Air conditioner indoor unit sleeve foam production system and production method thereof

Abstract

The invention discloses an air conditioner indoor unit sleeve foam production system and a production method thereof. The production system comprises a foam conveying device; the feeding robot is used for grabbing foam needed by the two opposite ends of the air conditioner indoor unit and placing the foam on the foam conveying device. The foam sleeving robot is used for grabbing the foam from the foam conveying device and installing the foam to the two opposite ends of the air conditioner indoor unit. According to the foam sleeving production system for the air conditioner indoor unit, the feeding robot is adopted to automatically grab foam and place the foam on the foam conveying device, then the foam sleeving robot grabs the foam from the foam conveying device and installs the foam to the two ends of the air conditioner indoor unit supported by the air conditioner supporting device in a suspended mode, and therefore automation of the foam sleeving process is achieved; and the problem of high labor intensity caused by manual operation is avoided, and the production efficiency is improved.

Description

Technical Field

[0001] The invention relates to the technical field of automated packaging, and in particular to a foam production system for an air conditioner inner cover and a production method thereof. Background Art

[0002] The last step in the production line of air conditioner indoor units is packaging. To prevent the indoor units from being damaged during transportation, foam is placed on both ends of the units to prevent collision. The indoor units themselves are heavy, and manual operation is not only time-consuming and labor-intensive, but may also affect production efficiency. Summary of the invention

[0003] The main purpose of the present invention is to provide an air conditioner inner cover foam production system and a production method thereof to solve the above technical problems.

[0004] The purpose of the present invention can be achieved by adopting the following technical solutions:

[0005] An air conditioner inner cover foam production system, comprising:

[0006] Foam delivery device;

[0007] A loading robot, used to grab the foam required at the two opposite ends of the air conditioner indoor unit and place the foam on the foam conveying device;

[0008] a foam robot, used for grabbing foam from the foam conveying device and installing it to opposite ends of the air conditioner indoor unit; and

[0009] The air conditioner supporting device is used to support the air conditioner indoor unit and keep the air conditioner indoor unit in a suspended state during the foam covering process.

[0010] Wherein, the foam conveying device comprises two foam conveying lines which are relatively distributed, and each of the foam conveying lines has a foam placing area and a foam taking area which are distributed along the conveying direction.

[0011] Wherein, the air conditioner inner cover foam production system also includes:

[0012] The sensing device comprises a first sensor for detecting whether the foam placement area is short of material, and a second sensor for detecting whether the foam material taking area has foam;

[0013] A control module is connected to the sensing device, the feeding robot and the foam-installing robot, and is used to control the foam grabbing action of the feeding robot and the foam installing action of the foam-installing robot according to the detection signals of the first sensor and the second sensor respectively.

[0014] Wherein, the feeding robot comprises a clamp mechanism, and the clamp mechanism comprises a first cylinder assembly and a second cylinder assembly that cooperate with each other to form a clamping space.

[0015] Wherein, the clamp mechanism further comprises:

[0016] A needle assembly disposed on the clamping surfaces of the first cylinder assembly and the second cylinder assembly, for piercing the foam in the clamping space; and

[0017] A limiting member is disposed between the first cylinder assembly and the second cylinder assembly, and is used for limiting the position of the foam when the needle assembly is drawn out of the foam.

[0018] Wherein, the foam robot comprises:

[0019] Two groups of clamping assemblies are arranged opposite to each other, each group of the clamping assemblies comprises a rotating cylinder and a clamping claw cylinder connected to each other; and

[0020] The driving device comprises a matched driving motor and a transmission mechanism. The driving device is arranged between the two groups of the clamping assemblies and is used to adjust the distance between the two groups of the clamping assemblies.

[0021] Wherein, the air conditioning supporting device comprises:

[0022] A support plate, used for supporting the indoor unit of the air conditioner;

[0023] The lifting mechanism comprises a lifting motor and a screw rod assembly which cooperate with each other. The lifting mechanism is arranged at the bottom of the supporting plate and is used to adjust the height of the supporting plate.

[0024] Wherein, the air conditioner inner cover foam production system further comprises: a control system, the control system comprising:

[0025] A parameter storage module, used to store the sleeve foam parameters of different models of air conditioner indoor units; and

[0026] An execution control module is used to control the actions of the feeding robot and the foam applying robot according to the foam applying parameters.

[0027] A method for producing foam for an air conditioner inner cover, the method for producing foam for an air conditioner inner cover being implemented by the above-mentioned air conditioner inner cover foam production system, comprises the following steps:

[0028] Control the loading robot to grab the left foam and the right foam from the tooling vehicle and place them in the corresponding foam placement areas of the foam conveying device respectively;

[0029] The air conditioner indoor unit is transported to a designated workstation, and the air conditioner supporting device is controlled to adjust the height of the air conditioner indoor unit so that the left and right ends of the air conditioner indoor unit are in a suspended state;

[0030] After the left foam and the right foam both arrive at the corresponding foam material taking areas, the control sleeve foam robot grabs the left foam and the right foam and installs them to the left end and the right end of the air conditioner indoor unit respectively.

[0031] Wherein, the method for producing the air conditioner inner cover foam further comprises the following steps:

[0032] Detect whether the foam placement area of ​​the foam conveying device is short of material;

[0033] When it is detected that the foam placement area is short of material, the feeding robot is controlled to perform a foam grabbing action;

[0034] Detecting whether there is foam in the foam material taking area of ​​the foam conveying device;

[0035] When it is detected that there is foam in the foam material taking area, the foam robot is controlled to perform the foam installation action.

[0036] Beneficial technical effects of the present invention:

[0037] The air-conditioner indoor unit cover foam production system provided by the present invention adopts a loading robot to automatically grab the foam and place it on the foam conveying device, and then the foam covering robot grabs the foam from the foam conveying device and installs it on the two ends of the air-conditioner indoor unit suspended by the air-conditioner support device, thereby realizing the automation of the foam covering process, avoiding the problem of high labor intensity caused by manual operation, and improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 A schematic diagram of a production system according to an embodiment of the present invention;

[0039] Figure 2 It is a three-dimensional schematic diagram of a clamp mechanism of a feeding robot of a production system according to an embodiment of the present invention;

[0040] Figure 3 It is a three-dimensional schematic diagram of a foam conveying line of a production system according to an embodiment of the present invention;

[0041] Figure 4 It is a three-dimensional schematic diagram of a clamping assembly and a driving device of a foam robot produced by a system according to an embodiment of the present invention;

[0042] Figure 5 It is a three-dimensional schematic diagram of an air conditioning support device of a production system according to an embodiment of the present invention.

[0043] Description of reference numerals:

[0044] In the figure: 10-foam conveying device, 11-foam conveying line, 20-feeding robot, 21-first cylinder assembly, 211-first needle group, 22-second cylinder assembly, 221-second needle group, 23-limiting member, 30-foam robot set, 40-air conditioning support device, 41-pallet, 42-lifting mechanism, 50-air conditioning indoor unit, 51-conveyor belt, 61-first sensor, 62-second sensor, 70-tooling vehicle, 81-rotating cylinder, 82-gripping cylinder, 83-driving device, 831-driving motor, 832-belt. DETAILED DESCRIPTION

[0045] In order to make the technical solution of the present invention more clear and specific to those skilled in the art, the present invention is further described in detail below in conjunction with embodiments and drawings, but the implementation manner of the present invention is not limited thereto.

[0046] like Figure 1-Figure 5 As shown, the embodiment provides a foam production system for air conditioner inner unit cover. The system includes a foam conveying device 10, a feeding robot 20, a foam covering robot 30 and an air conditioner support device 40. The system can realize the foam covering process of the left and right ends in the automatic packaging process of the air conditioner inner unit 50, thereby improving production efficiency.

[0047] The loading robot 20 grabs the foam for installation at two opposite ends of the air conditioner indoor unit 50 and places it on the foam conveying device 10. The two opposite ends of the air conditioner indoor unit 50 are the left end and the right end thereof. The foam grabbed by the loading robot 20 is divided into left foam and right foam according to their respective installation positions.

[0048] The foam conveying device 10 receives the foam grabbed by the loading robot 20 and conveys the foam to the designated area. After the foam arrives at the designated area, the foam collecting robot 30 near the area grabs it and installs it to the left and right ends of the air conditioner indoor unit 50 accordingly.

[0049] During the foaming process, the air conditioner indoor unit 50 is suspended under the action of the air conditioner support device 40. The suspended state here may refer to the air conditioner indoor unit 50 as a whole being suspended, or may refer to the left and right ends of the air conditioner indoor unit 50 being suspended. The above-mentioned suspended state is mainly to facilitate the foaming robot 30 to put the foam on the left and right ends of the air conditioner indoor unit 50.

[0050] In this embodiment, the loading robot 20 first grabs the left foam and the right foam from the tooling vehicle 70 and places them on the foam conveying device 10, and the foam conveying device 10 conveys the foam to the designated area; at the same time, after the air conditioner indoor unit 50 passes through the conveyor belt 51 to the designated position, the air conditioner support device 40 lifts it to a suitable height; when the foam and the air conditioner indoor unit 50 are in place, the foam covering robot 30 performs the foam covering action to complete the entire packaging process. The designated position here is located between the foam conveying device 10 and the foam covering robot 30, and the air conditioner indoor unit 50 is in a stationary state during the foam covering process.

[0051] In one embodiment, the foam conveying device 10 includes two relatively distributed foam conveying lines 11. Here, relatively distributed means left and right spaced distribution, and the two foam conveying lines 11 are used to convey left foam and right foam respectively.

[0052] By setting up two independent foam conveying lines 11, the foam required by the left and right ends of the air conditioner indoor unit 50 can be conveyed respectively, so that the loading and unloading of the left and right foams do not interfere with each other. Moreover, the relatively distributed left and right foams also make it easier for the foam robot 30 to pick them up at the same time, so as to be installed on the air conditioner indoor unit 50 synchronously.

[0053] In other embodiments, the foam conveying device 10 may include only one foam conveying line 11. The foam conveying line 11 is relatively wide and can convey left and right foams at the same time. Such a design can also achieve the purpose of clamping the foam robot 30 at the same time. In addition, the design also simplifies the control logic of the entire system, and there is no need to coordinate the running speeds of the two foam conveying lines 11.

[0054] In the embodiment of two foam conveying lines 11, the two foam conveying lines 11 correspond to one or two loading robots 20, and one foam conveying line 11 corresponds to one tooling vehicle 70. The two tooling vehicles 70 are spaced apart from each other, the tooling vehicle 70 on the left side is loaded with left foam, and the tooling vehicle 70 on the right side is loaded with right foam.

[0055] Each foam conveying line 11 includes a foam placement area and a foam picking area distributed along the respective conveying directions. Specifically, the foam placement area is located at the starting end of the conveying line, and is used to receive the foam placed by the loading robot 20. The foam picking area is located at the end of the conveying line, and is the position where the foam robot 30 picks up the material.

[0056] There is a certain distance between these two areas, which can serve as a buffer to prevent the air conditioner indoor unit 50 from reaching the designated position when the foam moves from the foam placement area to the foam extraction area.

[0057] In the embodiment of two foam conveying lines 11 , the production system further comprises a sensing device and a control module, wherein the sensing device comprises a first sensor 61 and a second sensor 62 .

[0058] The first sensor 61 is arranged in the foam placement area of ​​the foam conveying line 11 to detect whether the area is short of material. The second sensor 62 is arranged in the foam material taking area of ​​the foam conveying line 11 to detect whether there is foam in the area. Each foam conveying line 11 is equipped with the first sensor 61 and the second sensor 62.

[0059] The control module is respectively connected to the sensing device, the feeding robot 20 and the foaming robot 30. Specifically, the signal output ends of the first sensor 61 and the second sensor 62 are respectively electrically connected to the signal input end of the control module, and the control ends of the feeding robot 20 and the foaming robot 30 are respectively electrically connected to the signal output end of the control module. The control module specifically includes a signal processing module and an execution control module (not shown in the drawings).

[0060] The first sensor 61 and the second sensor 62 are both photoelectric sensors, each of which includes a transmitter and a receiver. The transmitter is installed on one side of the foam conveying line 11, and the receiver is installed on the other side of the foam conveying line 11. The optical axes of the transmitter and the receiver are perpendicular to the conveying direction of the foam conveying line 11.

[0061] In the actual working process:

[0062] When there is no foam in the foam placement area, the light signal emitted by the transmitter of the first sensor 61 can be received by the receiver, and the first sensor 61 sends a high-level signal to the control module. After receiving the signal, the control module converts it into a control instruction of the feeding robot 20 through the signal processing module, and the execution control module sends the instruction to the feeding robot 20, triggering the feeding robot 20 to perform the foam grabbing action.

[0063] The foam grabbing actions performed by the loading robot 20 according to the control instructions include: moving to the tooling vehicle 70, controlling the clamping mechanism to clamp the foam, conveying the foam to the foam placement area of ​​the foam conveying line 11, releasing the foam, etc.

[0064] When there is foam in the foam material taking area, the foam blocks the light signal emitted by the second sensor 62 transmitter, and the second sensor 62 sends a high level signal to the control module. After receiving the signal, the control module converts it into a control instruction of the foam robot 30 through the signal processing module, and the execution control module sends the instruction to the foam robot 30, triggering the foam robot 30 to perform the foam installation action.

[0065] The foam installation actions performed by the foam robot 30 according to the control instructions include: moving to the foam material collection area, controlling the clamping claw cylinder 82 to clamp the foam, rotating to the air conditioner indoor unit 50, adjusting the spacing of the clamping components, putting the foam on both ends of the air conditioner indoor unit 50, releasing the foam, etc.

[0066] In this embodiment, only when the second sensors 62 on the two foam conveying lines 11 send out material taking signals at the same time and the air conditioner indoor unit 50 is in place, the control module will send an execution instruction to the foaming robot 30. This design ensures that the left and right foams can be installed on the left and right ends of the air conditioner indoor unit 50 synchronously.

[0067] The design of this response mechanism realizes the automatic control of the foam setting process. Through multiple signal judgments, it ensures the reliability and continuity of the foam setting process and improves production efficiency.

[0068] Based on the two foam conveying lines 11 , in other embodiments, the sensing device uses an ultrasonic sensor instead of a photoelectric sensor.

[0069] Specifically, the first sensor 61 and the second sensor 62 on each foam conveying line are ultrasonic sensors, whose transmitting probe and receiving probe are relatively arranged on both sides of the foam conveying line, and the existence status of the foam is determined by detecting whether the ultrasonic signal is blocked by the foam.

[0070] The ultrasonic sensor is connected to the control module via a signal line, and the control module controls the actions of the feeding robot and the foam-covering robot according to the signal of the ultrasonic sensor.

[0071] In one embodiment, the loading robot 20 includes a clamp mechanism, which includes a first cylinder assembly 21 and a second cylinder assembly 22 that cooperate with each other, and the two cylinder assemblies form a clamping space.

[0072] When grabbing foam, the foam is located in the clamping space. In other words, the first cylinder assembly 21 and the second cylinder assembly 22 can clamp the foam when they are matched. This means that the layout between the two cylinder assemblies is not parallel up and down, but at right angles, obtuse angles or straight angles.

[0073] Taking the flat angle as an example, the first cylinder assembly 21 and the second cylinder assembly 22 are symmetrically distributed. When preparing to load the material, the clamping surfaces of the two cylinder assemblies are close to each other to clamp the foam on the tooling vehicle 70.

[0074] The feeding robot 20 controls the clamp mechanism to move above the foam conveying line, and the clamping surfaces of the two cylinder assemblies are moved away from each other so as to place the foam on the foam conveying line corresponding thereto. By setting up such a clamp mechanism, the foam can be stably and reliably grasped and released.

[0075] In this embodiment, the clamping surface of the first cylinder assembly 21 and the clamping surface of the second cylinder assembly 22 are respectively provided with a first needle group 211 and a second needle group 221. The two needle groups are used to pierce the foam in the clamping space respectively.

[0076] Here, the two cylinder assemblies are at right angles to each other, and the first needle group 211 and the second needle group 221 are perpendicular to each other. When the first cylinder assembly 21 and the second cylinder assembly 22 start to clamp, the two needle groups can penetrate the foam in the clamping space in a cross manner. In this way, the needle groups penetrate the foam from different directions, which can form a stable fixing effect.

[0077] The clamp mechanism further comprises a stopper 23 fixedly mounted between the two cylinder assemblies. When the first needle assembly 211 and the second needle assembly 221 are drawn out from the foam, the stopper 23 stops the foam and prevents the foam from moving with the needle assembly.

[0078] Specifically, when the two cylinder assemblies perform the clamping action, the stopper 23 abuts against the foam in the clamping space before the first needle group 211 and the second needle group 221. When the foam needs to be released, the cylinder drives the needle group to withdraw, and the stopper 23 still abuts against the foam, which can effectively prevent the foam from moving with the needle group and ensure that the foam is smoothly separated from the needle group. This is conducive to the foam-covering robot 30 to accurately clamp the foam and install it on the left and right ends of the air conditioner indoor unit 50.

[0079] In this embodiment, the first needle group 211 and the second needle group 221 each have one or more than two fine needles. When there are more than two, they are in a linear array. The tips of the fine needles can easily penetrate the foam without tearing the foam.

[0080] In this embodiment, the stopper 23 may be a rod-shaped structure. When the feeding robot 20 controls the clamp mechanism to move to a certain distance above the foam in the tooling vehicle 70, the bottom end of the stopper 23 abuts against the top surface of the foam. At this time, the cylinder controls the needle group to penetrate the foam in a cross-shaped manner to achieve stable clamping of the foam.

[0081] In one embodiment, the foam robot 30 includes two sets of gripping assemblies that are relatively distributed. Here, the relatively distributed means the left and right spaced distribution. Each set of gripping assemblies includes a rotating cylinder 81 and a gripping claw cylinder 82 that are connected. The two sets of gripping assemblies can be used to grab the left and right foams at the same time. The gripping claw cylinder 82 can adapt to foams of different thicknesses.

[0082] A driving device 83 is provided between the two groups of clamping components, and the driving device 83 includes a matching driving motor 831 and a transmission mechanism. The transmission mechanism can adjust the spacing between the two groups of clamping jaw components to adapt to different sizes of air conditioner indoor units 50. At the same time, it is also for the purpose of being able to install the foam at the left and right ends of the air conditioner indoor unit 50.

[0083] Specifically, the transmission mechanism adopts a belt transmission structure. The output shaft of the driving motor 831 is connected to the belt 832, and the belt 832 is driven to move by controlling the forward and reverse rotation of the driving motor 831, thereby realizing the opposite or reverse movement of the two groups of clamping components and adjusting the distance between the two groups of clamping components.

[0084] In the foaming process, the specific steps are as follows:

[0085] First, the rotary cylinders 81 on the two sets of clamping assemblies rotate synchronously and symmetrically, so that the clamping claws of the clamping claw cylinders 82 turn toward the foam conveying line 11 to grab the foam;

[0086] When the foam and the clamping jaws are in place, the clamping jaw cylinder 82 contracts to cause the clamping jaws to clamp their corresponding foam;

[0087] After clamping the foam, the foam-covering robot 30 ascends with the left foam and the right foam, and the rotary cylinder 81 rotates back to the initial position;

[0088] The driving motor 831 drives the clamping cylinders 82 at both ends to be pulled apart to a distance greater than the width of the air conditioner indoor unit 50 through the belt 832;

[0089] The foam-applying robot 30 drives the foam-applying fixture to move, so that the left foam is aligned with the left end of the air-conditioning indoor unit 50, and the right foam is aligned with the right end of the air-conditioning indoor unit 50;

[0090] After the foam is in place, the driving motor 831 is reversed, and the left and right foams are driven to shrink toward the center of the air conditioner indoor unit 50 through the belt 832, so that the foam is installed;

[0091] Finally, the gripper cylinder 82 releases the foam, completing the entire foam covering process.

[0092] In another embodiment, the driving device 83 includes two sets of screw drive assemblies. Each set of screw drive assemblies includes a driving motor and a screw, and the two sets of screws are arranged in parallel (not shown in the drawings).

[0093] The first drive motor is coaxially fixedly connected to the first screw rod; the second drive motor is coaxially fixedly connected to the second screw rod; the threads of the first screw rod and the second screw rod have opposite rotation directions; each screw rod is provided with a slider that matches its thread, and the slider is fixedly connected to the corresponding clamping assembly.

[0094] In the actual working process, the transmission process specifically includes the following steps:

[0095] First, the control system (PLC) sends rotation instructions to the two drive motors simultaneously;

[0096] Then, the two drive motors drive their respective screws to rotate synchronously;

[0097] Finally, since the threads of the two screw rods rotate in opposite directions, when the screw rods rotate, the two sliders will drive the clamping assemblies connected to them to move towards or in opposite directions, thereby adjusting the distance between the two sets of clamping assemblies.

[0098] In one embodiment, the air conditioner support device 40 includes a support plate 41 and a lifting mechanism 42. The support plate 41 is used to support the air conditioner indoor unit 50, and the lifting mechanism 42 includes a matching lifting motor and a screw assembly. The lifting motor drives the screw assembly to operate, and the height of the support plate 41 can be adjusted so that the air conditioner indoor unit 50 is at a suitable height position for covering the foam.

[0099] In this embodiment, the lifting mechanism 42 further comprises a guide assembly and a connecting seat. The guide assembly comprises a guide rod and a guide sleeve. The screw assembly comprises a screw rod, a screw nut and a bearing seat (not shown in the drawings).

[0100] Specifically, the bottom end of the screw rod is connected to the output shaft of the lifting motor through a coupling, and the top end of the screw rod is fixed to the frame (not shown in the drawings) through a bearing seat. A nut that matches its thread is sleeved on the screw rod, and the nut is fixedly connected to the connecting seat. Guide sleeves are symmetrically arranged on both sides of the connecting seat, and the guide sleeves are slidably matched with the guide rods fixed to the frame. The bottom of the support plate 41 is fixedly connected to the connecting seat.

[0101] In the actual working process, the lifting process specifically includes the following steps:

[0102] First, when the support plate 41 needs to rise, the control system sends a forward rotation command to the lifting motor, and the lifting motor drives the screw rod to rotate in the forward direction through the coupling;

[0103] Then, due to the thread matching relationship between the nut and the screw rod, the rotational motion of the screw rod is converted into the linear motion of the nut, thereby driving the connecting seat fixedly connected to the nut to move upward in the vertical direction;

[0104] At the same time, the guide sleeve slides along the guide rod to guide the lifting and lowering movement of the connecting seat to prevent the deflection during the lifting process;

[0105] Finally, the connecting seat drives the supporting plate 41 fixedly connected thereto to rise to a predetermined height, completing the lifting action of the supporting plate 41. When the supporting plate 41 needs to be lowered, the lifting motor can be controlled to reverse to achieve the opposite movement process.

[0106] In this embodiment, the air conditioner 50 is brought to the vicinity of the foam robot 30 by a conveyor belt 51, and a plurality of holes (not shown in the drawings) are vertically penetrated on the surface of the conveyor belt 51. The air conditioner 50 is placed above the holes, and the air conditioner support device 40 is located below the holes.

[0107] When the air conditioner indoor unit 50 is transported between the foam covering robot 30 and the foam conveying line 11, the conveying is stopped and the lifting mechanism 42 is started synchronously, so that the support plate 41 passes through the hole and lifts the air conditioner indoor unit 50 above it until the left and right ends of the air conditioner indoor unit 50 are suspended in the air. At this time, the foam covering robot 30 can cover the foam at both ends of the foam covering robot 30 on the air conditioner indoor unit 50 synchronously.

[0108] After the left and right ends of the air conditioner indoor unit 50 are covered with foam, the lifting mechanism 42 is started again to make the air conditioner indoor unit 50 fall on the conveyor belt 51, and then the air conditioner indoor unit 50 is conveyed to the next process.

[0109] In other embodiments, the air conditioner support device 40 can be used as a fixed station during the transportation of the air conditioner indoor unit 50. Specifically, the air conditioner support device 40 in this embodiment is only a plate-shaped structure with a supporting function. The conveyor belt 51 is an annular conveyor line, and a plurality of air conditioner support devices 40 are arranged on the conveyor line along its conveying direction. An air conditioner indoor unit 50 is placed on each air conditioner support device 40.

[0110] In the initial state of the air conditioner support device 40, the air conditioner indoor unit 50 above it is in a suspended state. After the air conditioner support device 40 is transported to the vicinity of the foam-covering robot 30, the foam-covering robot 30 can directly cover the foam on the left and right ends of the air conditioner indoor unit 50.

[0111] In another embodiment, two air conditioner support devices 40 are provided, and they are arranged on opposite sides of the conveyor belt 51 of the air conditioner indoor unit 50, specifically, the front side and the rear side of the conveyor belt 51. Each air conditioner support device 40 also includes a horizontal cylinder arranged between the lifting mechanism 42 and the support plate 41. Wherein:

[0112] The piston rod of the horizontal cylinder is extended and retracted in the horizontal direction. One end of the support plate 41 is fixedly connected to the end of the piston rod of the horizontal cylinder, and the other end is designed as a support end for lifting the indoor unit 50 of the air conditioner. The horizontal cylinder can be raised or lowered with the lifting mechanism 42. The connecting seat of the lifting mechanism 42 is fixedly connected to the horizontal cylinder, but not fixedly connected to the support plate 41, so as to ensure that the support plate 41 can extend or retract with the piston rod of the horizontal cylinder.

[0113] In the actual working process, the process specifically includes the following steps:

[0114] When the air conditioner indoor unit 50 is transported to the designated workstation via the conveyor belt 51, the horizontal cylinders located at the front and rear sides of the conveyor belt 51 act synchronously to push the respective support plates 41 to extend horizontally;

[0115] The supporting ends of the support plate 41 are respectively supported at the bottom of the air conditioner indoor unit 50; the lifting mechanism 42 is started, driving the horizontal cylinder, the support plate 41 and the air conditioner indoor unit 50 to rise synchronously;

[0116] When lifted to the correct position, the air conditioner indoor unit 50 is in a suspended state, which is convenient for the foam robot 30 to perform foam installation operations;

[0117] After the foam is installed, the lifting mechanism 42 is started again, driving the air conditioner indoor unit 50 to descend and reset;

[0118] The horizontal cylinder drives the support plate 41 to be retracted, and the air conditioner indoor unit 50 falls back onto the conveyor belt 51 to continue to be transported.

[0119] In this embodiment, the support plate 41 is designed as an L-shaped structure, including a horizontal section and a vertical section. The horizontal section is used as a support end to support the bottom of the air conditioner indoor unit 50, and the vertical section can prevent the air conditioner indoor unit 50 from lateral displacement during the lifting process.

[0120] The design of the air conditioning support device 40 arranged on opposite sides of the conveyor belt 51 has the following advantages:

[0121] The stability of the lifting and lowering process of the air-conditioning indoor unit 50 is improved through the synchronous support on the front and rear sides; the horizontal cylinder is used to drive the support plate 41 to extend and retract, so as to realize the rapid lifting and release of the air-conditioning indoor unit 50; the structural design of the L-shaped support plate 41 not only ensures the reliability of the support, but also prevents the displacement of the air-conditioning indoor unit 50.

[0122] In this embodiment, the control system uses PLC as the main controller to drive the actions of various parts of the production system to realize the automation process, and is equipped with an industrial computer to realize human-computer interaction. The control system specifically includes a parameter storage module and an execution control module (not shown in the drawings), and also includes the aforementioned control module.

[0123] The parameter storage module stores the foam parameters of different models of air conditioner indoor units 50. The foam parameters include:

[0124] The action parameters of the feeding robot 20 include the clamping force, clamping position, insertion depth of the needle assembly, etc. of the clamping mechanism;

[0125] The action parameters of the foam-coating robot 30 include the initial spacing between the two sets of clamping components, the spacing adjustment amount when the foam is coated, the clamping force of the clamping claw cylinder 82, the rotation angle of the rotating cylinder 81, etc.

[0126] When the foaming process is performed on a specific model of the air conditioner indoor unit 50, the operator selects the foaming parameters corresponding to the model through the industrial computer. The execution control module receives the foaming parameters and converts them into specific execution instructions for the corresponding mechanism. For example, when a 1.5-horsepower hanging machine is selected, the control system will automatically adjust the clamping component spacing of the foaming robot 30 to the corresponding size, and set the appropriate clamping force and rotation angle to ensure that the foam can be accurately mounted on both ends of the air conditioner indoor unit 50 of this model.

[0127] The control system can realize rapid switching and flexible production of the production line by pre-storing and calling the foam parameters of the air conditioner indoor units 50 of different models, thereby improving the versatility and flexibility of the production system.

[0128] Based on the above embodiments, when it is detected that there is no foam in the foam placement area of ​​the two foam conveying lines 11, the loading robot 20 is controlled to perform the loading action; when it is detected that there is foam in the foam picking area of ​​the two foam conveying lines 11, the foam covering robot 30 is controlled to perform the foam covering action.

[0129] When it is detected that there is a long-term shortage of material in the foam placement area of ​​one of the foam conveying lines 11, it means that there is no material in the tooling cart 70. At this time, the machine is immediately stopped and an alarm signal is issued to prompt the operator to replace the tooling cart 70.

[0130] Based on the above embodiments, the air conditioner inner cover foam production system realizes a fully automated foam installation process through the coordinated cooperation of various components. The details are as follows:

[0131] In terms of the cooperation between the foam conveying device 10 and the loading robot 20: the foam conveying device 10 includes two relatively distributed foam conveying lines 11, which are used to convey left foam and right foam respectively. Each foam conveying line 11 has a foam placement area and a foam material collection area. The loading robot 20 places the left and right foams respectively in the foam placement areas of the corresponding foam conveying lines 11 through a clamp mechanism composed of a first cylinder assembly 21 and a second cylinder assembly 22. The design of the needle group enables the clamp mechanism to stably grasp the foam, and the limiter 23 ensures that the foam is smoothly detached when released, ensuring the accurate positioning of the foam on the foam conveying line 11.

[0132] In terms of the cooperation between the foam conveying device 10 and the foaming robot 30: the two groups of clamping components of the foaming robot 30 can simultaneously grab the left and right foams from the foam material collection area through the cooperation of the rotating cylinder 81 and the clamping claw cylinder 82. The driving device 83 can adjust the distance between the two groups of clamping components through the driving motor 831 and the transmission mechanism to meet the installation requirements of air conditioner indoor units 50 of different specifications. This design ensures the synchronous installation of the left and right foams and avoids the deviation of the workpiece caused by asynchronous installation.

[0133] In terms of the coordination between the air conditioner support device 40 and the foam robot 30: the support plate 41 of the air conditioner support device 40 is adjusted in height through the lifting mechanism 42, so that the air conditioner indoor unit 50 is in a suspended state. This state facilitates the foam robot 30 to accurately control the installation position and posture of the foam. At the same time, the design of the support plate 41 can also prevent the air conditioner indoor unit 50 from lateral displacement during the lifting process, thereby ensuring the accuracy of the foam installation.

[0134] Under the coordination of the control system, the above components form a complete automated workflow:

[0135] 1. When the first sensor 61 detects that there is a lack of foam in the foam placement area, it triggers the loading robot 20 to perform the foam grabbing action;

[0136] 2. When the air conditioner indoor unit 50 reaches the designated position, the lifting mechanism 42 lifts it to a suitable height;

[0137] 3. After the second sensor 62 detects that the foam on the left and right sides are in place, the foam robot 30 performs the foam installation action;

[0138] 4. After installation is completed, the air conditioner indoor unit 50 is lowered to reset and continue to be transported.

[0139] This synergy: through the precise coordination of the mechanical structure, the accuracy and reliability of foam installation are guaranteed; through the linkage of sensors and control systems, the continuous automation of the production process is realized; through the design of adjustable mechanisms, the adaptability and versatility of the production system are improved.

[0140] Based on the above-mentioned embodiment of the air conditioner inner cover foam production system, this embodiment further provides a production method, and the specific steps include:

[0141] First, the loading robot 20 moves to the tooling vehicle 70 under the control of the control system, and grabs the left foam and the right foam on the tooling vehicle 70 through the clamp mechanism. The loading robot 20 places the left foam and the right foam in the foam placement areas of the two foam conveying lines 11 respectively.

[0142] At the same time, the air conditioner indoor unit 50 is transported to the designated workstation through the conveyor line. When the air conditioner indoor unit 50 is in place, the control system controls the lifting mechanism 42 of the air conditioner support device 40 to start. The lifting mechanism 42 drives the support plate 41 to rise, and lifts the air conditioner indoor unit 50 to a predetermined height, so that its left and right ends are in a suspended state, which is convenient for the foam robot 30 to install the foam.

[0143] After the foam conveyor line 11 conveys the left foam and the right foam to the foam material collection area, the control system controls the foam robot 30 to start the foam installation action. Specifically, the foam robot 30 moves to the foam material collection area, and the two groups of clamping components face the foam conveyor line 11 and grab the left foam and the right foam at the same time; then the foam robot 30 moves to the air conditioner indoor unit 50, and the two groups of clamping components face the corresponding ends of the air conditioner indoor unit 50, and the distance between the two groups of clamping components is adjusted by the driving device 83; finally, the left foam and the right foam are respectively mounted on the left end and the right end of the air conditioner indoor unit 50.

[0144] During the entire production process, the control system also monitors the status of the foam conveying line 11 in real time through the sensing device:

[0145] The first sensor 61 of the sensing device detects whether there is a shortage of material in the foam placement area. When a shortage of material is detected, the control system sends a control instruction to the feeding robot 20, triggering it to perform a foam grabbing action to achieve automatic foam replenishment. When a shortage of material is detected for a long time, the machine is immediately stopped and an alarm signal is issued to allow the operator to replace the tooling vehicle 70.

[0146] The second sensor 62 of the sensing device detects whether there is foam in the foam material collection area. Only when the material collection areas of the two foam conveying lines 11 are both detected with foam, the control system sends a control instruction to the foaming robot 30 to trigger it to perform the foam installation action. This design ensures that the left and right foams can be installed synchronously at both ends of the air conditioner indoor unit 50.

[0147] Through the above production method, the automation of the foam process of 50 sets of air conditioner indoor units is realized, and the production efficiency is improved. At the same time, the reliability and continuity of the production process are guaranteed through the real-time monitoring of the sensing device and the coordinated control of the control system.

[0148] The above description is only a further embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical solutions and concepts of the present invention within the scope disclosed by the present invention, which belong to the protection scope of the present invention.

Claims

1. An air conditioner inner cover foam production system, characterized in that: include: Foam delivery device; A loading robot, used to grab the foam required at the two opposite ends of the air conditioner indoor unit and place the foam on the foam conveying device; a foam robot, used for grabbing foam from the foam conveying device and installing it to opposite ends of the air conditioner indoor unit; and The air conditioner supporting device is used to support the air conditioner indoor unit and keep the air conditioner indoor unit in a suspended state during the foam covering process.

2. The air conditioner inner cover foam production system according to claim 1, characterized in that: The foam conveying device comprises two foam conveying lines which are arranged opposite to each other, and each of the foam conveying lines has a foam placing area and a foam taking area which are arranged along the conveying direction.

3. The air conditioner inner cover foam production system according to claim 2, characterized in that: Also includes: The sensing device comprises a first sensor for detecting whether the foam placement area is short of material, and a second sensor for detecting whether the foam taking area has foam; A control module is connected to the sensing device, the feeding robot and the foam-installing robot, and is used to control the foam grabbing action of the feeding robot and the foam installing action of the foam-installing robot according to the detection signals of the first sensor and the second sensor respectively.

4. The air conditioner inner cover foam production system according to claim 1, characterized in that: The feeding robot comprises a clamp mechanism, and the clamp mechanism comprises a first cylinder assembly and a second cylinder assembly that cooperate with each other to form a clamping space.

5. The air conditioner inner cover foam production system according to claim 4, characterized in that: The clamp mechanism also includes: A needle assembly disposed on the clamping surfaces of the first cylinder assembly and the second cylinder assembly, for piercing the foam in the clamping space; and A limiting member is disposed between the first cylinder assembly and the second cylinder assembly, and is used for limiting the position of the foam when the needle assembly is drawn out of the foam.

6. The air conditioner inner cover foam production system according to claim 2, characterized in that: The foam robot set comprises: Two groups of clamping assemblies are arranged opposite to each other, each group of the clamping assemblies comprises a rotating cylinder and a clamping claw cylinder connected to each other; and The driving device comprises a matched driving motor and a transmission mechanism. The driving device is arranged between the two groups of the clamping assemblies and is used to adjust the distance between the two groups of the clamping assemblies.

7. The air conditioner inner cover foam production system according to claim 1, characterized in that: The air conditioning supporting device comprises: A support plate, used for supporting the indoor unit of the air conditioner; The lifting mechanism comprises a lifting motor and a screw rod assembly which cooperate with each other. The lifting mechanism is arranged at the bottom of the supporting plate and is used to adjust the height of the supporting plate.

8. The air conditioner inner cover foam production system according to any one of claims 3 to 7, characterized in that: Also includes: A control system, the control system comprising: A parameter storage module is used to store the foam parameters of different models of air conditioner indoor units; as well as An execution control module is used to control the actions of the feeding robot and the foam applying robot according to the foam applying parameters.

9. A method for producing foam for an air conditioner inner cover, characterized in that: The method for producing foam for an air conditioner inner cover is implemented by the air conditioner inner cover foam production system according to any one of claims 3 to 8, comprising the following steps: Control the loading robot to grab the left foam and the right foam from the tooling vehicle and place them in the corresponding foam placement areas of the foam conveying device respectively; The air conditioner indoor unit is transported to a designated workstation, and the air conditioner supporting device is controlled to adjust the height of the air conditioner indoor unit so that the left and right ends of the air conditioner indoor unit are in a suspended state; After the left foam and the right foam both arrive at the corresponding foam material taking areas, the control sleeve foam robot grabs the left foam and the right foam and installs them to the left end and the right end of the air conditioner indoor unit respectively.

10. The method for producing air conditioner inner cover foam according to claim 9, characterized in that: The following steps are also included: Detect whether the foam placement area of ​​the foam conveying device is short of material; When it is detected that the foam placement area is short of material, the feeding robot is controlled to perform a foam grabbing action; Detecting whether there is foam in the foam material taking area of ​​the foam conveying device; When it is detected that there is foam in the foam material taking area, the foam robot is controlled to perform the foam installation action.

Images