An automated AGV cart and method of use thereof in vehicle assembly

Abstract

The application relates to the technical field of automobile assembly production lines, in particular to an automatic AGV (Automatic Guided Vehicle) trolley, which comprises a trolley head, a lifting and overturning mechanism, an electric control module, a variable-distance mechanism and a trolley tail, the trolley head and the trolley tail pull the lifting and overturning mechanism, the electric control module and the variable-distance mechanism to move; the lifting and overturning mechanism comprises a lifting platform I and a pair of overturnable clamping arms, the clamping arms are both rotationally installed on the lifting platform I to be opened and overturned outward; a UPS (Uninterruptible Power Supply) power supply and a TPM (Total Productive Maintenance) management device are arranged in the electric control module; the variable-distance mechanism comprises a front supporting platform and a rear supporting platform, the front supporting platform and the rear supporting platform can slide and translate longitudinally to change the front and rear clamping wheelbase. The automatic AGV trolley can be used to assemble a pickup truck and a light truck.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile assembly production lines, in particular to an automated AGV and a method for using the same in vehicle assembly. Background Art

[0002] Traditional assembly processes for commercial and passenger vehicle production lines typically utilize a purely mechanical mechanism consisting of drag chains, plate chains, and mechanical structural supports. Fixed chassis supports are typically used. When different models are put into production, supports are manually switched to meet the needs of each model. This traditional structure has the disadvantages of requiring a large number of different support types, hindering the flexible production of diverse vehicle types, hindering production efficiency, and increasing labor intensity.

[0003] At the same time, passenger cars and commercial vehicles are completely different products with different production processes. Through benchmarking investigations, it was found that there is currently no domestic OEM that produces commercial vehicles and passenger vehicles on mixed lines.

[0004] AGV, or automatic guided vehicle, can realize the requirements of automation, flexibility and punctuality in material handling operations, and constitute an automatic guided vehicle system (AGVS) together with automatic guidance systems, automatic loading and unloading systems, communication systems, safety systems and management systems. Summary of the Invention

[0005] In order to improve the process efficiency of automobile assembly, the present invention provides an automated AGV and its use method in vehicle assembly, applying highly automated AGV to the automobile assembly process, which is suitable for the assembly of various models. The specific technical solution is as follows:

[0006] An automated AGV vehicle comprises a vehicle head, a lifting and flipping mechanism, an electric control module, a pitch-changing mechanism and a vehicle tail, wherein the vehicle head and the vehicle tail pull the lifting and flipping mechanism, the electric control module and the pitch-changing mechanism to move;

[0007] The lifting and flipping mechanism includes a lifting platform I for lifting and a pair of flippable clamping arms, wherein the clamping arms are rotatably mounted on the lifting platform I to open and flip outward;

[0008] The electric control module is equipped with a UPS power supply and TPM management equipment for the trolley;

[0009] The pitch-changing mechanism comprises a front support platform and a rear support platform, and both the front support platform and the rear support platform can slide and translate longitudinally forward and backward to change the front and rear clamping wheelbases.

[0010] The above-mentioned automated AGV trolley, the rear support platform is configured as a pair of support arms that can be opened and closed laterally to change the clamping width.

[0011] The above-mentioned automated AGV trolley, the variable distance mechanism also includes a lifting platform II, and the front support platform and the rear support platform are respectively installed on the lifting platform II.

[0012] The above-mentioned automated AGV trolley has the front support platform driven by a variable pitch lead screw nut to achieve longitudinal translation, the rear support platform is driven by a reduction motor in conjunction with a linear bearing to achieve longitudinal translation, and the support arm of the rear support platform is driven by a variable width lead screw nut to achieve lateral opening and closing.

[0013] The above-mentioned automated AGV trolley, the lifting and flipping mechanism also includes a pair of flipping screw and nut parts installed on the lifting platform I, the screw in each flipping screw and nut part is arranged horizontally, and the nut is combined with the corresponding clamping arm through two sets of connecting rods to form a four-bar mechanism.

[0014] The above-mentioned automated AGV vehicle has a walking system and a differential motor for driving in the front of the vehicle, and a laser obstacle avoidance mechanism is installed in front of the front of the vehicle; a charging plate, a brake switch and a magnetic navigation sensor are provided in the rear of the vehicle, and a touch screen and an observation window are provided on the side of the rear of the vehicle; the electronic control module is also provided with an array of heat dissipation holes, a fan, a switch for starting and stopping the vehicle, a charging port and an emergency stop button.

[0015] The present invention also provides a vehicle assembly method, which uses the above-mentioned automated AGV car to assemble pickup trucks and light trucks respectively.

[0016] Specifically, the pickup truck and light truck assembly method includes the following steps:

[0017] S1) Frame assembly drop-off: The AGV automatically drives to the first station of the assembly line, receives vehicle information, controls the variable pitch mechanism to move the front and rear support platforms horizontally to meet the clamping wheelbase required for frame drop-off, and the lifting and flipping mechanism cooperates with the flipping mechanism to meet the support of the frame assembly;

[0018] S2) Front and rear axle installation: The front axle is installed at the sixth station, and the rear axle is installed at the fourth station. The AGV receives vehicle information and controls the lifting and flipping mechanism to meet the required height requirements for the front and rear axle installation.

[0019] S3) The frame assembly is flipped at the ninth station; the AGV receives vehicle information and controls the variable pitch mechanism to clamp the front and rear support platforms to meet the requirements of the chassis after flipping; the lifting and flipping mechanism flips to meet the requirements of the chassis support;

[0020] S4) The engine is unloaded at the twelve workstations; the AGV receives vehicle information and controls the lifting height of the lifting and flipping mechanism to meet the engine unloading height requirements;

[0021] S5) Cargo box unloading and loading is performed at the fourteenth workstation; the AGV receives vehicle information and controls the lifting height change of the lifting and flipping mechanism to meet the cargo box unloading and chassis connection height requirements;

[0022] S6) Cab installation: Pickup trucks’ cabs are installed at station 16, while light trucks’ cabs are installed at stations 23 or 24. The AGV receives vehicle information and controls the lifting height of the lifting and flipping mechanism to meet the required height for cab installation and chassis connection.

[0023] S7) Tire Assembly: Pickup and light truck tires are assembled at station 18, and tightened at station 19. Light truck spare tires are assembled at station 18, and pickup spare tires are assembled at station 20. The AGV receives vehicle information and controls the lifting height of the lifting and flipping mechanism to meet the tire installation and tightening height requirements.

[0024] S8) Car doors are assembled at stations 34 and 35; the AGV receives vehicle information and controls the lifting height of the lifting and flipping mechanism to meet the door installation height requirements;

[0025] S9) High workstation: Pickup trucks are equipped with six high workstations, from the 20th to the 25th, to complete the tightening of the cab, cargo box and frame fixing points, the connection of the pipelines and wiring harnesses at the bottom of the vehicle, and the assembly of various assembly guards. For pickup truck models, at the 25th workstation, the AGV trolley receives vehicle information and controls the variable distance mechanism to move the front and rear support platforms horizontally to meet the support and clamping of the whole vehicle. The lifting and flipping mechanism cooperates with the flipping to meet the support of the whole vehicle assembly; light truck models do not require high-position lifting and assembly, and continue to use AGV trolleys for assembly, thereby realizing flexible production of pickup trucks and light trucks on the same line.

[0026] S10) Complete vehicle off-line: A lifting platform is set up at the 30th station at the end of the chassis line to assist the AGV trolley in disengaging so that the complete vehicle can be off-line; after the AGV trolley carries the assembled complete vehicle to the right position, it gives a signal to the lifting platform, which automatically rises to support the tires of the complete vehicle. At this time, the AGV trolley and the complete vehicle detach and drive out of the assembly line, and then automatically drive to the first station of the assembly line along the return line to realize the cycle operation.

[0027] The beneficial effects of the present invention are as follows: the AGV trolley can realize clamping and supporting vehicle bodies of different models through automatic control and adjustment, combining information technology and automation technology, realizing the common assembly process of AGV assembly trolleys of various models, realizing automatic switching of support requirements of various models, reducing the number of AGV trolleys invested, pioneering the common assembly process of two different types of light trucks and pickup trucks, realizing the automatic operation of the production line, and greatly saving the investment cost of the production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a schematic diagram of the AGV structure from a top view of the present invention;

[0029] Figure 2 This is a schematic diagram of the main structure of the AGV of the present invention;

[0030] Figure 3 It is a schematic cross-sectional structural diagram of the AGV vehicle of the present invention;

[0031] Figure 4 Schematic diagram of the lifting and flipping mechanism of the AGV trolley of the present invention;

[0032] Figure 5 This is a schematic diagram of the internal structure of the lifting and flipping mechanism of the AGV trolley of the present invention;

[0033] Figure 6 Schematic diagram of the variable pitch mechanism of the AGV trolley of the present invention;

[0034] Figure 7 This is a schematic diagram of the internal structure of the variable pitch mechanism of the AGV trolley of the present invention.

[0035] In the figure: 1 is the front of the vehicle, 2 is the lifting and flipping mechanism, 3 is the electronic control module, 4 is the pitch changing mechanism, 5 is the rear of the vehicle, 6 is the edge contact, 11 is the laser obstacle avoidance mechanism, 12 is the differential motor, 13 is the walking system, 21 is the base I, 22 is the lifting cylinder I, 23 is the lifting platform I, 24 is the clamping arm, 25 is the rotating shaft, 26 is the connecting rod, 27 is the flipping motor, 28 is the flipping screw nut, 31 is the UPS power supply, 32 is the TPM management device, 33 is the heat dissipation hole, 34 is the fan, 35 is the switch, 36 is the charging port, 37 is the emergency stop button, 41 is the base II, 42 is the lifting cylinder II, 43 is the lifting platform II, 44 is the rear support platform, 45 is the pitch changing screw nut, 46 is the front support platform, 47 is the width changing screw nut, 51 is the touch screen, 52 is the observation window, 53 is the charging plate, 54 is the brake switch, and 55 is the magnetic navigation sensor. DETAILED DESCRIPTION

[0036] The technical solution of the present invention is described in detail below with reference to the accompanying drawings.

[0037] The AGV of this embodiment is equipped with a safety system, a guidance system, a travel system, a control system, a power supply system, etc. The vehicle body includes a front end 1, a lifting and flipping mechanism 2, an electric control module 3, a pitch-changing mechanism 4, and a rear end 5. The front end 1 and rear end 5 pull the lifting and flipping mechanism 2, the electric control module 3, and the pitch-changing mechanism 4 to move.

[0038] The safety system is to install a laser obstacle avoidance mechanism 11 and a touch edge 6 in front of the vehicle head 1, and use a long-distance and wide-area laser sensor to ensure the safety of the vehicle body. The detection area suitable for the road conditions of the AGV vehicle's driving route can be freely defined.

[0039] The guiding system is located at the parking space 5, and is equipped with a high-precision magnetic navigation sensor 5 specially used for AGV, and is matched with a high-frequency RFID card reader for positioning control, and has reliable guidance and high instantaneous reaction sensitivity.

[0040] The walking system is arranged in the front 1 and the tail 5, and is driven by a high-power differential motor 12.

[0041] The control system takes PLC as the core, controls the operation of each motor through programs and drivers, and is equipped with a rich man-machine interactive control touch screen 51, so that the universality and modularization of system control are realized, each functional module has stable and reliable performance, clear division of labor, and simple operation. The electrical components are communicated and controlled through CANOPEN.

[0042] The power supply system is a way of setting a charging plate 53 in the parking space 5, using a non-mechanical contact method for power and signal transmission technology, and its working principle is similar to that of a traditional transformer, which also uses magnetic field coupling to convert and transmit electric energy-magnetic field energy-electric energy. Another way is to switch to battery power through UPS power supply in the area where wireless power supply is not laid out, to ensure the continuous operation of the AGV. The overall power supply is wireless power supply by the charging plate 53, and after power is taken, the voltage and current are converted through UPS and TPM to supply power to the electrical components and charge the battery. The electric control module 3 is provided with a UPS power supply 31 and a TPM management device 32 for supplying power to the AGV. TPM is "full production and maintenance", which is a full production and maintenance mode, and its main points are "production and maintenance" and "full participation". Through the establishment of a full-system employee participation production and maintenance activity, the device performance is optimized. The electric control module 3 is also provided with a plurality of heat dissipation holes 33, a fan 34, a switch 35 for starting and stopping the AGV, a charging port 36 and an emergency stop button 37.

[0043] The tail 5 is also provided with an observation window 52 and a brake switch 54. The observation window 52 is used to observe the running state of the drive, and is used for visual troubleshooting when a fault occurs. The brake switch 54 is used to open the drive to release the brake in the event of an abnormality of the AGV, and the AGV is manually pushed to be offline.

[0044] The lifting and overturning mechanism 2 includes a lifting platform I 23, a pair of overturnable clamping arms 24 and a pair of overturning screw nut members 28. The overturning screw nut members 28 are installed on the lifting platform I 23, the screw in each of the overturning screw nut members 28 is arranged transversely, and the nut is combined with the corresponding clamping arm 24 into a four-bar mechanism through two groups of connecting rods 26. The clamping arms 42 are rotatably installed on the lifting platform I 23 and can be opened and overturned outwardly by the overturning screw nut members 28.

[0045] The variable pitch mechanism 4 includes a lifting platform II 43, a front support platform 46, and a rear support platform 44. The front support platform 46 and the rear support platform 44 are respectively mounted on the lifting platform II 43. The front support platform 46 and the rear support platform 44 can both slide and translate longitudinally forward and backward to change the clamping distance, that is, to clamp vehicles with different wheelbases. The longitudinal sliding of the rear support platform 44 is achieved by driving elements such as a motor and a reducer in conjunction with linear bearings, while the front support platform 46 is driven by the variable pitch screw nut 45 to achieve longitudinal sliding and translation.

[0046] like Figure 6 and Figure 7 As shown, the rear support platform 44 is configured as a pair of support arms that can be opened and closed laterally to change the clamping width, and the support arms of the rear support platform 44 are driven by the variable width lead screw nut member 47 to achieve lateral opening and closing.

[0047] Applying the above-mentioned automated AGV to the assembly line of pickup trucks and light trucks includes the following steps:

[0048] S1) Frame assembly placement: The AGV automatically drives to the first workstation of the assembly line, receives vehicle information from the HMES production management system, and controls the front support platform 46 and the rear support platform 44 of the variable pitch mechanism 4 to slide horizontally to meet the support and clamping requirements for frame placement; the lifting and flipping mechanism 2 cooperates to flip to meet the support requirements of the frame assembly.

[0049] S2) Front and rear axle installation: The front axle is installed at station 6, and the rear axle is installed at station 4. The AGV receives vehicle information from the HMES production management system and controls the lifting and flipping mechanism 2 to adjust the lifting height to meet the front and rear axle installation height requirements and meet ergonomic requirements.

[0050] S3) The frame assembly is flipped at the ninth station; the AGV receives vehicle information from the HMES production management system and controls the lifting and flipping mechanism 2 to adjust the lifting height to meet the chassis support clamping after flipping; the flipping mechanism automatically flips to meet the chassis support.

[0051] S4) The engine is unloaded at the twelve workstations; the AGV receives vehicle information from the HMES production management system and controls the lifting and flipping mechanism 2 to adjust the lifting height to meet the engine unloading height requirements and achieve ergonomic needs.

[0052] S5) The container is unloaded at the fourteenth workstation; the AGV receives vehicle information from the HMES production management system and controls the lifting and flipping mechanism 2 to adjust the lifting height to meet the container unloading and chassis connection height requirements and achieve ergonomic needs.

[0053] S6) Cab installation: The pickup truck cab is installed at station 16, and the light truck cab is installed at stations 23 and 24. The AGV receives vehicle information from the HMES production management system and controls the lifting and flipping mechanism 2 to adjust the lifting height to meet the height requirements for cab installation and chassis connection, achieving ergonomic requirements.

[0054] S7) Tire Assembly: Pickup and light truck tires are assembled at station 18, and tightened at station 19. Light truck spare tires are assembled at station 18, and pickup spare tires are assembled at station 20. The AGV receives vehicle information from the HMES production management system and controls the lifting and flipping mechanism 2 to adjust the lifting height to meet the tire installation and tightening height requirements, realizing ergonomic needs.

[0055] S8) Car doors are assembled at stations 34 and 35; the AGV receives vehicle information from the HMES production management system and controls the lifting and flipping mechanism 2 to adjust the lifting height to meet the door installation height requirements and achieve ergonomic needs.

[0056] S9) High Station: Pickup trucks are equipped with six high stations, from 20 to 25, for securing the cab, cargo box, and frame, connecting the piping and wiring harnesses underneath the vehicle, and assembling the various assembly guards. At station 25, for pickup trucks, the AGV receives vehicle information from the HMES production management system and controls the variable distance mechanism 4 and the lifting and tilting mechanism 2 to support and clamp the entire vehicle. Light trucks, which do not require high-station lifting and assembly, continue to utilize the AGV for assembly. The lifting and tilting mechanism 2 adjusts the lift height to accommodate the installation requirements of different components, enabling flexible, co-located production of pickup and light trucks.

[0057] S10) Complete Vehicle Offline: A lifting platform is installed at the 30th station at the end of the chassis line to assist the AGV in disengaging and facilitating the vehicle's off-line. Once the AGV, carrying the assembled vehicle, arrives at the location, it signals the lifting platform, which automatically raises to support the vehicle's tires. The AGV then disengages the vehicle, exits the assembly line, and automatically returns to the first station along the return line, completing the cycle.

Claims

1. An automated AGV vehicle, characterized by: The vehicle comprises a front end (1), a lifting and turning mechanism (2), an electric control module (3), a pitch-changing mechanism (4), and a rear end (5), wherein the front end (1) and the rear end (5) pull the lifting and turning mechanism (2), the electric control module (3), and the pitch-changing mechanism (4) to move; The lifting and flipping mechanism (2) comprises a lifting platform I (23) for lifting, a pair of flippable clamping arms (24) and a pair of flipping screw nut members (28) mounted on the lifting platform I (23), wherein the clamping arms (24) are rotatably mounted on the lifting platform I (23) to open and flip outward; the screw in each flipping screw nut member (28) is arranged transversely, and the nut is combined with the corresponding clamping arm (24) through two sets of connecting rods (26) to form a four-bar mechanism; The electric control module (3) is provided with a UPS power supply (31) and a TPM management device (32) for supplying power to the vehicle; The pitch-changing mechanism (4) comprises a front support platform (46), a rear support platform (44) and a lifting platform II (43), wherein the front support platform (46) and the rear support platform (44) can both slide and translate longitudinally forward and backward to change the front and rear clamping wheelbases; the rear support platform (44) is configured as a pair of support arms that can be opened and closed transversely to change the clamping width; the front support platform (46) and the rear support platform (44) are respectively mounted on the lifting platform II (43); the front support platform (46) is driven by a pitch-changing lead screw nut (45) to achieve longitudinal translation, the rear support platform (44) is driven by a reduction motor in conjunction with a linear bearing to achieve longitudinal translation, and the support arms of the rear support platform (44) are driven by a width-changing lead screw nut (47) to achieve transverse opening and closing.

2. The automated AGV according to claim 1, characterized in that: The front of the vehicle (1) is provided with a walking system (13) and a differential motor (12) for driving, and a laser obstacle avoidance mechanism (11) is installed in front of the front of the vehicle (1); a charging plate (53), a brake switch (54) and a magnetic navigation sensor (55) are provided in the rear of the vehicle (5), and a touch screen (51) and an observation window (52) are provided on the side of the rear of the vehicle (5); the electric control module (3) is also provided with an array of heat dissipation holes (33), a fan (34), a switch for starting and stopping the vehicle (35), a charging port (36) and an emergency stop button (37).

3. A vehicle assembly method, characterized in that: The automated AGV trolley described in any one of claims 1 to 2 is used to assemble pickup trucks and light trucks respectively.

4. The vehicle assembly method according to claim 3, characterized in that: The pickup truck and light truck assembly method includes the following steps: S1) Frame assembly drop-off: The AGV automatically moves to the first workstation of the assembly line, receives vehicle information, controls the variable pitch mechanism (4) to make the front support platform (46) and the rear support platform (44) move horizontally to meet the clamping wheelbase required for frame drop-off, and the lifting and flipping mechanism (2) cooperates with the flipping to meet the support of the frame assembly; S2) Front and rear axle installation: The front axle is installed at the sixth station and the rear axle is installed at the fourth station; the AGV receives vehicle information and controls the lifting and flipping mechanism (2) to rise and fall to meet the height requirements for the front and rear axle installation; S3) The frame assembly is flipped at the ninth workstation; the AGV receives vehicle information and controls the variable pitch mechanism (4) to enable its front support platform (46) and rear support platform (44) to meet the clamping requirements of the frame chassis after flipping; the lifting and flipping mechanism (2) (2) flips to meet the support requirements of the chassis; S4) The engine is unloaded at the twelve workstations; the AGV receives the vehicle information and controls the change of the lifting height of the lifting and flipping mechanism (2) to meet the engine unloading height requirement; S5) The cargo box is unloaded at the fourteenth workstation; the AGV receives the vehicle information and controls the lifting height change of the lifting and flipping mechanism (2) to meet the cargo box unloading and chassis connection height requirements; S6) Cab drop: The pickup truck’s cab is dropped at the sixteenth station, and the light truck’s cab is dropped at the twenty-third and twenty-fourth stations; the AGV receives vehicle information and controls the lifting height of the lifting and flipping mechanism (2) to meet the height requirements for cab drop and chassis connection; S7) Tire assembly: The tires of pickup trucks and light trucks are assembled at the 18th station and tightened at the 19th station; the spare tires of light trucks are assembled at the 18th station and the spare tires of pickup trucks are assembled at the 20th station; the AGV receives vehicle information and controls the lifting height of the lifting and flipping mechanism (2) to meet the requirements of tire installation and tightening height; S8) Car door assembly is performed at the thirty-fourth and thirty-fifth stations; the AGV receives vehicle information and controls the lifting height of the lifting and flipping mechanism (2) to meet the door installation height requirement; S9) High workstation: Pickup trucks are equipped with six high workstations, from the 20th to the 25th, to complete the tightening of the cab, cargo box and frame fixing points, the connection of the pipelines and wiring harnesses at the bottom of the vehicle, and the assembly of each assembly guard plate. At the 25th workstation of the pickup truck model, the AGV trolley receives vehicle information and controls the variable distance mechanism (4) to make its front support platform (46) and rear support platform (44) move horizontally to meet the support clamping of the whole vehicle, and the lifting and flipping mechanism (2) cooperates with the flipping to meet the support of the whole vehicle assembly; light truck models do not need high-workstation lifting and assembly, and continue to use AGV trolleys for assembly, thereby realizing the flexible production of pickup trucks and light trucks on the same line; S10) Complete vehicle off-line: A lifting platform is set up at the 30th station at the end of the chassis line to assist the AGV trolley in disengaging so that the complete vehicle can be off-line; after the AGV trolley carries the assembled complete vehicle to the place, it gives a signal to the lifting platform, which automatically rises to support the tires of the complete vehicle. At this time, the AGV trolley and the complete vehicle detach and drive out of the assembly line, and automatically drive to the first station of the assembly line along the return line to realize the cycle operation.

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