Machining and assembling method and system for die castings

Abstract

The invention relates to a die casting machining and assembling method and system.The method comprises the steps that before machining, a to-be-machined die casting is moved to a first measuring station from a feeding station for size pre-measurement of key features, and then the die casting meeting the requirement is moved to a machining station for machining; the machined die castings are moved to an assembly station to be assembled, the key sizes of the to-be-machined die castings, the machined die castings and the assembled die castings are measured on a second measurement station, the die castings meeting the requirements are moved to an inspection station to be subjected to comprehensive inspection of the sizes, the assembly quality and the surface quality, the die castings not meeting the requirements are directly removed, and then the die castings are subjected to inspection. And the die castings meeting the requirements are moved to a discharging station to be used in the next working procedure. According to the method, the different production stages of the die castings can be detected before machining, after machining, after assembling and at the inspection station, the die castings which do not meet the requirements in the production assembling process are removed, and the finished product quality of the die castings before discharging is guaranteed.

Description

Technical Field

[0001] The present disclosure relates to the technical field of automobile parts processing, and in particular, to a processing and assembly method and system for die castings. Background Art

[0002] With the rapid growth of global demand for new energy vehicles, new energy vehicle manufacturers have begun to adopt the integrated die-casting production method, which is a one-time molding without the complicated process of stamping first and then welding. Integrated die-casting technology is an innovation of traditional automobile manufacturing technology. Since integrated die-casting integrates a large component as a whole, it is impossible to guarantee the position and contour of its matching features with the counterpart. Moreover, due to the relatively soft material properties of aluminum alloy itself, it is necessary to use higher-strength rivet nuts, threaded sleeves, self-extruding threaded sleeves and other parts to assemble on large castings to improve their local assembly strength. Therefore, new requirements are put forward for the subsequent processing and assembly process of large castings.

[0003] In the related technologies, the processing production line for large castings is relatively simple. The rotation of the workpiece between each workstation is achieved by robots. Most of the assembly stations are manually operated or require human participation. The entire production line lacks sampling, testing and quality analysis in the production process, and lacks judgment on whether the incoming workpiece models of blanks, semi-finished products and finished workpieces meet the system target requirements. It cannot adapt to the ever-changing product transformation production and product quality assurance. Summary of the invention

[0004] The purpose of the present disclosure is to provide a method and system for processing and assembling die castings, so as to at least partially solve the related technical problems.

[0005] In order to achieve the above-mentioned object, the present disclosure provides, in a first aspect, a method for processing and assembling a die casting, comprising:

[0006] Move the die casting to be processed from the loading station to the first measuring station;

[0007] Pre-sizing of key features of die castings at the first measuring station;

[0008] Performing machining on the die castings with qualified size pre-measurement results at the machining station, wherein the machining includes machining of rivet holes, threaded sleeve holes, self-extrusion nut holes and process benchmarks;

[0009] Assemble self-extrusion nuts, pull rivet nuts and threaded sleeves on machined die castings at the assembly station;

[0010] In-line measurement of the key dimensions of the die casting to be processed and / or machined and / or assembled at the second measuring station;

[0011] Check the size, assembly quality and surface quality of die castings at the inspection station;

[0012] Move the qualified die castings to the unloading station.

[0013] Optionally, after the step of machining the die casting with qualified size pre-measurement at the processing station, the method further comprises:

[0014] The deburring and chip removal station removes burrs and cutting chips from machined die castings.

[0015] Optionally, the method further comprises:

[0016] Before the die-casting parts enter each workstation, the information codes on the die-casting parts are scanned and identified.

[0017] Optionally, the method further comprises:

[0018] When the die casting does not meet the preset requirements in dimensional pre-measurement, online measurement and inspection, the die casting is rejected; and / or

[0019] The die castings after machining and assembly are tested respectively, and when the test results do not meet the preset requirements, the die castings are rejected.

[0020] Optionally, the method further comprises:

[0021] When the machined die castings reach the first preset sampling frequency, performing dimensional inspection on the last die casting of the first preset sampling frequency; and / or

[0022] When the die castings that have been assembled reach the second preset sampling frequency, the assembly characteristic test is performed on the last die casting of the second preset sampling frequency.

[0023] Optionally, the step of assembling the self-extrusion nut, the rivet nut and the threaded sleeve on the machined die casting at the assembly station comprises:

[0024] Autowiring:

[0025] Assembling the self-extruding nut on the die casting at the first assembly station;

[0026] Assembling the die casting with rivet nuts and / or threaded sleeves at the second assembly station;

[0027] and / or

[0028] Manual assembly:

[0029] Assemble the rivet nuts on the die casting at the third assembly station;

[0030] The threaded sleeves are assembled on the die casting at the fourth assembly station.

[0031] Optionally, the step of assembling the self-extrusion nut, the rivet nut and the threaded sleeve on the machined die casting at the assembly station further includes:

[0032] Monitoring assembly information during automatic assembly and manual assembly; wherein the assembly information includes torque parameters, angle parameters, tension parameters, stroke parameters and quantity parameters;

[0033] Whether the assembly is qualified is determined according to the assembly information and the preset information.

[0034] Optionally, the step of moving the die casting to be processed from the loading station to the first measuring station includes:

[0035] Automatic loading, where a loading robot automatically moves the die casting to be processed from the loading station to the first measuring station; and / or

[0036] Manual loading: the die casting to be processed is manually moved from the loading station to the first measuring station through the loading hanger.

[0037] In a second aspect of the present disclosure, a die casting processing and assembly system is also provided, comprising:

[0038] A loading device, used to move the die casting to be processed from the loading station to the first measuring station;

[0039] A first measuring device, for pre-sizing a key feature of the die casting at a first measuring station;

[0040] A processing device, used for machining the die casting with qualified size pre-measurement results at a processing station, wherein the machining includes the machining of rivet holes, threaded socket holes, self-extrusion nut holes and process benchmarks;

[0041] An assembly device, used for assembling self-extrusion nuts, pull rivet nuts and threaded sleeves on machined die castings at an assembly station;

[0042] A second measuring device is used for online measuring the key dimensions of the die casting to be processed and / or machined and / or assembled at a second measuring station;

[0043] Inspection device, used to inspect the size, assembly quality and surface quality of the die casting at the inspection station;

[0044] The unloading device is used to move the die castings that have passed the inspection to the unloading station.

[0045] Optionally, the system further comprises a chip removal device for removing burrs and cutting chips from the die casting that has been machined at a deburring and chip removal station.

[0046] Optionally, the feeding device comprises:

[0047] An automatic loading mechanism, comprising a loading robot, wherein the loading robot is used to move the die casting to be processed from a first loading station to a first measuring station; and / or

[0048] The manual loading mechanism comprises a loading hanger, and the loading hanger is used to move the die casting to be processed from the second loading station to the first measuring station.

[0049] Optionally, the processing device comprises a first robot, a second robot and a plurality of CNC processing centers, wherein the first robot is used to move the die casting to be processed at the first measuring station to the plurality of CNC processing centers;

[0050] The second robot is used to move the die-casting part processed by the CNC machining center to the first transfer station.

[0051] Optionally, the assembly device comprises an automatic assembly device, the automatic assembly device comprises at least one first assembly mechanism and at least one first assembly station, the first assembly mechanism and the first assembly station correspond one to one;

[0052] The first assembly mechanism is configured to automatically assemble a self-extrusion nut on the die casting at the first assembly station;

[0053] The automatic assembly device further comprises at least one second assembly mechanism and at least one second assembly station, wherein the second assembly mechanism and the second assembly station correspond to each other one by one;

[0054] The second assembly mechanism is configured to automatically assemble the rivet nut and / or the threaded sleeve to the die casting at the second assembly station; and / or

[0055] The assembly device further comprises a manual assembly device, which comprises at least one third assembly mechanism and at least one third assembly station; the third assembly station is used to position and fix the die casting of the rivet nut to be assembled;

[0056] The third assembly mechanism is configured to assemble the rivet nut on the die casting at the third assembly station through manual operation;

[0057] The manual assembly device comprises at least one fourth assembly mechanism and at least one fourth assembly station; the fourth assembly station is used to position and fix the die casting to be assembled with the threaded sleeve;

[0058] The fourth assembly mechanism is configured to assemble a threaded sleeve on the die casting at the fourth assembly station through manual operation.

[0059] Optionally, the assembly device further comprises a third robot and a fourth robot; the third robot is used to move the die casting at the first transfer station, the deburring and chip removal station and the first assembly station; the fourth robot is used to move the die casting at the first assembly station, the second assembly station and the second transfer station; and / or

[0060] The assembly device further comprises a fifth robot and a sixth robot; the fifth robot is used to move the die casting at the second transfer station, the third assembly station and the fourth assembly station; the sixth robot is used to move the die casting at the fourth assembly station and the third transfer station; and / or

[0061] The system further comprises a seventh robot for moving the die casting at the third transfer station, the second measuring station and the fourth transfer station; and / or

[0062] The inspection station includes a front inspection station and a back inspection station;

[0063] The system also includes an eighth robot and a ninth robot;

[0064] The eighth robot is used to move the die casting to the fourth transfer station and the reverse inspection station;

[0065] The ninth robot is used to move die-cast parts between the front inspection station and the unloading station.

[0066] Optionally, the system further comprises a first buffer station disposed between the first transfer station and the first assembly station, for temporarily storing the die castings to be assembled;

[0067] The third robot is configured to be able to move the die casting at the first transfer station, the deburring and chip removal station, the first assembly station and the first buffer station; and / or

[0068] The system further comprises a second buffer station disposed between the third transfer station and the second measuring station, for temporarily storing the die casting to be measured;

[0069] The sixth robot is configured to move the die casting at the fourth assembly station, the third transfer station and the second buffer station;

[0070] The seventh robot is configured to move the die casting at the third transfer station, the second measuring station, the fourth transfer station and the second buffer station.

[0071] Optionally, the system further comprises a first sampling inspection station disposed adjacent to the first transfer station, a second sampling inspection station disposed adjacent to the third transfer station, and a third sampling inspection station disposed adjacent to the second measurement station;

[0072] The third robot is configured to be able to move the die casting at the first transfer station, the deburring and chip removal station, the first assembly station, the first buffer station and the first sampling station;

[0073] The sixth robot is configured to move the die casting at the fourth assembly station, the third transfer station, the second buffer station and the second sampling station;

[0074] The seventh robot is configured to move the die casting at a third transfer station, a second measuring station, a fourth transfer station, a second buffer station and a third sampling station.

[0075] Optionally, the system also includes a scanning device, and there are multiple scanning devices, which are respectively arranged at the first measuring station, the processing station, the assembly station, and the second measuring station, and are used to scan and identify the information code on the die-casting at the first measuring station, the processing station, the assembly station, and the second measuring station.

[0076] Optionally, the system further comprises a control device, which is communicatively connected with the loading device, the first measuring device, the processing device, the assembly device, the second measuring device, the inspection device and the unloading device respectively.

[0077] Through the above technical scheme, that is, the processing and assembly method of die-castings disclosed in the present invention, before processing, the die-castings to be processed are moved from the loading station to the first measuring station for pre-measurement of the dimensions of key features, the die-castings that do not meet the requirements are directly rejected, and the die-castings that meet the requirements are moved to the processing station for machining, and the machined die-castings are moved to the assembly station for assembly of self-extrusion nuts, rivet nuts and threaded sleeves. At the second measuring station, the key dimensions of the die-castings to be processed, after machining and after assembly can be measured respectively, the die-castings that do not meet the requirements are directly rejected, and the die-castings that meet the requirements are moved to the inspection station for comprehensive inspection of dimensions, assembly quality and surface quality. Similarly, the die-castings that do not meet the requirements are directly rejected, and the die-castings that meet the requirements are moved to the unloading station for use in the next process. This method can inspect the different production stages of die-castings before machining, after machining, after assembly and at the inspection station, and eliminate die-castings that do not meet the requirements during production and assembly through multiple inspection links, thereby ensuring the quality of the finished products of die-castings before cutting.

[0078] Other features and advantages of the present disclosure will be described in detail in the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0079] The accompanying drawings are used to provide a further understanding of the present disclosure and constitute a part of the specification. Together with the following specific embodiments, they are used to explain the present disclosure but do not constitute a limitation of the present disclosure. In the accompanying drawings:

[0080] Figure 1 It is a flow chart of a method for processing and assembling a die casting provided in some embodiments of the present disclosure.

[0081] Figure 2 It is a process flow chart of a method for processing and assembling die castings provided in some embodiments of the present disclosure.

[0082] Figure 3 It is a schematic plan view of a processing and assembly system for die castings provided in some embodiments of the present disclosure.

[0083] Figure 4 This disclosure is based on Figure 3 Enlarged view of part A in .

[0084] Figure 5 This disclosure is based on Figure 3 Enlarged view of part B in .

[0085] Figure 6 This disclosure is based on Figure 3 Enlarged view of part C in .

[0086] Figure 7 This disclosure is based on Figure 3 Enlarged view of part D in .

[0087] Figure 8 This disclosure is based on Figure 3 Enlarged view of part E in .

[0088] Description of Reference Numerals

[0089] 100-loading device; 110-first loading station; 120-second loading station; 121-loading hanger; 130-first measuring station; 200-processing device; 300-chip blowing device; 310-deburring station; 320-chip removal station; 331-third loading station; 332-first unloading station; 400-first assembly machinery; 410-first assembly station; 500-second assembly mechanism; 510-second assembly station; 600-third assembly mechanism; 610-third assembly station; 700-fourth assembly mechanism; 710-fourth assembly station; 800-second measuring device; 810-second measuring station; 900-reverse inspection device; 910-reverse inspection station; 1000-front inspection device; 1001-front inspection station; 1100-unloading device; 1110-unloading station;

[0090] R01-loading robot; R02-first robot; R03-second robot; R04-third robot; R05-fourth robot; R06-chip removal robot; R07-riveting robot; R08-threaded braces robot; R09-fifth robot; R10-sixth robot; R11-measuring robot; R12-seventh robot; R13-eighth robot; R14-ninth robot;

[0091] C1-first sampling station; C2-third sampling station; D1-unqualified material unloading station; S1-first buffer station; S2-second buffer station; T1-first transfer station; T2-second transfer station; T3-third transfer station; T4-fourth transfer station; T5-turnover table. DETAILED DESCRIPTION

[0092] The specific implementation of the present disclosure is described in detail below in conjunction with the accompanying drawings. It should be understood that the specific implementation described herein is only used to illustrate and explain the present disclosure, and is not used to limit the present disclosure.

[0093] In the present disclosure, unless otherwise stated, the directional words used, such as "inside" and "outside", refer to the inside and outside of the corresponding component outline, and "far" and "near" refer to the corresponding structure or corresponding component being far away from or from another structure or component; in addition, it should be noted that the terms used, such as "first" and "second", etc., are used to distinguish one element from another element and do not have order and importance. In addition, in the description with reference to the drawings, the same mark in different drawings represents the same element.

[0094] In order to achieve the above-mentioned purpose, the present disclosure provides a method for processing and assembling a die casting, which includes steps S101 to S107.

[0095] In step S101, the die casting to be processed is moved from a loading station to a first measuring station.

[0096] In step S102, the key features of the die casting are pre-measured at the first measuring station.

[0097] In step S103, the die-casting parts with qualified dimensional prediction results are machined at a processing station, wherein the machining includes the machining of rivet holes, threaded socket holes, self-extrusion nut holes and process benchmarks.

[0098] In step S104, the self-extrusion nut, the rivet nut and the threaded sleeve are assembled on the machined die-casting at the assembly station.

[0099] In step S105, the key dimensions of the die casting to be processed and / or machined and / or assembled are measured online at the second measuring station.

[0100] In step S106, the size, assembly quality and surface quality of the die casting are inspected at an inspection station.

[0101] In step S107, the die castings that pass the inspection are moved to the unloading station.

[0102] Through the above technical scheme, that is, the processing and assembly method of die-castings disclosed in the present invention, before processing, the die-castings to be processed are moved from the loading station to the first measuring station for pre-measurement of the dimensions of key features, the die-castings that do not meet the requirements are directly rejected, and the die-castings that meet the requirements are moved to the processing station for machining, and the machined die-castings are moved to the assembly station for assembly of self-extrusion nuts, rivet nuts and threaded sleeves. At the second measuring station, the key dimensions of the die-castings to be processed, after machining and after assembly can be measured respectively, the die-castings that do not meet the requirements are directly rejected, and the die-castings that meet the requirements are moved to the inspection station for comprehensive inspection of dimensions, assembly quality and surface quality. Similarly, the die-castings that do not meet the requirements are directly rejected, and the die-castings that meet the requirements are moved to the unloading station for use in the next process. This method can inspect the different production stages of die-castings before machining, after machining, after assembly and at the inspection station, and eliminate die-castings that do not meet the requirements during production and assembly through multiple inspection links, thereby ensuring the quality of the finished products of die-castings before cutting.

[0103] It should be noted that the method can be used for the production and assembly of die-castings based on the following die-casting processing and assembly system.

[0104] In some other embodiments, after machining the die casting having qualified pre-measured dimensions at a processing station, the method further comprises: removing burrs and cutting chips from the machined die casting at a deburring and chip removing station.

[0105] The steps of deburring and chip removal are carried out after the step of machining the die-casting parts with qualified pre-measured dimensions at the processing station, and before the step of assembling the machined die-casting parts with self-extrusion nuts, rivet nuts and threaded sleeves at the assembly station, so as to completely remove the burrs and cutting chips remaining from machining before assembly, so as to avoid affecting the overall quality and assembly quality.

[0106] In another embodiment, the method further includes: scanning and identifying information codes on the die-cast parts before the die-cast parts enter each workstation.

[0107] The information code on the die casting can be in any suitable form that can read and identify the workpiece information, for example, it can be a QR code or an electronic tag. It is understandable that a corresponding code scanning device can be set at each station to record the detection, processing and assembly information of the die casting by scanning the information code on the die casting before the die casting enters each station, and it is also convenient for the program call of the robot or mechanism in the subsequent process. For example, a QR code reader can be configured at each station of the die casting processing and assembly system to read the QR code on the workpiece, so as to realize the accurate tracking and real-time tracing of the workpiece (die casting) in the entire system. The processing information of the die casting after each process: such as the workpiece QR code, workpiece model, processing completion time of each station, workpiece qualification information, processing quality information, and assembly monitoring data will be recorded and uploaded to the control device of the system (such as MES system) in real time, so as to realize the full-line tracing and online measurement of the product processing quality.

[0108] In some other embodiments, the method also includes: when the die-casting does not meet the preset requirements in dimensional pre-measurement, online measurement and inspection, the die-casting is rejected; and / or, the die-casting after machining and after assembly are inspected separately, and when the inspection results do not meet the preset requirements, the die-casting is rejected.

[0109] When die castings are being inspected, produced, and assembled, unsuitable products can be removed. If die castings are found to not meet the preset requirements during the first measurement station before machining, the second measurement station after assembly, and the inspection station, the die castings can be removed from the system; if they meet the preset requirements, they can proceed to the next station normally.

[0110] In addition, the die-castings, assembly quality and assembly information during machining and assembly are inspected. When the inspection results meet the predetermined requirements, the die-castings enter the next workstation. When the inspection results do not meet the requirements, the die-castings are discarded.

[0111] It should be noted that the burr and chip removal of the die-casting is also detected. When the requirements are met, the die-casting enters the next station. If not, it can be repaired (for example, the burr and chip removal operation is performed again) or the die-casting can be removed from the system.

[0112] In one embodiment, the method further includes: when the machined die-casting reaches a first preset sampling frequency, performing dimensional inspection on the last die-casting of the first preset sampling frequency; and / or, when the assembled die-casting reaches a second preset sampling frequency, performing assembly characteristic test on the last die-casting of the second preset sampling frequency.

[0113] In order to facilitate the supervision of the quality of the same batch of die-castings, when the number of machining reaches the first preset sampling frequency, that is, the required batch number, the last die-casting after machining at the first preset sampling frequency can be inspected for various dimensions. When the dimension inspection is qualified, the batch can enter the next process. Among them, the first preset sampling frequency can be set according to actual needs, for example, it can be 20, 30 or 50. Specific inspection items may include the size and process reference accuracy of rivet holes, threaded socket holes, and self-extrusion nut holes.

[0114] In addition, when the assembly quantity reaches the second preset sampling frequency, that is, the required batch quantity, the last die-casting after assembly at the second preset sampling frequency can be tested for various assembly characteristics. When the assembly characteristic test is qualified, the batch can enter the next process. Among them, the second preset sampling frequency can be set according to actual needs, for example, it can be 50, 60 or 100 pieces. Specific assembly characteristic test items may include the assembly depth, position, quantity, etc. of self-extrusion nuts, pull rivet nuts and threaded sleeves.

[0115] In another embodiment, the step of assembling the self-extrusion nut, the rivet nut and the threaded sleeve on the machined die casting at the assembly station includes: automatic assembly: assembling the self-extrusion nut on the die casting at the first assembly station; assembling the rivet nut and / or the threaded sleeve on the die casting at the second assembly station. And / or, manual assembly: assembling the rivet nut on the die casting at the third assembly station; assembling the threaded sleeve on the die casting at the fourth assembly station.

[0116] The step of assembling the self-extrusion nut, the rivet nut and the threaded sleeve on the machined die casting at the assembly station includes an automatic assembly step and a manual assembly step, wherein in the automatic assembly step, the self-extrusion nut can be automatically assembled at the first assembly station by using a first assembly mechanism, and the rivet nut and / or the threaded sleeve can be automatically assembled at the second assembly station by using a second assembly mechanism. It is understood that the first assembly mechanism may include an automatic tightening gun, and the second assembly mechanism may include an automatic rivet gun and an automatic threaded sleeve gun.

[0117] In the manual assembly step, the third assembly mechanism can be used to manually complete the assembly of the rivet nut at the third assembly station, and the fourth assembly mechanism can be used to manually complete the assembly of the threaded sleeve at the fourth assembly station.

[0118] Manual assembly can ensure the normal operation of the entire system when there is a fault in the automatic assembly, and can also assist in the assembly during the automatic assembly (the assembly efficiency of rivet nuts and threaded sleeves in this type of automatic production line is relatively low at present), thus improving the production efficiency of the entire system. In addition, the operator can use a manual rivet gun to manually assemble the feature points that are poorly accessible to the automatic assembly robot.

[0119] It is understandable that the third assembly mechanism may include a manual tightening gun, and the fourth assembly mechanism may include a manual threaded socket gun.

[0120] In another embodiment, the step of assembling self-extrusion nuts, rivet nuts and threaded sleeves on the machined die-casting parts at the assembly station also includes: monitoring assembly information during automatic assembly and manual assembly; wherein the assembly information includes torque parameters, angle parameters, tension parameters, stroke parameters and quantity parameters; and determining whether the assembly is qualified based on the assembly information and preset information.

[0121] By real-time monitoring of assembly information during the automatic assembly step and the manual assembly step and comparing it with the preset information, it is possible to determine whether the die-casting after automatic assembly and manual assembly is qualified. If it meets the preset information, it is qualified and the workpiece is transferred to the next workstation; if it does not meet the preset information, it is unsuitable and the workpiece is rejected.

[0122] Specifically, monitoring assembly information during automatic assembly and manual assembly includes: monitoring first assembly information during self-extrusion nut assembly, wherein the first assembly information includes torque parameters and angle parameters; monitoring second assembly information during rivet nut assembly, wherein the second assembly information includes tension parameters, stroke parameters and quantity parameters; monitoring third assembly information during threaded socket assembly, wherein the third assembly information includes stroke parameters and quantity parameters; and determining whether the assembly quality is qualified based on the first assembly information, the second assembly information, the third assembly information and preset information.

[0123] In some embodiments, the step of moving the die casting to be processed from the loading station to the first measuring station includes automatic loading and manual loading steps:

[0124] In the automatic loading step, the die casting to be processed is automatically moved from the loading station to the first measuring station by a loading robot; and / or, in the manual loading step, the die casting to be processed is manually moved from the loading station to the first measuring station by a loading hanger.

[0125] There can be two loading stations, a first loading station for automatic loading and a second loading station for manual loading, wherein the first loading station is configured as two, and while one station is loading, the other station can perform the turnover work of the empty material frame and the full material frame. Each blank material frame can hold 5 workpieces. When the material frame is empty (detected and counted by the visual camera on the seven-axis robot), the shortage information is notified to the logistics department through the MES system. In some embodiments, the logistics department can arrange for a forklift operator to replace the material frame.

[0126] The first loading station for automatic loading can replace and circulate the material frame through the AGV trolley. The MES system directly sends instructions to the AGV trolley. The AGV automatically transports the empty material frame away, and another AGV trolley places the full material frame at the corresponding position.

[0127] The seven-axis robot gripper is equipped with a camera, which identifies the position coordinates of the large casting in the blank frame. When the robot takes the material, it performs position compensation, thereby realizing automatic grasping of large castings. Therefore, the position of the AGV when replacing the material frame does not need to be very accurate, and a positioning error of 50mm is allowed.

[0128] like Figures 3 to 8 As shown, the present disclosure also provides a die casting processing and assembly system, which includes a loading device 100, a first measuring device, a processing device 200, an assembly device, a second measuring device 800, an inspection device and a unloading device 1100. Among them, the loading device 100 is used to move the die-casting to be processed from the loading station to the first measuring station 130; the first measuring device is used to perform dimensional prediction on the key features of the die-casting at the first measuring station 130; the processing device 200 is used to machine the die-casting with qualified dimensional prediction results at the processing station, wherein the machining includes the processing of rivet holes, threaded sleeve holes, self-extrusion nut holes and process benchmarks; the assembly device is used to assemble self-extrusion nuts, rivet nuts and threaded sleeves on the machined die-casting at the assembly station; the second measuring device 800 is used to perform online measurement of the key dimensions of the die-casting to be processed and / or machined and / or assembled at the second measuring station 810; the inspection device is used to inspect the size, device quality and surface quality of the die-casting at the inspection station; the unloading device 1100 is used to move the die-casting that has passed the inspection to the unloading station 1110.

[0129] According to the above technical scheme, the die-casting to be processed is moved from the loading station to the first measuring station 130 by the first measuring device before processing to perform size prediction of key features, the die-casting that does not meet the requirements is directly rejected, and the die-casting that meets the requirements is moved to the processing station for machining by the processing device 200, the machined die-casting is moved to the assembly station for assembly of self-extrusion nuts, rivet nuts and threaded sleeves by the assembly device, the key dimensions of the die-casting to be processed, after machining and after assembly can be measured respectively by the second measuring device 800 at the second measuring station 810, the die-casting that does not meet the requirements is directly rejected, and the die-casting that meets the requirements is moved to the inspection station for comprehensive inspection of size, assembly quality and surface quality, similarly, the die-casting that does not meet the requirements is directly rejected, and the die-casting that meets the requirements is moved to the unloading station 1110 for use in the next process. The system can inspect die-castings at different production stages before machining, after machining, after assembly and at the inspection station. It can eliminate die-castings that do not meet the requirements during production and assembly through multiple inspection links to ensure the quality of finished die-castings before cutting.

[0130] In yet another embodiment, the system further comprises a chip removing device for removing burrs and cutting chips from the die casting after machining at a deburring and chip removing station.

[0131] A third loading station 331 and a first unloading station 1110332 can be set before the deburring and chip removing station, and loading and unloading can be performed by the third robot R04. The chip removal device includes a deburring tool (rotating cutter head) and a deburring robot, which can be fixed on the fixture platform. The rotating cutter head has a certain amount of floating, which can match the changes in the contour of the large casting blank. The deburring robot grabs the workpiece and approaches the rotating cutter head along a specific trajectory to deburr, and then comes to the chip removal station 320, and uses compressed air to blow away the aluminum chips remaining on the surface of the workpiece. The chip blowing area can cover all characteristic surfaces where aluminum chips are likely to remain.

[0132] The deburring and chip removing stations include the third loading station 331, the first unloading station 1110332, the deburring station 310 and the chip removing station 320. After the deburring robot takes the material from the third loading station 331, it grabs the die casting and runs a specific robot trajectory in the deburring station 310 to perform deburring of the corresponding features, and then moves to the chip removing station 320 for chip blowing. After completing the deburring and chip blowing actions, the deburring robot unloads the die casting to the first unloading station 1110332. The chip removing device can also remove burrs from the machined die casting by methods such as grinding and polishing. By deburring and chip removal, on the one hand, the die casting processing quality requirements are met, and on the other hand, it can also avoid affecting the subsequent assembly quality.

[0133] In some other embodiments, the loading device 100 includes an automatic loading mechanism and a manual loading mechanism, wherein the automatic loading mechanism includes a loading robot R01, which is used to move the die-casting to be processed from the first loading station 110 to the first measuring station 130; and / or the manual loading mechanism includes a loading hanger 121, which is used to move the die-casting to be processed from the second loading station 120 to the first measuring station 130.

[0134] There can be two loading stations, a first loading station 110 for automatic loading and a second loading station 120 for manual loading, wherein the first loading station 110 is configured as two, and while one station is loading, the other station can perform the turnover work of the empty material frame and the full material frame. Each blank material frame can hold 5 workpieces. When the material frame is empty (detected and counted by the visual camera on the seven-axis robot), the shortage information is notified to the logistics department through the MES system. In some embodiments, the logistics department can arrange for a forklift operator to replace the material frame.

[0135] The seven-axis robot gripper is equipped with a camera, which identifies the position coordinates of the large casting in the blank frame. When the robot takes the material, it performs position compensation, thereby realizing automatic grasping of large castings. Therefore, the position of the AGV when replacing the material frame does not need to be very accurate, and a positioning error of 50mm is allowed.

[0136] In another embodiment, the processing device 200 includes a first robot R02, a second robot R03 and multiple CNC machining centers, the first robot R02 is used to move the die-castings to be processed in the first measuring station 130 to the multiple CNC machining centers; the second robot R03 is used to move the die-castings processed by the CNC machining center to the first transfer station T1.

[0137] The processing device 200 includes four identical CNC machining centers, a first robot R02 and a second robot R03, both of which are seven-axis robots. The first robot R02 is responsible for loading the die-casting blank, and the second robot R03 is responsible for unloading the semi-finished large casting after machining. The CNC machining center completes the processing of features such as rivet nuts, threaded socket holes, self-extrusion nut holes, process reference holes and process reference surfaces.

[0138] This CNC machining center can adopt an advanced gantry vertical five-axis dual-spindle structure and a special positioning fixture design. It can complete the feature processing of six surfaces of large castings in one process, with high processing efficiency and good dimensional stability.

[0139] Quality inspection of CNC machining center: The quality inspection frequency (for example: 1 / 20) can be set in each machining center. When the CNC machining center completes the continuous processing of 20 workpieces, it will send a signal to the line PLC. After deburring and chip blowing, the workpiece is unloaded from the first inspection station C1 for quality inspection. The quality inspection is divided into manual inspection fixture measurement and online three-coordinate measurement inspection. After all are qualified, the batch of workpieces is judged to be qualified and allowed to enter the next station.

[0140] Automatic mold change in CNC machining center: Since the workpiece (die casting) blank is consistent, the fixture does not need to be switched, only the processing program needs to be switched. The equipment can exchange signals with the line PLC. After the line sends the model information of the workpiece to the CNC machining center, the machining center equipment automatically selects the processing program of the corresponding model and completes all feature processing. After the machining process, workpieces of different models have different processing features. After the CNC machining center is completed, the workpiece is placed in the first transfer station T1 by the second robot R03, and the workpiece is placed in the deburring and chip removal station by the third robot R04.

[0141] It should be noted that each CNC machining center equipment is equipped with a safety shielding door in front of the switch door. When a device fails and needs maintenance, the shielding door is closed and the device is opened independently and does not communicate with the line. Other equipment can still operate normally.

[0142] In some embodiments, the assembly device includes an automatic assembly device, which includes at least one first assembly mechanism and at least one first assembly station 410, and the first assembly mechanism corresponds to the first assembly station 410 one by one; the first assembly mechanism is configured to automatically assemble a self-extrusion nut to the die casting at the first assembly station 410. The automatic assembly device also includes at least one second assembly mechanism 500 and at least one second assembly station 510, and the second assembly mechanism 500 corresponds to the second assembly station 510 one by one; the second assembly mechanism 500 is configured to automatically assemble a rivet nut and / or a threaded sleeve to the die casting at the second assembly station 510.

[0143] Among them, the first assembly mechanism can be a tightening gun, and the corresponding equipment automatically installs the self-extruding nut on the tightening gun head or the operator manually installs the self-extruding nut on the tightening gun head. The third robot R04 puts the workpiece to be assembled from the loading and unloading table of the chip blowing device 300 on the loading slide. After the workpiece is clamped, the slide slides to the assembly station, and the equipment automatically runs the assembly program. After the assembly is completed, the slide slides out, and the fourth robot R05 unloads the qualified workpiece to the second assembly station 510. Among them, the first assembly station 410 adopts a dual parallel station, and the assembly content is exactly the same. When one device fails, the other device can still work, and the start-up rate of the production line is improved.

[0144] The hole of the self-extrusion nut is a smooth hole. During assembly, the self-extrusion nut is subjected to pressure perpendicular to the end face of the nut while rotating, so that the nut can extrude the same thread on the workpiece base material. This method is used to connect tightly and is not prone to nut loosening. The tightening torque and tightening angle are monitored throughout the nut assembly process to ensure that the flange end face of the self-extrusion nut fits the workpiece and reaches the specified torque range.

[0145] After the fourth robot R05 places the workpiece to be assembled in the second assembly station 510, the second assembly mechanism 500 in the station automatically assembles the rivet nuts and / or threaded sleeves. The second assembly station 510 may be a double-station rotary table.

[0146] The second assembly station 510 adopts a double-station turntable, which effectively improves the station utilization rate. Two automatic riveting robots R07 (or one automatic riveting robot R07 and one automatic threaded sleeve robot R08) are used to automatically rivet and / or install threaded sleeves on different areas of the large casting at the same time.

[0147] Due to the large deformation of the mold surface of large castings, and the thin-walled structure near the rivet hole with a draft angle, the position, axis, and normal direction of the hole of each workpiece are poorly consistent. Therefore, each rivet robot R07 can be equipped with a visual recognition system. The visual recognition camera is installed near the rivet gun head. The camera takes pictures and calculates to automatically compensate for the position of the rivet hole and complete the installation of the automatic rivet nut.

[0148] In some other embodiments, the assembly device also includes a manual assembly device, which includes at least one third assembly mechanism 600 and at least one third assembly station 610; the third assembly station 610 is used to position and fix the die-casting to be assembled with the rivet nut; the third assembly mechanism 600 is configured to be able to assemble the rivet nut on the die-casting at the third assembly station 610 through manual operation; the manual assembly device includes at least one fourth assembly mechanism 700 and at least one fourth assembly station 710; the fourth assembly station 710 is used to position and fix the die-casting to be assembled with the threaded sleeve; the fourth assembly mechanism 700 is configured to be able to assemble the threaded sleeve on the die-casting at the fourth assembly station 710 through manual operation.

[0149] The third assembly station 610 is a station for manually assembling rivet nuts. The fifth robot R09 loads the semi-finished workpiece to the third assembly station 610. The operator uses a manual rivet gun to manually assemble the installation points of the rivet nuts installed by the first assembly mechanism or the feature points with poor accessibility of the automatic assembly robot.

[0150] The fourth assembly station 710 is a station for manually assembling threaded sleeves: the fifth robot R09 loads the semi-finished workpiece from the manual riveting station to the manual assembly of threaded sleeves station, and the operator holds a manual assembly of threaded sleeves gun for manual assembly. The first assembly station 410 and the second assembly station 510 adopt a double parallel station form. The station consists of two identical stations. When the operator operates in parallel station one, the robot loads and unloads from parallel station two; when the operator exits from station one and enters station two to operate, the robot loads and unloads from parallel station one. The operator has almost no waiting time in the entire workflow, and the station utilization rate is high.

[0151] In some other embodiments, the assembly device further includes a third robot R04 and a fourth robot R05; the third robot R04 is used to move the die castings at the first transfer station T1, the deburring and chip removal station and the first assembly station 410; the fourth robot R05 is used to move the die castings at the first assembly station 410, the second assembly station 510 and the second transfer station T2. ​​Among them, the first transfer station T1 is used to transfer the workpiece from the machining to the deburring and chip removal station, and to the assembly station after the deburring and chip removal; the second transfer station T2 is used to complete the transfer between automatic assembly and manual assembly. It should be noted that the third robot R04 and the fourth robot R05 are both seven-axis robots.

[0152] In another embodiment, the assembly device further includes a fifth robot R09 and a sixth robot R10; the fifth robot R09 is used to move the die castings at the second transfer station T2, the third assembly station 610 and the fourth assembly station 710; the sixth robot R10 is used to move the die castings at the fourth assembly station 710 and the third transfer station T3. The third transfer station T3 is used for the transfer of workpieces between the completion of manual assembly and the second measurement station 810. It should be noted that the fifth robot R09 and the sixth robot R10 are also seven-axis robots.

[0153] In another embodiment, the system further includes a seventh robot R12, which is used to move the die castings between the third transfer station T3, the second measuring station 810 and the fourth transfer station T4. Among them, the fourth transfer station T4 is used for the transfer of the workpiece when the online measurement is completed to the inspection station or returned to the sampling station. It should be noted that the seventh robot R12 is also a seven-axis robot. The workpiece with measurement is placed on the rotating table of the second measuring station 810 by the seventh robot R12, and the measuring robot R11 automatically selects the corresponding measurement program according to the state of the workpiece (blank, semi-finished product, finished product). After the measurement is qualified, the workpiece will enter the fourth transfer station T4.

[0154] It should be noted that the second measuring device 800 may be a laser radar measuring system, which performs 100% measurement on the key features of the assembled large casting to ensure the product quality of the large casting.

[0155] In another embodiment, the inspection device includes a back inspection mechanism and a front inspection mechanism; the inspection station includes a back inspection station 910 corresponding to the back inspection mechanism and a front inspection station 1001 corresponding to the front inspection mechanism; the system also includes an eighth robot R13 and a ninth robot R14; the eighth robot R13 is used to move the die casting between the fourth transfer station T4 and the back inspection station 910; the ninth robot R14 is used to move the die casting between the front inspection station 1001 and the unloading station 1110. Among them, the eighth robot R13 puts the workpiece on the back inspection station 910, and the quality inspector enters the station to inspect the appearance quality of the workpiece, such as shrinkage holes, black skin, etc.; at the same time, some manual deburring tasks and assembly quality inspections can be performed at this station. The inspection device also includes a turning table, and the back inspection station 910 needs to be turned over by the eighth robot R13 and placed on the turning table T5 after completing the inspection work, and then the ninth robot R14 takes the work from the turning table and moves it to the front inspection station 1001. The quality inspector enters this station to inspect the appearance quality of the workpiece, such as shrinkage holes, black skin, etc. At the same time, some manual deburring tasks and assembly quality inspections can be performed at this station. After all inspections are qualified, the ninth robot R14 automatically unloads the qualified workpieces to the unloading station 1110 (finished product frame). If the workpiece is found to be unqualified at the back inspection station 910 or the front inspection station 1001, the corresponding robot will put the workpiece into the unqualified station for repair or removal.

[0156] Optionally, the system also includes a first buffer station S1 located between the first transfer station T1 and the first assembly station 410, for temporarily storing die-castings to be assembled; the third robot R04 is configured to be able to move die-castings at the first transfer station T1, the deburring and chip removal station, the first assembly station 410 and the first buffer station S1; and / or, the system also includes a second buffer station S2 located between the third transfer station T3 and the second measuring station 810, for temporarily storing die-castings to be measured; the sixth robot R10 is configured to move die-castings at the fourth assembly station 710, the third transfer station T3 and the second buffer station S2; the seventh robot R12 is configured to move die-castings at the third transfer station T3, the second measuring station 810, the fourth transfer station T4 and the second buffer station S2. Among them, in the first buffer station S1 between the first transfer station T1 and the first assembly station 410, when the chip removal device or the assembly device fails and needs to be repaired, the third robot R04 can temporarily store the workpieces going to the first transfer station T1, the burr chip removal station 320, and the first assembly station 410 in the first buffer station to improve the system's operating rate. For example, each first buffer station can store three workpieces. When the assembly station fails, there can be a buffer time of six workpieces here to improve the production line operating rate.

[0157] Similarly, at the second buffer station S2 between the third transfer station T3 and the second measuring station 810, when the detection capability of the second measuring device 800 cannot meet the detection requirements of the current system, the sixth robot R10 can temporarily store a part of the workpieces in the second buffer station to avoid material blockage at the second measuring station 810. For example, four second buffer stations are configured near the second measuring station 810, each of which can store three workpieces, and there can be a total of twelve workpiece cache space. The second cache station is mainly used for caching normal workpieces of the production line when the measuring station is performing random inspection and measurement work, to prevent the second measuring station 810 from being blocked and affecting the production of the previous station.

[0158] In some embodiments, the system also includes a first sampling station C1 arranged adjacent to the first transfer station T1, a second sampling station arranged adjacent to the third transfer station T3, and a third sampling station C2 arranged adjacent to the second measuring station 810; the third robot R04 is configured to be able to move the die-casting at the first transfer station T1, the deburring and chip removal station, the first assembly station 410, the first buffer station S1 and the first sampling station C1; the sixth robot R10 is configured to move the die-casting at the fourth assembly station 710, the third transfer station T3, the second buffer station S2 and the second sampling station; the seventh robot R12 is configured to move the die-casting at the third transfer station T3, the second measuring station 810, the fourth transfer station T4, the second buffer station S2 and the third sampling station C2.

[0159] In order to realize the sampling inspection step, the system also includes a first sampling inspection station C1, a second sampling inspection station (not shown in the figure) and a third sampling inspection station C2, and the three sampling inspection stations have both sampling inspection unloading and loading functions. Among them, the first sampling inspection station C1 is used for when the processing quantity of the CNC machining center reaches the sampling inspection requirement, the workpiece is discharged from the station for inspection or re-loaded after the inspection is qualified. The inspection can be manually inspected and online measured at the second measurement station 810. Unqualified workpieces can also be discharged from this station without the operator entering the station to manually remove the workpiece. It should be noted that the first sampling inspection station C1 adopts a trolley docking form. After the workpiece is unloaded to this station, the workpiece can be directly taken out by the trolley for measurement or rework. It should be noted that since the second sampling inspection station and the third sampling inspection station C2 are relatively close, they can also share a sampling inspection station.

[0160] The second sampling station is used for unloading and loading workpieces when the number of workpieces reaches the sampling inspection requirements after assembly. Therefore, select the finished product sampling button on the button box next to the station, and the seven-axis robot will unload the assembled workpieces onto the sampling inspection trolley. After unloading, the finished workpieces will be sent to the laboratory or the second measurement station 810 for assembly performance testing of the assembled parts. Workpieces that pass the test can be reloaded from the second sampling station.

[0161] The third sampling inspection station C2 is used for sampling the loading and / or unloading of workpieces at the second measuring station 810, and any suitable mechanism may be used, including but not limited to an AGV.

[0162] Optionally, the system also includes a scanning device, which is multiple and is respectively arranged at the first measuring station 130, the processing station, the assembly station, and the second measuring station 810, and is used to scan and identify the information code on the die-casting at the first measuring station 130, the processing station, the assembly station, and the second measuring station 810.

[0163] Each workstation in the system is equipped with a QR code reader to read the QR code on the workpiece, so as to achieve accurate tracking and real-time traceability of the workpiece in the production line. The processing information of the workpiece after each process: such as the workpiece QR code, workpiece model, processing completion time of each workstation, workpiece qualification information, processing quality information, and assembly monitoring data will be recorded and uploaded to the MES system in real time, so as to achieve full-line traceability of product processing quality.

[0164] Among them, there is a QR code reading and writing device on the first measuring platform. When the workpiece is placed on the first measuring platform, the equipment automatically reads the QR code on the workpiece, and according to the production task, binds the QR code information of the workpiece to the required model and stores it in the PLC. At the same time, the workpiece QR code information and workpiece information are automatically uploaded to the MES system.

[0165] The first transfer station T1 is equipped with a QR code reader. When the third robot R04 grabs the workpiece, the device has completed the reading of the workpiece QR code and matched the workpiece model. There is a model detection sensor on the robot gripper to detect the difference characteristics of different models, so as to perform secondary error prevention for model identification. The model information is sent to the assembly station, and the assembly station runs the assembly program of the corresponding model.

[0166] A QR code reader is installed on the slide fixture of the first assembly station 410. When the workpiece is placed on the fixture, the QR code of the workpiece is read. After the self-extrusion nut is assembled, the tightening gun binds the assembly torque and assembly curve with the workpiece QR code and sends them to the MES system.

[0167] A QR code reader is installed on each of the two fixtures of the turntable of the second assembly station 510. When the workpiece is placed on the fixture, the workpiece QR code is automatically read and the workpiece model is identified. The second assembly machine automatically runs the assembly program of the corresponding model.

[0168] The third sampling station C2 is equipped with a handheld barcode scanner. Before loading, the operator needs to read the QR code on the workpiece. The PLC system automatically determines the status and model of the workpiece based on the QR code information of the workpiece, and automatically selects the measurement program.

[0169] The third transfer station T3 is equipped with a QR code reading and writing device. When the workpiece is placed at the third transfer station T3, the QR code of the workpiece is read, and the measurement result of the online measurement is bound with the QR code of the workpiece and sent to the MES system.

[0170] A QR code reader is installed on the fixture of the quality inspection station. When the workpiece enters the quality inspection station, the QR code of the workpiece will be automatically read, and all historical information bound to the workpiece (including but not limited to the following information: die-casting qualified information, flaw detection qualified information, machining qualified information, assembly qualified information, online measurement information, quality sampling information, etc.) will be displayed in the computer at the edge of the line. If the quality inspector reviews all the data and the manual visual inspection shows that the quality is qualified, the workpiece is considered qualified and allowed to be packed.

[0171] Optionally, the system further includes a control device, which is respectively connected to the loading device 100, the first measuring device, the processing device 200, the assembly device, the second measuring device 800, the inspection device and the unloading device 1100. The control device is used to control the operation of the entire system, wherein the control system can adopt an MES system.

[0172] like Figure 2 As shown, the die casting processing and assembly method and system disclosed in the present invention are described in detail through a specific embodiment below:

[0173] The integrated large casting blank material frame is loaded, and the blank is automatically loaded to the first measuring table (first measuring station 130) by the robot (loading robot R01), and the first measuring device is used to detect whether the size measurement of the key points of the blank meets the requirements of the drawing. If not, the blank workpiece is removed; if it is satisfied, the robot (first robot R02) loads the blank workpiece that meets the requirements of the drawing to the CNC machining center fixture (machining station), and processes the rivet holes, threaded sleeve holes, self-extrusion nut holes, and the positioning reference holes and positioning surfaces. Then the finished workpiece is automatically deburred and removed (such as aluminum chips) by the chip removal device. At this time, it is necessary to judge when the machined workpiece reaches the set first sampling frequency, for example, 20 pieces are one sampling frequency, that is, when the processing quantity reaches 20 pieces, one piece is sampled. When the first sampling frequency is met, the workpiece is sampled for measurement to determine whether the size measurement is qualified. If it is unqualified, the semi-finished workpiece is removed, and if it is qualified, the self-extrusion nut is assembled. If the first sampling inspection frequency is not met, the self-extrusion nut is also assembled. After the self-extrusion nut is assembled, it is determined whether the torque / angle monitoring during the assembly process meets the preset range requirements. If not, the semi-finished workpiece is removed. If it meets, the rivet nut is automatically assembled. After the rivet nut is assembled, it is determined whether the tension / stroke / quantity monitoring during the assembly process meets the preset range requirements. If not, the semi-finished workpiece is removed. If it meets, the rivet nut is manually assembled. Similarly, after the manual assembly is completed, it is determined whether the tension / stroke / quantity monitoring during the assembly process meets the preset range requirements. If not, the semi-finished workpiece is removed. If it meets, the threaded sleeve is manually assembled. After the manual assembly is completed, it is determined whether the stroke / quantity monitoring during the assembly process meets the preset range requirements. If not, the semi-finished workpiece is removed. If it meets, it is determined whether the assembled workpiece reaches the set second sampling inspection frequency. When the assembled workpiece reaches the set second sampling inspection frequency, for example, 50 pieces are one sampling inspection frequency, that is, when the assembly quantity reaches 50 pieces, one piece is sampled. When the second sampling inspection frequency is met, the workpiece is sampled for assembly characteristic test to determine whether the assembly characteristic test is qualified. If it is unqualified, it will be scrapped. If it is qualified, 100% measurement of key dimensions will be performed. If the second sampling inspection frequency is not met, 100% measurement of key dimensions will also be performed, and it will be determined whether 100% measurement of key dimensions is qualified. If it is unqualified, the finished workpiece will be removed. If it is qualified, the bottom surface appearance of the finished workpiece will be inspected and it will be determined whether it is qualified. If the bottom surface appearance is unqualified, the finished workpiece will be removed. If it is qualified, the front surface appearance of the finished workpiece will be inspected and it will be determined whether it is qualified. If it is unqualified, the finished workpiece will be removed. If it is qualified, the finished workpiece will be automatically packed.

[0174] The die casting processing and assembly method and system disclosed in the present invention have the following advantages:

[0175] Automatic model switching can realize mixed-line production of rear floors of large castings of different models, meeting the production needs of continuous turnover of products of different models. The present disclosure can define different models of rear floors using the same die-cast blank during product design, and distinguish models through machining features and assembly features. Therefore, the tooling fixtures in the production line can share a set of positioning references and clamping points, and there is no need to replace the fixtures when the workpiece model is switched. At the same time, a blank workpiece model recognition mechanism is provided on the manipulator gripper, and the workpiece model is judged by the difference features of different models contacted by the probe, and secondary recognition and error prevention are performed. According to the recognized model, the corresponding assembly program is automatically run;

[0176] The present invention configures a QR code reader on each workstation fixture to read the QR code information of the workpiece, and can bind all the processing data, monitoring data, and dimensional measurement data of the production line with the QR code one by one and upload them to the MES system, thereby realizing the quality control of the integrated large castings in the whole production process;

[0177] The present invention adopts a large number of automated equipment, such as automatic loading of blanks, automatic assembly of self-extruding nuts, automatic assembly of rivet nuts, 100% online automatic measurement, automatic packaging of finished products, etc., which reduces the number of operators in the production line and improves the production efficiency of the production line.

[0178] The present invention makes extensive use of the parallel double-station design, which solves the huge cycle waste caused by the loading and unloading process of large castings and improves the station utilization rate. In particular, in the design of the manual assembly station and the quality gate inspection station, the parallel double-station + fixture independent frame design is adopted, and the operator can freely operate around the workpiece at the station, which is highly flexible and scalable. The product adds new assembly features without adding new assembly stations, and adding operators to the parallel station can still meet the specified production capacity requirements.

[0179] The present invention adds a blank pre-inspection function in front of the CNC machining center, which can quickly and effectively remove unqualified workpieces, thereby improving the product qualification rate of the CNC machining center and reducing the failure rate of the machining center equipment alarm.

[0180] Based on the instability of the current products of large integrated castings and the premise that the automation application rate is not high, the present invention adopts a combination of automatic and manual methods to improve the fault tolerance and stability of the production line. For example: the production line adopts automatic loading of blanks, but a manual loading station is reserved; the production line adopts an automatic riveting system, but at the same time, a parallel double station + fixture independent frame design production line layout is adopted. By reserving a manual station, when an automatic station fails, the production line can still operate stably, ensuring the start-up rate of the production line.

[0181] The preferred embodiments of the present disclosure are described in detail above in conjunction with the accompanying drawings; however, the present disclosure is not limited to the specific details in the above embodiments. Within the technical concept of the present disclosure, a variety of simple modifications can be made to the technical solution of the present disclosure, and these simple modifications all fall within the protection scope of the present disclosure.

[0182] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present disclosure will not further describe various possible combinations.

[0183] In addition, various embodiments of the present disclosure may be arbitrarily combined, and as long as they do not violate the concept of the present disclosure, they should also be regarded as the contents disclosed by the present disclosure.

Claims

1. A method for processing and assembling a die casting, characterized in that: include: Move the die casting to be processed from the loading station to the first measuring station; Pre-sizing of key features of die castings at the first measuring station; Performing machining on the die castings with qualified size pre-measurement results at the machining station, wherein the machining includes machining of rivet holes, threaded sleeve holes, self-extrusion nut holes and process benchmarks; Assemble self-extrusion nuts, pull rivet nuts and threaded sleeves on machined die castings at the assembly station; In-line measurement of the critical dimensions of the die casting to be processed and / or machined and / or assembled at the second measuring station; Check the size, assembly quality and surface quality of die castings at the inspection station; Move the qualified die castings to the unloading station.

2. The method according to claim 1, characterized in that After the step of machining the die casting with qualified size pre-measurement at the processing station, the method further comprises: The deburring and chip removal station removes burrs and cutting chips from machined die castings.

3. The method according to claim 1 or 2, characterized in that: The method further comprises: Before the die-casting parts enter each workstation, the information codes on the die-casting parts are scanned and identified.

4. The method according to claim 1, characterized in that: The method further comprises: When the die casting does not meet the preset requirements in dimensional pre-measurement, online measurement and inspection, the die casting is rejected; and / or The die castings after machining and assembly are tested respectively, and when the test results do not meet the preset requirements, the die castings are rejected.

5. The method according to claim 1, characterized in that The method further comprises: When the machined die castings reach the first preset sampling frequency, perform dimensional inspection on the last die casting of the first preset sampling frequency; and / or When the die castings that have been assembled reach the second preset sampling frequency, the assembly characteristic test is performed on the last die casting of the second preset sampling frequency.

6. The method according to claim 1, characterized in that The step of assembling the self-extrusion nut, the rivet nut and the threaded sleeve on the machined die casting at the assembly station comprises: Autowiring: Assembling the self-extruding nut on the die casting at the first assembly station; Assembling the die casting with rivet nuts and / or threaded sleeves at the second assembly station; and / or Manual assembly: Assemble the rivet nuts on the die casting at the third assembly station; The threaded sleeves are assembled on the die casting at the fourth assembly station.

7. The method according to claim 6, characterized in that The step of assembling the self-extrusion nut, the rivet nut and the threaded sleeve on the machined die casting at the assembly station also includes: Monitoring assembly information during automatic assembly and manual assembly; wherein the assembly information includes torque parameters, angle parameters, tension parameters, stroke parameters and quantity parameters; Whether the assembly is qualified is determined according to the assembly information and the preset information.

8. The method according to claim 1, characterized in that The step of moving the die casting to be processed from the loading station to the first measuring station includes: Automatic loading, where a loading robot automatically moves the die casting to be processed from the loading station to the first measuring station; and / or Manual loading: the die casting to be processed is manually moved from the loading station to the first measuring station through the loading hanger.

9. A die casting processing and assembly system, characterized in that: include: A loading device, used to move the die casting to be processed from the loading station to the first measuring station; A first measuring device, for pre-sizing a key feature of the die casting at a first measuring station; A processing device, used for machining the die casting with qualified size pre-measurement results at a processing station, wherein the machining includes the machining of rivet holes, threaded socket holes, self-extrusion nut holes and process benchmarks; An assembly device, used for assembling self-extrusion nuts, pull rivet nuts and threaded sleeves on machined die castings at an assembly station; A second measuring device is used for online measuring the key dimensions of the die casting to be processed and / or machined and / or assembled at a second measuring station; Inspection device, used to inspect the size, assembly quality and surface quality of the die casting at the inspection station; The unloading device is used to move the die castings that have passed the inspection to the unloading station.

10. The system according to claim 9, characterized in that The system also includes a chip removal device for removing burrs and cutting chips from the die casting that has been machined at a deburring and chip removal station.

11. The system according to claim 9, characterized in that The feeding device comprises: An automatic loading mechanism, comprising a loading robot, wherein the loading robot is used to move the die casting to be processed from a first loading station to a first measuring station; and / or The manual loading mechanism comprises a loading hanger, and the loading hanger is used to move the die casting to be processed from the second loading station to the first measuring station.

12. The system according to claim 9, characterized in that The processing device comprises a first robot, a second robot and a plurality of CNC processing centers, wherein the first robot is used to move the die casting to be processed at the first measuring station to the plurality of CNC processing centers; The second robot is used to move the die-casting part processed by the CNC machining center to the first transfer station.

13. The system according to claim 9, characterized in that The assembly device comprises an automatic assembly device, the automatic assembly device comprises at least one first assembly mechanism and at least one first assembly station, the first assembly mechanism and the first assembly station correspond one to one; The first assembly mechanism is configured to automatically assemble a self-extrusion nut on the die casting at the first assembly station; The automatic assembly device further comprises at least one second assembly mechanism and at least one second assembly station, wherein the second assembly mechanism and the second assembly station correspond to each other one by one; The second assembly mechanism is configured to automatically assemble the rivet nut and / or the threaded sleeve to the die casting at the second assembly station; and / or The assembly device further comprises a manual assembly device, which comprises at least one third assembly mechanism and at least one third assembly station; the third assembly station is used to position and fix the die casting of the rivet nut to be assembled; The third assembly mechanism is configured to assemble the rivet nut on the die casting at the third assembly station through manual operation; The manual assembly device comprises at least one fourth assembly mechanism and at least one fourth assembly station; the fourth assembly station is used to position and fix the die casting to be assembled with the threaded sleeve; The fourth assembly mechanism is configured to assemble a threaded sleeve on the die casting at the fourth assembly station through manual operation.

14. The system according to claim 13, characterized in that The assembly device further comprises a third robot and a fourth robot; the third robot is used to move the die casting at the first transfer station, the deburring and chip removal station and the first assembly station; the fourth robot is used to move the die casting at the first assembly station, the second assembly station and the second transfer station; and / or The assembly device further comprises a fifth robot and a sixth robot; the fifth robot is used to move the die casting at the second transfer station, the third assembly station and the fourth assembly station; the sixth robot is used to move the die casting at the fourth assembly station and the third transfer station; and / or The system further comprises a seventh robot for moving the die casting at the third transfer station, the second measuring station and the fourth transfer station; and / or The inspection station includes a front inspection station and a back inspection station; The system also includes an eighth robot and a ninth robot; The eighth robot is used to move the die casting to the fourth transfer station and the reverse inspection station; The ninth robot is used to move die-cast parts between the front inspection station and the unloading station.

15. The system according to claim 14, characterized in that The system further comprises a first buffer station disposed between the first transfer station and the first assembly station, for temporarily storing the die castings to be assembled; The third robot is configured to be able to move the die casting at the first transfer station, the deburring and chip removal station, the first assembly station and the first buffer station; and / or The system further comprises a second buffer station disposed between the third transfer station and the second measuring station, for temporarily storing the die casting to be measured; The sixth robot is configured to move the die casting at the fourth assembly station, the third transfer station and the second buffer station; The seventh robot is configured to move the die casting at the third transfer station, the second measuring station, the fourth transfer station and the second buffer station.

16. The system according to claim 15, characterized in that The system further includes a first sampling inspection station disposed adjacent to the first transfer station, a second sampling inspection station disposed adjacent to the third transfer station, and a third sampling inspection station disposed adjacent to the second measurement station; The third robot is configured to be able to move the die casting at the first transfer station, the deburring and chip removal station, the first assembly station, the first buffer station and the first sampling station; The sixth robot is configured to move the die casting at the fourth assembly station, the third transfer station, the second buffer station and the second sampling station; The seventh robot is configured to move the die casting at a third transfer station, a second measuring station, a fourth transfer station, a second buffer station and a third sampling station.

17. The system according to any one of claims 9 to 16, characterized in that: The system also includes a scanning device, which is multiple and is respectively arranged at a first measuring station, a processing station, an assembly station, and a second measuring station, and is used to scan and identify information codes on the die-casting at the first measuring station, the processing station, the assembly station, and the second measuring station.

18. The system according to claim 17, characterized in that The system further comprises a control device, which is respectively connected in communication with the loading device, the first measuring device, the processing device, the assembling device, the second measuring device, the inspection device and the unloading device.

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