly processing system includes a server, a processing table, and a robot arm 3, the assembly processing system also includes a conveying module 2, a limit module, a welding module, a quality assessment module, and a robot arm 3 control module, the server is respectively connected to the conveying module 2, the limit module, the welding module, the quality assessment module, and the robot arm 3 control module, and the intermediate data and process data of the conveying module 2, the limit module, the welding module, the quality assessment module, and the robot arm 3 control module are stored in the database of the server for query or call;

[0061] The conveying module 2 transports the first assembly and the second assembly to the processing table, the limiting module limits the first assembly 11 and the second assembly 17 transported by the conveying module 2, and abuts the first assembly 11 and the second assembly 17 to be assembled, the welding module welds the abutting first assembly 11 and the second assembly 17, the control module of the robot arm 3 controls the moving path of the welding module to cooperate with the welding module to weld the abutting first assembly 11 and the second assembly 17, the quality assessment module collects the welding position 18 of the welding module, and evaluates the collected welding data to form an assessment result, and feeds the assessment result back to the welding module to trigger the welding module to adjust the welding parameters;

[0062] The assembly processing system also includes a central processing unit, which is respectively connected to the conveying module 2, the limit module, the welding module, the quality assessment module, and the robot arm 3 control module, and centrally controls the conveying module 2, the limit module, the welding module, the quality assessment module, and the robot arm 3 control module based on the central processing unit, and transmits the control data of the central processing unit to the database of the server, thereby improving the assembly accuracy and assembly efficiency of the entire system;

[0063] The limiting module is arranged on the processing table, and the limiting module includes a limiting unit and a supporting unit, the limiting unit limits the first assembly and the second assembly to be transported, and the supporting unit adjusts the posture of the limiting unit so that the first assembly 11 to be assembled and the second assembly 17 can be close to each other;

[0064] Optionally, the limiting unit includes an α adsorption component, a β adsorption component, and a posture adjustment component, wherein the α adsorption component performs adsorption and limiting on the first assembly 11, the β adsorption component performs position limiting adsorption on the second assembly 17, and the posture adjustment component finely adjusts the postures of the α adsorption component and the β adsorption component, respectively, so that the spacing between the first assembly 11 adsorbed by the α adsorption component and the second assembly 17 adsorbed by the β adsorption component is equal;

[0065] The α adsorption member and the β adsorption member are independently connected to the posture adjustment member to form an α adsorption portion and a β adsorption portion, respectively, and the postures of the first assembly 11 adsorbed by the α adsorption member and the second assembly 17 adsorbed by the β adsorption member are finely adjusted;

[0066] The α adsorption component includes a first adsorption nozzle 21, a first adsorption pump, a first extension rod 20, a first extension drive mechanism and a first extension detection member, wherein the first adsorption pump is connected to the first adsorption nozzle 21 through a first adsorption tube to form a first adsorption portion, the first extension detection member detects the extension length of the first extension rod 20, one end of the first extension rod 20 is drivingly connected to the first extension drive mechanism to form a first drive portion, and the other end of the first extension rod 20 is connected to the first adsorption portion;

[0067] The first extension drive mechanism drives the first extension rod 20 to make the first extension rod 20 extend and retract, and adjusts the position of the first adsorption portion, so that the first adsorption portion can adsorb the first assembly 11, and ensures that the α adsorption member can adsorb the outer wall of the first assembly 11 with different structures;

[0068] At the same time, the first extension detection member is used to provide feedback on the extension length of the first extension rod 20, so that the central processor can compare the extension amount of the first extension rod 20 with the set parameter (target extension amount). If the two are different, the central processor drives the first extension drive mechanism to drive the first extension rod to be consistent with the set parameter (target extension amount), thereby accurately controlling the position of the first adsorption portion;

[0069] The β adsorption component includes a second adsorption nozzle 29, a second adsorption pump, a second extension rod 28, a second extension drive mechanism and a second extension detection member, wherein the second adsorption pump is connected to the second adsorption nozzle 29 through a second adsorption tube to form a second adsorption portion, the second extension detection member detects the extension length of the second extension rod 28, one end of the second extension rod 28 is drivingly connected to the second extension drive mechanism to form a second drive portion, and the other end of the second extension rod 28 is connected to the second adsorption portion;

[0070] The second extension drive mechanism drives the second extension rod 28, so that the second extension rod 28 performs a telescopic action, and adjusts the position of the second adsorption portion, so that the second adsorption portion can adsorb the second assembly 17, and ensures that the α adsorption member can adsorb the outer wall of the second assembly 17 with different structures;

[0071] At the same time, the extension length of the second extension rod 28 is fed back through the second extension detection member, so that the central processor can compare the extension amount of the second extension rod 28 with the set parameter (target extension amount). If the two are different, the central processor drives the second extension rod through the second extension drive mechanism, so that the second extension rod is consistent with the set parameter (target extension amount), thereby accurately controlling the position of the second adsorption portion;

[0072] Optionally, the posture adjustment component includes a steering sub-component and a tilt adjustment sub-component, the steering component steers the position of the tilt adjustment sub-component, and the tilt adjustment sub-component adjusts the postures of the α adsorption component and the β adsorption component;

[0073] The steering sub-component includes a fixed seat 9, a steering seat 25, a steering drive mechanism 24, an identification probe 26, and at least two positioning markers 22. The fixed seat 9 is used to support the steering seat 25. One side end face of the steering seat 25 is hinged with one side end face of the steering seat 25 to form a steering portion. The steering drive mechanism 24 is arranged on the fixed seat 9 and drives the steering seat 25 to rotate along the axis of the hinge position. At least two positioning markers 22 are arranged on the fixed seat 9 and are evenly spaced along the circumference of the steering portion. The identification probe 26 is arranged on the steering seat 25 and is arranged opposite to at least two positioning markers 22.

[0074] The steering sub-component further includes a steering gear 23, the steering gear 23 is nested on the steering seat 25, and the steering drive mechanism 24 is meshed with the steering gear 23, so that the steering drive mechanism 24 drives the steering seat 25 to rotate along the axis of the hinged position;

[0075] In this embodiment, the tilt adjustment sub-component is arranged on the steering sub-component.

[0076] When the steering sub-component rotates, the tilt adjustment sub-component, the α adsorption component and the β adsorption component, and the first assembly 11 adsorbed by the α adsorption component and the second assembly 17 adsorbed by the β adsorption component are driven to rotate synchronously;

[0077] The tilt adjustment sub-component includes an inflatable airbag 10, an inflating pump, an electronic deflation valve 27, and a placement seat 19. The placement seat 19 is used to place the inflatable airbag 10. The inflating pump is used to inflate the inflatable airbag 10 so that the inflatable airbag 10 bulges and changes the position of a limiting unit arranged on the inflatable airbag 10, thereby adjusting the position of the limiting unit. The electronic deflation valve 27 is arranged on the inflatable airbag 10 and is connected to the inside of the inflatable airbag 10 so that the gas in the inflatable airbag 10 is discharged.

[0078] When the gas in the inflatable airbag 10 is discharged, the inflatable airbag 10 is deflated and changes the original position of the limiting unit, so that the limiting unit returns to the original state;

[0079] In this embodiment, the α adsorption member and the β adsorption member are independently connected to the posture adjustment member to form an α adsorption portion and a β adsorption portion; the workbench 1 is provided with a first hidden cavity 12 and a second hidden cavity, and the abutting unit is respectively arranged in the first hidden cavity 12 and the second hidden cavity, so that the abutting unit adjusts the positions of the α adsorption portion and the β adsorption portion respectively, thereby bringing the α adsorption portion and the β adsorption portion closer to each other (at this time, the α adsorption portion and the β adsorption portion have adsorbed the first assembly 11 and the second assembly 17);

[0080] Specifically: the abutting unit respectively abuts the first assembly part adsorbed by the α adsorption part and the second assembly part 17 adsorbed by the β adsorption part against each other to form a welding posture (that is, the abutting unit on one side of the first hidden cavity 12 brings the first assembly part adsorbed by the α adsorption part and the abutting unit on one side of the second hidden cavity brings the second assembly part 17 adsorbed by the β adsorption part closer together, and abuts and merges in the middle to form a welding posture); the abutting unit includes a fixed rod 6, a movable rod 8, an abutting rod 5, an abutting driving mechanism, and a telescopic detection member, the fixed rod 6 is arranged on the bottom wall of the hidden cavity, one end of the movable rod 8 is hinged to one end of the fixed rod 6 to form a hinged part 7, the other end of the movable rod 8 is respectively connected to the α adsorption part or the β adsorption part posture adjustment unit to form an abutting part, one end of the abutting rod 5 is connected to the abutting part, and the other end of the abutting rod 5 is driven and connected to the abutting driving mechanism to form an action part, the action part is arranged at the other end of the fixed rod 6, and the telescopic detection member detects the telescopic length of the abutting rod 5;

[0081] After the β adsorption member adsorbs the second assembly 17, the abutment rod 5 is extended under the drive of the abutment driving mechanism, so that the β adsorption portion rotates around the axis of the hinge portion 7, so that the first assembly 11 adsorbed on the α adsorption portion and the second assembly 17 adsorbed on the β adsorption portion are abutted against each other, so as to ensure that the first assembly 11 and the second assembly 17 form a welding posture;

[0082] Through the cooperation between the limit unit and the abutment unit, the assembly parts can be assembled without manual intervention, which greatly reduces the labor intensity and ensures that the whole system has the advantages of high assembly angle adjustment accuracy, strong welding assembly capability and high intelligence.

[0083] Optionally, the welding module includes a welding unit, a positioning unit, and a welding parameter adjustment unit, the welding unit welds the first assembly 11 and the second assembly 17 that are close to each other with hot melt adhesive, the positioning unit positions the welding unit so that the welding unit welds directly to the welding position 18, and the welding parameter adjustment unit calculates new welding parameters according to the evaluation result of the evaluation module, and adjusts and controls the welding process according to the new welding parameters;

[0084] Wherein, the welding module is arranged on the execution end of the robot arm 3;

[0085] In this embodiment, the hot melt adhesive is a colloid specially used for automobile lamps and is used for sealing of parts assembly;

[0086] The welding unit includes a hot melt adhesive supply component and a heating component. The hot melt adhesive supply component supplies the hot melt adhesive, and the heating component heats the supplied hot melt adhesive so that the supplied hot melt adhesive can form a molten state and adhere to the two abutting first assembly parts 11 and second assembly parts 17;

[0087] The hot melt adhesive supply component includes a delivery pump, a delivery nozzle, a delivery pipe, and a storage tank. The storage tank stores the hot melt adhesive. The heating component is arranged in the storage tank and heats the hot melt adhesive stored in the storage tank so that the hot melt adhesive becomes a molten state. The delivery pump is arranged in the delivery pipe, and one end of the delivery pipe is connected to the storage tank, and the other end of the delivery pipe is connected to the delivery nozzle. When the delivery pump is running, the molten hot melt adhesive is transmitted to the delivery nozzle through the delivery pipe and adhered to the gap between the first assembly 11 and the second assembly 17. The heating component includes a heating element, a current controller, and a heating inner cavity. The heating inner cavity is arranged on the inner wall of the storage tank, and the heating element is arranged in a spiral around the heating inner cavity so that the hot melt adhesive stored in the storage tank is heated.

[0088] Wherein, the current controller controls the current applied to the heating element to achieve control of different temperatures;

[0089] The positioning unit includes a positioning rod 31, a sensing member 32, and a telescopic member. The positioning rod 31 is arranged on the telescopic member to form a positioning portion. The positioning portions are symmetrically arranged on both sides of the welding unit and position the first assembly 11 and the second assembly 17 in a welding posture. The sensing member 32 is arranged on the positioning rod 31 and senses the contact force between the positioning rod 31 and the first assembly 11 and the second assembly 17.

[0090] The sensing member 32 includes a data storage device, a contact plate, and at least one pressure sensor. The at least one pressure sensor is arranged on the contact plate and is evenly spaced along the extension direction of the contact plate. The contact plate is configured to be arranged on the contact end surface of the positioning rod 31 and the first assembly 11 and the second assembly 17. The data storage device stores contact pressure data collected by the at least one pressure sensor.

[0091] The telescopic member includes a telescopic rod 30 and a telescopic driving mechanism, one end of the telescopic rod 30 is drivingly connected to the telescopic driving mechanism, and the other end of the telescopic rod 30 is connected to the positioning rod 31, thereby forming the positioning portion, wherein the axis of the telescopic rod 30 and the axis of the positioning rod 31 are perpendicular to each other;

[0092] At the same time, the positioning parts are symmetrically arranged on both sides of the welding unit, and position the first assembly 11 and the second assembly 17, so that the welding unit can just weld the gap between the abutting first assembly 11 and the second assembly 17, thereby improving the assembly accuracy and reliability;

[0093] Wherein, the positioning position is set to the regular outer contour of the first assembly 11 and the second assembly 17;

[0094] If the irregular first assembly 11 and the second assembly 17 need to be manually assisted to determine the positioning part before positioning using the positioning position, this is a technical means well known to those skilled in the art, so it will not be described in detail in this embodiment;

[0095] The welding parameter adjustment unit includes a parameter adjustment controller and a feedback sensor array, wherein the sensor array monitors key parameters of the welding process in real time and feeds back data of the key parameters to the parameter adjustment controller, and the parameter adjustment controller receives the evaluation result of the quality evaluation and the real-time key parameters of the welding process to determine the welding parameters;

[0096] The feedback sensor array includes a temperature sensor, a flow sensor and a solenoid valve. The temperature sensor monitors the temperature of the hot melt adhesive in real time. The flow sensor is used to collect the flow of the delivery pipeline. The solenoid valve is used to adjust the spray opening of the hot melt adhesive.

[0097] When the first assembly 11 and the second assembly 17 are welded, the welding is performed with the default welding parameters, and after the welding set distance is reached, the welding position 18 is evaluated, and the welding parameters are dynamically adjusted according to the evaluation results to improve the accuracy and reliability of the assembly welding;

[0098] Among them, the default welding parameters are obtained and determined based on historical data or welding experience, and are initial parameters that have been preset in the system. This is a technical means well known to technicians in this field. Technicians in this field can refer to relevant technical manuals to learn about the technology, so they are not described one by one in this embodiment; Optionally, the quality assessment module includes a collection unit and an evaluation unit, the collection unit collects state data of the welding position 18 of the welding module, and the evaluation unit evaluates the welding position 18 according to the state data collected by the collection unit to form an evaluation result;

[0099] The acquisition unit includes an image acquisition component and a detection component, the image acquisition component acquires image data of the welding position 18, and the detection component detects the welding position 18 to acquire detection data of the welding position 18;

[0100] At the same time, the image acquisition component and the detection component are arranged on the mechanical arm, and perform image acquisition and detection on the welded position;

[0101] Wherein, the image acquisition component includes an image acquisition probe and an auxiliary light source, the auxiliary light source performs supplementary light to the image acquisition probe during the acquisition process, and the image acquisition probe acquires image data of the welding position 18;

[0102] The detection component includes an ultrasonic transmitter, an ultrasonic receiver and a signal processor. The ultrasonic transmitter is used to transmit ultrasonic pulses to the welding position 18, the ultrasonic receiver is used to receive the reflected ultrasonic signal and convert it into an electrical signal, and the signal processor is used to process the ultrasonic signal to generate uniformity and internal quality data of the weld.

[0103] Optionally, the conveying module 2 includes a transport unit and a correction unit, the transport unit transports the first assembly 11 and the second assembly 17 to be assembled, and the correction unit corrects the postures of the transported first assembly 11 and the second assembly 17 so that the first assembly 11 and the second assembly 17 fall into the limiting unit;

[0104] The transport unit comprises at least two transport belts 13 and a transport driving mechanism, wherein the at least two transport driving mechanisms independently drive the at least two transport belts 13 to form a γ transport section and a λ transport section;

[0105] The γ transport part and the λ transport part transport the first assembly 11 and the second assembly 17 to be welded independently.

[0106] The correction unit includes a correction plate 15, a correction rod 14, and a correction drive mechanism. One end of the correction rod 14 is connected to one end of the correction plate 15, and the other end of the correction rod 14 is drivingly connected to the correction drive mechanism to form a correction part. The correction part is arranged on both sides of the conveying direction of the conveyor belt 13, and corrects the first assembly 11 or the second assembly 17 transported by the conveyor belt 13 to ensure that the first assembly 11 and the second assembly 17 can accurately fall on the α adsorption part and the β adsorption part, and be adsorbed by the α adsorption part and the β adsorption part;

[0107] The correction parts symmetrically arranged on the conveyor belt 13 correct and place the first assembly 11 and the second assembly 17 in the middle of the conveyor belt 13, so that the first assembly 11 and the second assembly 17 fall accurately on the α adsorption part and the β adsorption part; that is, the correction parts on both sides of the conveyor belt 13 correct the first assembly 11 and the second assembly 17 toward the middle, so that the first assembly 11 and the second assembly 17 can be accurately placed and fall on the α adsorption part and the β adsorption part under the transmission of the conveyor belt 13;

[0108] The first assembly 11 and the second assembly 17 are transported by the transport module, which improves the efficiency of transportation and ensures that the entire system can be assembled quickly, so that the entire system has the advantages of high assembly efficiency and strong automatic operation capability;

[0109] The quality assessment module further includes a data processing unit, which processes the status data collected by the collection unit;

[0110] Specifically, the data processing unit acquires image data and processes the image data according to the following steps:

[0111] S21. Image data acquisition

[0112] Use a high-definition camera to photograph the weld position and obtain a high-resolution weld image;

[0113] S22. Image preprocessing

[0114] Preprocessing the collected images to improve image quality and facilitate subsequent analysis. The preprocessing includes but is not limited to the following: de-noising, grayscale, and contrast enhancement;

[0115] Denoising: Use Gaussian filter or median filter to remove noise from the image;

[0116] Grayscale processing: convert color images into grayscale images to simplify subsequent processing steps;

[0117] Contrast enhancement: Use histogram equalization method to enhance image contrast and highlight the weld edge;

[0118] S23, the step of determining the width coefficient W' of the weld at the welding position 18 comprises:

[0119] First, the weld width W is calculated. The calculation of its value is mainly achieved through edge detection and contour extraction. Specifically:

[0120] Edge detection: Use the Canny edge detection algorithm to extract the edges in the image;

[0121] Use the Canny edge detection algorithm (edges(x,y) indicates whether the pixel (x,y) is detected as an edge pixel in the image):

[0122]

[0123] Where I is the pixel value of the grayscale image at position (x, y), is the gradient of the image in the x direction;

[0124] T low and T high It is the low threshold and high threshold used for edge detection, and its value is set by the system;

[0125] Contour extraction: Use OpenCV's findContours function to extract contours from the image;

[0126] Extract the contours in the edge detection results and find the maximum contour C; where C is the maximum contour, which is a set of boundary points;

[0127] Calculate weld width: The width of the weld is determined by calculating the minimum circumscribed rectangle of the weld outline:

[0128] Calculate the minimum circumscribed rectangle R of the maximum contour C. The weld width W is defined as the width of the rectangle:

[0129] W=min(width(R),height(R));

[0130] Where W is the weld width, R is the minimum enclosing rectangle, width(R) and height(R) are the width and height of the minimum enclosing rectangle;

[0131] The width factor W' of the weld at the welding position is calculated based on the comprehensive surface quality:

[0132]

[0133] Where W is the weld width, W min and W max It is the minimum and maximum value of the weld width in the historical data of the assembly process of this component;

[0134] S24, the step of determining the weld surface quality coefficient S' of the welding position comprises:

[0135] First, the weld surface quality S is calculated. Its value is mainly achieved by analyzing the texture characteristics and smoothness of the weld area. Specifically:

[0136] Region segmentation: Use a mask to segment the weld area from the image;

[0137] The weld area is segmented from the image using a mask and defined as area A, where A is the weld area, which is a set of pixel points;

[0138] Texture analysis: Use gray level co-occurrence matrix (GLCM) to extract the texture features of the weld area, such as contrast, uniformity, etc.

[0139] Specifically: Use gray level co-occurrence matrix (GLCM) to extract the texture features of the weld area:

[0140]

[0141] Where P(i,j,d,θ) is the gray-level co-occurrence matrix, which indicates the co-occurrence frequency of the pixel pair (i,j) with gray values ​​i and j at the distance d and direction θ. (x1,y1) and (x2,y2) are a pair of pixels in image A. I(x1,y1)=i indicates that the gray value of pixel (x1,y1) is i, and I(x2,y2)=j indicates that the gray value of pixel (x2,y2) is j. d is the distance between two pixels, usually 1. θ is the direction between two pixels. Commonly used directions are 0°, 45°, 90°, and 135°.

[0142] The numerator of the above equation: {(x1,y1),(x2,y2)∈A|I(x1,y1)=i,I(x2,y2)=j} represents the number of pixel pairs with grayscale values ​​i and j at distance d and direction θ, that is, this part represents the number of pixel pairs in the image that satisfy the following conditions:

[0143] The gray value of pixel (x1, y1) is i;

[0144] The grayscale value of pixel (x2, y2) is j;

[0145] The distance between pixel (x1, y1) and pixel (x2, y2) is d;

[0146] The direction between pixel (x1, y1) and pixel (x2, y2) is θ;

[0147] Denominator: {(x1,y1),(x2,y2)∈A} is the total number of pixel pairs in area A that meet the distance d and direction θ;

[0148] In summary, the above formula is an exemplary description of the gray level co-occurrence matrix. The gray level co-occurrence matrix is ​​a conventional processing method in the image processing process. This is a technical method well known to those skilled in the art. Those skilled in the art can refer to relevant technical manuals to learn about the technology, so it will not be described in detail in this embodiment.

[0149] Calculate contrast and homogeneity:

[0150]

[0151] Where P(i,j,d,θ) is the gray-level co-occurrence matrix, which represents the frequency of occurrence of pixel pair (i,j) at distance d and direction θ;

[0152] Smoothness calculation: Use the gradient information of the image to calculate the smoothness of the weld area. Specifically, calculate the gradient amplitude G(x, y) at position (x, y) in weld area A:

[0153]

[0154] In the formula, among which: and is the gradient of the image in the x and y directions, obtained through image processing technology;

[0155] Calculate smoothness:

[0156]

[0157] Where A is the weld area in the image, N is the number of pixels in the weld area A, and its value is obtained through image processing technology. G(x,y): the gradient amplitude at the position (x,y);

[0158] Comprehensive surface quality: Combined with texture characteristics and smoothness, calculate the comprehensive surface quality S of the weld:

[0159]

[0160] Where contrast is contrast (used to measure the degree of local variation of texture), homogeneity is uniformity (used to measure the smoothness of texture), and smoothness is smoothness (its value is equal to the average value of the gradient amplitude in the weld area);

[0161] Calculate the weld surface quality coefficient S' at the welding position:

[0162] S′=lg(S+1);

[0163] Where S is the comprehensive surface quality of the weld;

[0164] The data processing unit obtains the data detected by the detection component and processes the detected data according to the following steps:

[0165] S31, calculating the weld uniformity coefficient E' of the welding position:

[0166] First, calculate the weld uniformity E (weld uniformity reflects the uniform distribution of weld materials; ultrasonic testing can be used to evaluate the uniformity of weld materials) according to steps S31.1 to S31.5:

[0167] S31.1, Ultrasonic emission and reception:

[0168] Transmit: The ultrasonic transmitter transmits ultrasonic pulses to the weld area;

[0169] Receiving: The ultrasonic receiver receives the ultrasonic signal reflected from inside the weld;

[0170] S31.2, Signal processing:

[0171] Sampling: Sample the received ultrasonic signal to obtain the time series data S(t) of the reflected signal:

[0172] S31.3. Calculate energy density: Divide the signal S(t) into N hour time windows Δt i , each window contains several sampling points;

[0173] Compute the energy of the signal in each time window:

[0174]

[0175] In the formula, E i is the signal energy of the i-th time window;

[0176] S31.4. Uniformity calculation: Calculate the energy standard deviation σ of the set sampling or acquisition time windows E :

[0177]

[0178] Where N is the total number of sampling or acquisition time windows, μ E is the average value of the energy of all time windows, satisfying:

[0179]

[0180] Where N is the total number of sampling or acquisition time windows, E i is the signal energy of the i-th time window;

[0181] S31.5. Calculate the weld uniformity E:

[0182]

[0183] In the formula, σ E The energy standard deviation of all time windows for the set sampling or acquisition;

[0184] The weld uniformity coefficient E' of the welding position is calculated according to the calculated weld uniformity E:

[0185]

[0186] Where, E is the uniformity of the weld;

[0187] S32, calculating the internal defect coefficient D' of the welding position:

[0188] First, calculate the internal defects D of the weld (internal defects of the weld reflect whether there are defects such as cracks and pores inside the weld; ultrasonic testing can be used to identify and locate these defects) according to steps S32.1 to S32.5:

[0189] S32.1. Ultrasonic emission and reception:

[0190] Transmit: The ultrasonic transmitter transmits ultrasonic pulses to the weld area;

[0191] Receiving: The ultrasonic receiver receives the ultrasonic signal reflected from inside the weld;

[0192] S32.2, signal processing: sampling: sampling the received ultrasonic signal to obtain the time series data S(t) of the reflected signal;

[0193] S32.3, Defect identification: Identify abnormal peaks in the reflection signal through signal amplitude and echo time. These abnormal peaks usually correspond to defects inside the weld;

[0194] Identify defects in the ultrasonic signal by following these steps:

[0195] Signal peak detection: Perform peak detection on the ultrasonic signal S(t) to identify all local maxima (peaks) in the signal;

[0196] Peak detection formula (e.g. using simple thresholding or more sophisticated signal processing techniques):

[0197] Peaks = {S(t k )|S(t k )>Threshold};

[0198] Among them, t k is the time point when the peak value appears, S(t k ) is the peak value of the ultrasonic signal at the time point when the peak value appears, and Threshold is the threshold value of peak detection set by the system;

[0199] Defect signal amplitude: The abnormal peaks in the identified signal peaks are regarded as defects, and the amplitudes of these peaks are recorded. i ;

[0200] At the same time, the number of defect signals that appear is counted, recorded as N d (number of identified defects);

[0201] S32.4, Defect Scoring:

[0202] Calculate the score D for each defect i :

[0203]

[0204] In the formula, A i is the amplitude of the ith defect, max(S(t)) is the maximum amplitude of the signal;

[0205] S32.5. Calculate the sum of all defect scores D:

[0206]

[0207] Where N d is the number of defects identified, D i is the score of the ith defect;

[0208] Based on the sum of all defect scores D, the internal defect coefficient D' of the welding position is calculated:

[0209]

[0210] Where D is the sum of the internal defect scores of the weld;

[0211] Optionally, the evaluation unit obtains the pre-processed state data and calculates the weld state index Weld according to the following formula:

[0212]

[0213] Wherein, W' is the width coefficient of the weld at the welding position, S' is the surface quality coefficient of the weld at the welding position, E' is the uniformity coefficient of the weld at the welding position, and D' is the internal defect coefficient of the welding position;

[0214] If the weld state index Weld does not fall within the set monitoring threshold range [QC1, QC2], the welding parameter adjustment unit is triggered to adjust the welding parameters;

[0215] If the weld state index Weld falls within the set monitoring threshold range [QC1, QC2], it means that the weld quality is qualified;

[0216] The set monitoring threshold range [QC1, QC2] is set by the system or the administrator according to the actual situation and input from the human-computer interaction interface. This is a technical means well known to those skilled in the art. Those skilled in the art can refer to the relevant technical manuals to learn about the technology, so it will not be described in detail in this embodiment.

[0217] Through the cooperation between the evaluation unit and the acquisition unit, the quality of the welding process is evaluated, ensuring that the entire system has the advantages of strong online verification capability, good automatic operation capability, high production efficiency, high intelligence, and reliable assembly accuracy;

[0218] In this embodiment, the welding parameters include: welding temperature T, welding glue amount G and welding speed V;

[0219] In this embodiment, the welding parameter adjustment unit obtains the evaluation result and determines the new welding parameter according to the following formula:

[0220]

[0221] Where, T new is the new soldering temperature, T currentis the current real-time welding temperature, which is collected by the temperature sensor set in the conveying pipeline, K T is the temperature adjustment coefficient, and its value is set by the system according to the actual situation, Weld is the weld state index, QC1 is the lower limit of the set monitoring threshold range, and QC2 is the upper limit of the set monitoring threshold range;

[0222]

[0223] In the formula, G new is the new welding glue amount, G current is the current real-time glue volume, which is collected by the flow sensor installed in the conveying pipeline. G is the glue quantity adjustment coefficient, and its value is set by the system according to the actual situation, Weld is the weld state index, QC1 is the lower limit of the set monitoring threshold range, and QC2 is the upper limit of the set monitoring threshold range;

[0224]

[0225] Where V new is the new welding speed, V current is the current real-time welding speed, whose value is collected by the speed sensor set on the robot arm, K V is the glue quantity adjustment coefficient, and its value is set by the system according to the actual situation, Weld is the weld state index, QC1 is the lower limit of the set monitoring threshold range, and QC2 is the upper limit of the set monitoring threshold range;

[0226] At the same time, in this embodiment, the temperature adjustment coefficient K T The value range of is: 1.0~2.0;

[0227] Value trend: A higher temperature adjustment coefficient indicates that the welding temperature is sensitive to the weld state index and that the temperature needs to be adjusted precisely to ensure welding quality;

[0228] Glue adjustment coefficient K G The value range of is: 0.5~1.5;

[0229] Value trend: The glue amount adjustment coefficient is relatively small, which means that the effect of glue amount change on weld state index is relatively mild, but still needs to be precisely controlled;

[0230] Welding speed adjustment factor K V The value range of is: 0.8~1.2;

[0231] Value trend: The welding speed adjustment coefficient is in the medium range, which means that the welding speed has a certain influence on the weld state index and the speed needs to be adjusted appropriately;

[0232] In addition, a temperature adjustment factor K is provided. T , Glue quantity adjustment coefficient K G , welding speed adjustment coefficient K V The values ​​of are given as examples, specifically:

[0233] 1) Combination assembly of polypropylene (PP) and polycarbonate (PC)

[0234] First assembly: Polypropylene (PP)

[0235] First assembly: polycarbonate (PC)

[0236] Then, the temperature adjustment coefficient K T =1.3;

[0237] Glue adjustment coefficient K G =1.0;

[0238] Welding speed adjustment factor K V =0.9;

[0239] 2) Combination of aluminum alloy and tempered glass

[0240] First assembly: aluminum alloy

[0241] First assembly: tempered glass

[0242] Then, the temperature adjustment coefficient K T =1.7;

[0243] Glue adjustment coefficient K G =1.2;

[0244] Welding speed adjustment factor K V =1.0;

[0245] 3) Combination assembly of ABS plastic and polycarbonate (PC)

[0246] First assembly part: ABS plastic

[0247] First assembly: polycarbonate (PC)

[0248] Then, the temperature adjustment coefficient K T =1.4;

[0249] Glue adjustment coefficient K G =1.1;

[0250] Welding speed adjustment factor K V =0.9;

[0251] In summary, the temperature adjustment factor K T , Glue quantity adjustment coefficient K G, welding speed adjustment coefficient K V The value of needs to be determined in combination with a specific scenario or actual situation and input from a human-computer interaction interface or a control input interface. This is a technical means well known to those skilled in the art, and therefore will not be described in detail in this embodiment;

[0252] In addition, the above new welding parameters are only used as an example, and those skilled in the art can adjust them according to actual conditions, so they will not be described in detail in this example;

[0253] Through the coordinated use of the quality assessment module and the welding module, the quality control capability of the assembly process is made more accurate, ensuring that the entire system has the advantages of good assembly quality, high processing efficiency, high intelligence, strong quality monitoring capability, and good real-time dynamic adjustment;

[0254] The control module of the robot arm 3 includes a visual guidance unit, a posture acquisition unit and a motion control unit. The visual guidance unit guides the welding posture or welding position 18 of the first assembly 11 and the second assembly 17. The posture acquisition unit acquires posture data of the robot arm 3. The motion control unit controls the robot arm 3 according to the posture data acquired by the posture acquisition unit, so that the robot arm 3 drives the welding module to weld the first assembly 11 and the second assembly 17 along the positioning position.

[0255] The visual guidance unit includes a camera and an image processor, wherein the camera is used to capture the welding area, and the image processor processes the image of the welding area acquired by the camera to identify the welding position 18;

[0256] The image processor processes and identifies the captured welding area and obtains the welding position 18, which is a conventional method in the field of robot control or image processing technology. This is also a technical method well known to those skilled in the art. Those skilled in the art can refer to relevant technical manuals to learn about the technology, so it will not be described in detail in this embodiment.

[0257] The posture acquisition unit includes at least one force sensor and a position sensor, wherein at least one force sensor monitors the force applied by the mechanical arm 3, and at least one position sensor monitors the joint position and angle of the mechanical arm 3;

[0258] The motion control unit includes at least one actuator 16, which is arranged at each joint of the mechanical arm 3 and drives each joint of the mechanical arm 3 so that each joint of the mechanical arm 3 rotates;

[0259] In this embodiment, a control flow of a robot arm 3 control module is provided, and the specific steps are as follows:

[0260] S11, initialization phase

[0261] S11.1, System startup: Start the motion control unit and load the control program;

[0262] Initialize each sensor and actuator 16, perform self-test and calibration;

[0263] S11.2. Read welding task information

[0264] Obtain information of the current welding task from the server, including welding position 18, path and parameters; wherein, since the first assembly 11 and the second assembly 17 have been transported to the processing table by the conveying module 2;

[0265] S12, identification and positioning stage

[0266] S12.1, visual guidance unit start

[0267] The vision guidance unit is activated and the camera captures the image of the welding area;

[0268] S12.2 Image Processing

[0269] Analyzing the image through image processing algorithms (such as edge detection and feature matching) to identify welding locations 18 and feature points;

[0270] S12.3. Calculate position

[0271] Calculate the coordinates of the welding position 18 and convert them into the coordinate system of the robot arm 3;

[0272] S13, Motion Planning Stage

[0273] Step S13.1: Path planning

[0274] According to the welding position 18 and the welding task information, the motion planning algorithm is used to calculate the optimal motion path of the robot arm 3 to ensure that obstacles are avoided and the target position is reached;

[0275] S13.2, generate trajectory: generate the motion trajectory of the robot arm 3 according to the planned path, including joint angle, speed and acceleration;

[0276] S14, welding execution stage

[0277] S14.1, motion control: start the servo actuator 16, control the movement of each joint of the robot arm 3 according to the generated trajectory, and move the welding module to the welding position 18;

[0278] S14.2, welding operation: the welding module is started, and the hot melt glue gun applies hot melt glue to the welding position 18, and at the same time, the temperature control, glue quantity control and cooling control work together to ensure the welding quality;

[0279] S14.3, Real-time monitoring: The sensor monitors the key parameters of the welding process, such as force, position and temperature, in real time, and feeds back the data of the force sensor and position sensor to the controller for real-time adjustment;

[0280] S15, Evaluation and Adjustment Phase

[0281] S15.1, quality assessment: after welding is completed, the assessment module collects data of the welding position 18 through the optical detection unit and the ultrasonic detection unit, and the assessment unit performs assessment based on the collected data to generate an assessment result of the welding state;

[0282] S15.2. Parameter adjustment

[0283] Based on the evaluation results, the welding parameter adjustment unit automatically adjusts the welding parameters (such as temperature, glue amount and welding speed) to optimize the next welding operation;

[0284] S16, Ending Phase

[0285] S16.1. Records and reports

[0286] Upload the execution data and quality assessment results of the welding task to the server and record them in the database;

[0287] S16.2. Prepare for the next task

[0288] The robot arm 3 returns to the initial position and is ready to perform the next welding task;

[0289] In this embodiment, the control of the robot arm 3 can also be adjusted according to actual conditions. The above is only an exemplary description of the robot arm 3.

[0290] In addition, the present invention also provides an assembly processing method for automobile lamp production, the assembly processing method comprising the following steps:

[0291] S1, transporting the first assembly part 11 and the second assembly part 17 to be assembled to the assembly station through the conveying module 2;

[0292] S2, the limiting module limits and absorbs the first assembly 11 and the second assembly 17 transported into the processing table, and makes the first assembly 11 and the second assembly 17 to be assembled abut against each other to form a welding posture;

[0293] S3, controlling the robot arm 3 to carry the welding module to weld the first assembly 11 and the second assembly 17 in a welding posture through the robot arm 3 control module, so that the first assembly 11 and the second assembly 17 to be assembled are adhered with hot melt adhesive to form a welding position 18;

[0294] S4, the quality assessment module collects the status data of the welding position 18, and evaluates the welding status index Weld of the welding position 18 according to the collected status data to form an evaluation result;

[0295] S5, the welding module dynamically triggers adjustment and control of welding parameters according to the evaluation results;

[0296] Optionally, the assembly processing method further includes: in step S5, when a trigger condition is met, the welding module determines a new welding parameter according to the welding state index and a monitoring threshold range [QC1, QC2] set by the system, and triggers the welding module to adjust and control the welding process according to the new welding parameter;

[0297] In this embodiment, the trigger condition is set as: the welding state index does not fall within the monitoring threshold range [QC1, QC2] set by the system;

[0298] Optionally, the assembly processing method further includes: in step S2, during the welding process, the limiting module adjusts the postures of the first assembly 11 and the second assembly 17 to cooperate with the welding module for welding;

[0299] The assembly processing method further includes: transmitting the calculated welding temperature T, welding glue amount G and welding speed V to the welding module and the robot arm 3 control module, so that the welding module can accurately control the welding process;

[0300] In this embodiment, the assembly processing method further includes: after the welding of the first assembly 11 and the second assembly 17 is completed, the welded finished product is transferred to another location for storage, and the welding of the next assembly is performed to achieve the purpose of continuous operation, so as to improve the efficiency of the entire assembly process;

[0301] Among them, transferring the welded finished product is a method well known to those skilled in the art, and thus will not be described in detail.

[0302] Embodiment 2: This embodiment should be understood to include all the features of any of the above embodiments, and further improve upon them. Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Fig. 9 , Fig.10 , Fig.11 and Fig.12 As shown, the limiting unit further includes a posture sampling subunit and a posture evaluation subunit, wherein the posture acquisition subunit is used to acquire the tilt posture of the inflatable airbag to form posture acquisition data, and the posture evaluation subunit evaluates the postures of the first assembly 11 and the second assembly 17 according to the posture acquisition data;

[0303] The posture sampling subunit includes a tilt sensor and a placement seat, wherein the placement seat is used to place the tilt sensor, and the tilt sensor is used to measure the tilt angle of the inflatable airbag;

[0304] Wherein, the tilt sensor is installed on the limit unit or the adsorption member to monitor its tilt angle in real time;

[0305] At the same time, the output voltage V θ The relationship with the tilt angle θ is linear, that is:

[0306] θ=k θ ·V θ +b θ ;

[0307] Where θ is the tilt angle in degrees, V θ is the voltage output by the inclination sensor, in volts (V), and its value can be directly collected by the inclination sensor. θ is the conversion factor, in degrees / volt, obtained from experimental calibration data, b θ is the offset, in degrees, and its value represents the output voltage offset when the sensor is at zero tilt angle (horizontal position); the determination of the offset usually requires experimental calibration (determined by the installed hardware equivalent to a known value);

[0308] Based on the above relationship, the posture evaluation subunit obtains the target tilt angle θtarget and calculates the required inflation volume V according to the following formula: air,target :

[0309]

[0310] In the formula, k V It indicates the proportionality coefficient between the inflation volume and the tilt angle. Its unit is degree / liter. Specifically, it indicates how many degrees the tilt angle increases for every liter increase in inflation volume. VIndicates the offset, its unit is degree. Specifically, it indicates the initial offset of the tilt angle when the inflation volume is zero.

[0311] Among them, the proportional coefficient k between the inflation volume and the tilt angle V , offset b V The determination is made through experimental calibration, and the specific steps include:

[0312] S41, Initial calibration

[0313] Initial state record: record the tilt angle θ0 when the airbag is not inflated;

[0314] Record the corresponding inflation volume Vair, 0 = 0 liters;

[0315] S42, initial offset b V : Initial offset b V Directly take it as θ0, that is:

[0316] b V =θ0;

[0317] S43, step-by-step inflation calibration

[0318] Stepwise inflation: a certain amount of gas is added to the airbag each time, for example: ΔVair = 0.1 liter;

[0319] Record the tilt angle θ after each inflation;

[0320] Data recording: record multiple sets of inflation volume Vair and corresponding tilt angle θ;

[0321] S44. Regression analysis

[0322] Linear regression model: Establish a linear relationship model between the inflation volume Vair and the tilt angle θ:

[0323] θ=k V V air +b V ;

[0324] Least Squares Method: Calculate the regression coefficient k using the least squares method V and offset b V ;

[0325] The calibration constant k of the system is determined by the above steps S41 to S44. V and offset b V ;

[0326] The posture evaluation subunit evaluates the required inflation volume V air,targetThe airbag is inflated by the central processor to achieve the calculated inflation volume V. air,target ;

[0327] At the same time, the current tilt angle θ is monitored in real time through the inclination sensor. If the current tilt angle is equal to the target tilt angle θ target If not, continue to adjust the inflation volume of the airbag;

[0328] Through the cooperation between the posture sampling subunit and the posture evaluation subunit, the airbag inflation volume and the component tilt angle are precisely controlled, thereby ensuring the stability and reliability of the assembly process;

[0329] In this embodiment, through the cooperation between the limiting unit and the abutting unit, the first assembly 11 and the second assembly 17 can abut against each other, ensuring that the entire system has the advantages of high assembly efficiency, good assembly accuracy and high intelligence.

[0330] The contents disclosed above are only preferred feasible embodiments of the present invention, and do not limit the protection scope of the present invention. Therefore, all equivalent technical changes made using the contents of the present invention specification and drawings are included in the protection scope of the present invention. In addition, the elements therein can be updated as technology develops.

Claims

1. An assembly processing system for automobile lamp production, the assembly processing system comprising a server, a processing table, and a robot arm, characterized in that: The assembly processing system further includes a conveying module, a limiting module, a welding module, a quality assessment module, and a robotic arm control module, and the server is connected to the conveying module, the limiting module, the welding module, the quality assessment module, and the robotic arm control module respectively; The conveying module transports the first assembly and the second assembly to the processing table, the limiting module limits the first assembly and the second assembly transported by the conveying module, and abuts the first assembly and the second assembly to be assembled, the welding module welds the abutting first assembly and the second assembly, the robot arm control module controls the moving path of the welding module to cooperate with the welding module to weld the abutting first assembly and the second assembly, the quality assessment module collects the welding position of the welding module, and evaluates the collected welding data to form an evaluation result, and feeds the evaluation result back to the welding module to trigger the welding module to adjust the welding parameters; The limiting module is arranged on the processing table, and the limiting module includes a limiting unit and a supporting unit, the limiting unit limits the first assembly and the second assembly to be transported, and the supporting unit adjusts the posture of the limiting unit so that the first assembly to be assembled and the second assembly can be close to each other; The limiting unit includes an α adsorption component, a β adsorption component, and a posture adjustment component, wherein the α adsorption component performs adsorption and positioning of the first assembly, the β adsorption component performs position-limiting adsorption of the second assembly, and the posture adjustment component finely adjusts the postures of the α adsorption component and the β adsorption component, respectively, so that the spacing between the first assembly adsorbed by the α adsorption component and the second assembly adsorbed by the β adsorption component is equal; The α adsorption member and the β adsorption member are independently connected to the posture adjustment member to form an α adsorption portion and a β adsorption portion, respectively, and the postures of the first assembly adsorbed by the α adsorption member and the second assembly adsorbed by the β adsorption member are finely adjusted; The posture adjustment component includes a steering subcomponent and a tilt adjustment subcomponent, wherein the steering subcomponent is used to steer the position of the tilt adjustment subcomponent, and the tilt adjustment subcomponent is used to adjust the postures of the α adsorption component and the β adsorption component; Wherein, the steering sub-component comprises a fixed seat, a steering seat, a steering drive mechanism, an identification probe, and at least two positioning markings, the fixed seat is used to support the steering seat, one side end face of the steering seat is hinged with one side end face of the steering seat to form a steering portion, and the steering drive mechanism is arranged on the fixed seat, and drives the steering seat to rotate along the axis of the hinge position, at least two positioning markings are arranged on the fixed seat, and are evenly spaced along the circumference of the steering portion, and the identification probe is arranged on the steering seat, and is arranged opposite to at least two positioning markings; The tilt adjustment sub-component includes an inflatable airbag, an inflatable pump, an electronic deflation valve, and a placement seat, wherein the placement seat is used to place the inflatable airbag, the inflatable pump is used to inflate the inflatable airbag so that the inflatable airbag bulges, and change the position of a limiting unit arranged on the inflatable airbag, thereby adjusting the position of the limiting unit, and the electronic deflation valve is arranged on the inflatable airbag and connected to the inside of the inflatable airbag so that the gas in the inflatable airbag is discharged; The welding module includes a welding unit, a positioning unit, and a welding parameter adjustment unit. The welding unit welds the first assembly and the second assembly that are close to each other with hot melt adhesive. The positioning unit positions the welding unit so that the welding unit welds at the welding position. The welding parameter adjustment unit calculates new welding parameters according to the evaluation result of the evaluation module, and adjusts and controls the welding process according to the new welding parameters. The positioning unit includes a positioning rod, a sensing member, and a telescopic member. The positioning rod is arranged on the telescopic member to form a positioning portion. The positioning portions are symmetrically arranged on both sides of the welding unit and position the first assembly and the second assembly in a welding posture. The sensing member is arranged on the positioning rod and senses the contact force between the positioning rod and the first assembly and the second assembly. Wherein, the welding module is arranged on the execution end of the robot arm.

2. The assembly and processing system for automobile lamp production according to claim 1, characterized in that: The quality assessment module includes a collection unit and an assessment unit, wherein the collection unit collects state data of the welding position of the welding module, and the assessment unit assesses the welding position according to the state data collected by the collection unit to form an assessment result; The acquisition unit includes an image acquisition component and a detection component. The image acquisition component acquires image data of the welding position. The detection component detects the welding position and acquires detection data of the welding position.

3. The assembly and processing system for automobile lamp production according to claim 2, characterized in that: The conveying module includes a transport unit and a correction unit, wherein the transport unit transports the first assembly and the second assembly to be assembled, and the correction unit corrects the postures of the transported first assembly and the second assembly so that the first assembly and the second assembly fall into the limiting unit; The transport unit comprises at least two transport belts and a transport driving mechanism, wherein the at least two transport driving mechanisms independently drive the at least two transport belts to form a γ transport part and a λ transport part; The γ transport part and the λ transport part transport the first assembly to be welded and the second assembly to be welded respectively and independently.

4. The assembly and processing system for automobile lamp production according to claim 3, characterized in that: The quality assessment module further includes a data processing unit, which processes the status data collected by the collection unit; The data processing unit acquires image data and processes the image data according to the following steps: S21. Image data acquisition Use a high-definition camera to photograph the weld position and obtain a high-resolution weld image; S22. Image preprocessing Preprocessing the collected images to improve image quality and facilitate subsequent analysis. The preprocessing includes but is not limited to the following: de-noising, grayscale, and contrast enhancement; Denoising: Use Gaussian filter or median filter to remove noise from the image; Grayscale processing: convert color images into grayscale images to simplify subsequent processing steps; Contrast enhancement: Use histogram equalization method to enhance image contrast and highlight the weld edge; S23, the step of determining the width coefficient W' of the weld at the welding position 18 comprises: First, the weld width W is calculated. The calculation of its value is mainly achieved through edge detection and contour extraction. Specifically: Edge detection: Use the Canny edge detection algorithm to extract the edges in the image; Using the Canny edge detection algorithm, edges(x,y) is used to indicate whether the pixel (x,y) is detected as an edge pixel in the image: Where I is the pixel value of the grayscale image at position (x, y), is the gradient of the image in the x direction; T low and T high It is the low threshold and high threshold used for edge detection, and its value is set by the system; Contour extraction: Use OpenCV's findContours function to extract contours from the image; Extract the contours in the edge detection results and find the maximum contour C; where C is the maximum contour, which is a set of boundary points; Calculate weld width: The width of the weld is determined by calculating the minimum circumscribed rectangle of the weld outline: Calculate the minimum circumscribed rectangle R of the maximum contour C. The weld width W is defined as the width of the rectangle: W=min(width(R),height(R)); Where W is the weld width, R is the minimum enclosing rectangle, width(R) and height(R) are the width and height of the minimum enclosing rectangle; The width factor W' of the weld at the welding position is calculated based on the comprehensive surface quality: Where W is the weld width, W min and W max It is the minimum and maximum value of the weld width in the historical data of the assembly process of this component; S24, the step of determining the weld surface quality coefficient S' of the welding position comprises: First, the weld surface quality S is calculated. Its value is mainly achieved by analyzing the texture characteristics and smoothness of the weld area. Specifically: Region segmentation: Use a mask to segment the weld area from the image; The weld area is segmented from the image using a mask and defined as area A, where A is the weld area, which is a set of pixel points; Texture analysis: Gray-level co-occurrence matrix (GLCM) is used to extract the texture features of the weld area; Specifically: Use gray level co-occurrence matrix (GLCM) to extract the texture features of the weld area: Where P(i,j,d,θ) is the gray-level co-occurrence matrix, which indicates the co-occurrence frequency of the pixel pair (i,j) with gray values ​​i and j at the distance d and direction θ. (x1,y1) and (x2,y2) are a pair of pixels in image A. I(x1,y1)=i indicates that the gray value of pixel (x1,y1) is i, and I(x2,y2)=j indicates that the gray value of pixel (x2,y2) is j. d is the distance between two pixels, and θ is the direction between two pixels. Commonly used directions are 0°, 45°, 90°, and 135°. The numerator of the above equation: {(x1,y1),(x2,y2)∈A|I(x1,y1)=i,I(x2,y2)=j} represents the number of pixel pairs with grayscale values ​​i and j at distance d and direction θ, that is, this part represents the number of pixel pairs in the image that satisfy the following conditions: The grayscale value of pixel (x1, y1) is i; The grayscale value of pixel (x2, y2) is j; The distance between pixel (x1, y1) and pixel (x2, y2) is d; The direction between pixel (x1, y1) and pixel (x2, y2) is θ; Denominator: {(x1,y1),(x2,y2)∈A} is the total number of pixel pairs in area A that meet the distance d and direction θ; Calculate contrast and homogeneity: Where P(i,j,d,θ) is the gray-level co-occurrence matrix, which represents the frequency of occurrence of pixel pair (i,j) at distance d and direction θ; Smoothness calculation: Use the gradient information of the image to calculate the smoothness of the weld area. Specifically, calculate the gradient amplitude G(x, y) at position (x, y) in weld area A: In the formula, among which: and is the gradient of the image in the x and y directions, obtained through image processing technology; Calculate smoothness: Where A is the weld area in the image, N is the number of pixels in the weld area A, and its value is obtained through image processing technology. G(x,y): the gradient amplitude at the position (x,y); Comprehensive surface quality: Combined with texture characteristics and smoothness, calculate the comprehensive surface quality S of the weld: Where, contrast is contrast, which is used to measure the degree of local variation of texture; homogeneity is uniformity, which is used to measure the smoothness of texture; smoothness is smoothness, and its value is equal to the average value of the gradient amplitude in the weld area; Calculate the weld surface quality coefficient S' at the welding position: S′=lg(S+1); Where S is the comprehensive surface quality of the weld; The data processing unit obtains the data detected by the detection component and processes the detected data according to the following steps: S31, calculating the weld uniformity coefficient E' of the welding position: S31.

1. Ultrasonic emission and reception: Transmit: The ultrasonic transmitter transmits ultrasonic pulses to the weld area; Receiving: The ultrasonic receiver receives the ultrasonic signal reflected from inside the weld; S31.2, Signal processing: Sampling: Sample the received ultrasonic signal to obtain the time series data S(t) of the reflected signal: S31.

3. Calculate energy density: Divide the signal S(t) into N hour time windows Δt i , each window contains several sampling points; Compute the energy of the signal in each time window: In the formula, E i is the signal energy of the i-th time window; S31.

4. Uniformity calculation: Calculate the energy standard deviation σ of the set sampling or acquisition time windows E : Where N is the total number of sampling or acquisition time windows, μ E is the average value of the energy of all time windows, satisfying: Among them, E i is the signal energy of the i-th time window; S31.

5. Calculate the weld uniformity E: The weld uniformity coefficient E' of the welding position is calculated according to the calculated weld uniformity E: S32, calculating the internal defect coefficient D' of the welding position: S32.

1. Ultrasonic emission and reception: Transmit: The ultrasonic transmitter transmits ultrasonic pulses to the weld area; Receiving: The ultrasonic receiver receives the ultrasonic signal reflected from inside the weld; S32.2, signal processing: sampling: sampling the received ultrasonic signal to obtain the time series data S(t) of the reflected signal; S32.3, Defect identification: Identify abnormal peaks in the reflection signal through signal amplitude and echo time; Identify defects in the ultrasonic signal by following these steps: Signal peak detection: Perform peak detection on the ultrasonic signal S(t) to identify all local maxima in the signal; Peak detection formula: Peaks={S(t k )|S(t k )>Threshold}; Among them, t k is the time point when the peak value appears, S(t k ) is the peak value of the ultrasonic signal at the time point when the peak value appears, and Threshold is the threshold value of peak detection set by the system; Defect signal amplitude: The abnormal peaks in the identified signal peaks are regarded as defects, and the amplitudes of these peaks are recorded. i ; At the same time, the number of defect signals that appear is counted, recorded as N d ; S32.4, Defect Scoring: Calculate the score D for each defect i : In the formula, A i is the amplitude of the ith defect, max(S(t)) is the maximum amplitude of the signal; S32.

5. Calculate the sum of all defect scores D: Where N d is the number of defects identified, D i is the score of the ith defect; Based on the sum of all defect scores D, the internal defect coefficient D' of the welding position is calculated: Where D is the sum of the internal defect scores of the weld; The evaluation unit obtains the pre-processed state data and calculates the weld state index Weld according to the following formula: Wherein, W' is the width coefficient of the weld at the welding position, S' is the surface quality coefficient of the weld at the welding position, E' is the uniformity coefficient of the weld at the welding position, and D' is the internal defect coefficient of the welding position; If the weld state index Weld does not fall within the set monitoring threshold range [QC1, QC2], the welding parameter adjustment unit is triggered to adjust the welding parameters.

5. An assembly method for automobile lamp production, which is applied to the assembly system for automobile lamp production according to claim 4, characterized in that: The assembly method comprises the following steps: S1, transporting the first assembly part and the second assembly part to be assembled to the assembly station through the conveying module; S2, the limiting module limits and absorbs the first assembly and the second assembly transported into the processing table, and makes the first assembly and the second assembly to be assembled abut against each other to form a welding posture; S3, controlling the robotic arm to carry the welding module to weld the first assembly and the second assembly that are in a welding posture through the robotic arm control module, so that the hot melt adhesive is adhered between the first assembly and the second assembly to be assembled to form a welding position; S4, the quality assessment module collects the status data of the welding position, and evaluates the welding status index Weld of the welding position according to the collected status data to form an evaluation result; S5. The welding module dynamically triggers adjustment and control of welding parameters according to the evaluation results.

6. The assembly method for automobile lamp production according to claim 5, characterized in that: The assembly processing method also includes: in step S5, when the trigger condition is met, the welding module determines new welding parameters according to the welding state index and the monitoring threshold QC set by the system, and triggers the welding module to adjust and control the welding process according to the new welding parameters.

7. The assembly method for automobile lamp production according to claim 6, characterized in that: The assembly processing method further includes: in step S2, during the welding process, the limiting module adjusts the postures of the first assembly part and the second assembly part to cooperate with the welding module for welding.

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