Door plate welding system and welding method applying same

Abstract

The invention relates to the technical field of plastic processing, and provides a door plate welding system and a welding method applying the door plate welding system.The door plate welding system comprises a door plate, a welding part, an intelligent clamping module, a welding module, a quality detection module, an intelligent control module and an exception handling module; the intelligent clamping module collects shape data of the transported door plate, analyzes the door plate according to the shape data to form an analysis result, and adaptively adjusts the clamping posture and the adsorption pressure of the door plate according to the analysis result; the welding module is used for welding the door plate and the welding piece which are assembled and abut against each other to form a welding assembly; the quality detection module is used for detecting welding seam data formed by welding and evaluating a welding seam according to the welding seam data to form an evaluation result; the intelligent control module controls the welding module and the intelligent clamping module according to the evaluation result, and the abnormity processing module sorts and picks out abnormal welding assemblies formed by welding according to the evaluation result.

Description

Technical Field

[0001] The invention relates to the technical field of plastic processing, and in particular to a door panel welding system and a welding method using the same. Background Art

[0002] In the current common structure of automobile door panels, automobile door panels are mostly composed of a combination of multiple layers of plastic parts. Different processes are used to fix the multiple layers of plastic parts together. Ultrasonic welding is one of the processes. The ultrasonic welding process converts 50 / 60 Hz current into 15, 20, 35 or 40KHz electrical energy through an ultrasonic generator. The converted high-frequency electrical energy is converted again into mechanical motion of the same frequency through a transducer. The mechanical motion is then transmitted to the welding head through a set of amplitude-changing rod devices that can change the amplitude. The welding head transmits the received vibration energy to the joint of the workpiece to be welded. In this area, the vibration energy is converted into heat energy through friction to melt the plastic.

[0003] For example, Chinese patent CN213412962U discloses an ultrasonic welding membrane for automobile door panels. Although the inner buckle structure of the automobile door panel is supported by the undercut mechanism to realize the automatic clamping of plastic parts, it ignores the refined control of the combined abutment between the workpieces, resulting in the defect of suspended welding process and reduced welding quality.

[0004] In addition, the prior art also has the following defects: 1. Traditional plastic door panel welding technology, such as single ultrasonic welding or hot melt welding methods, often does not accurately position the welding points when facing complex geometric structures of door panels (such as multiple curved surfaces and irregular edges). The position of the welding head is difficult to dynamically adjust, resulting in uneven or misaligned welding, which reduces the welding quality, especially when dealing with complex structures with high precision requirements.

[0005] 2. Traditional processes are usually designed for a single welding method, and the welding speed is limited, especially in large-scale production, it is difficult to meet the high-beat production requirements.

[0006] 3. Existing production lines mostly use manual or offline methods to detect welding quality, which leads to defects such as high error rate and inability to provide real-time data feedback after detection.

[0007] 4. The existing clamping mechanism has poor adaptability to complex door panel shapes, especially in multi-arc structures or non-planar designs, and cannot ensure that the welded parts are always in a tightly fitted state. As a result, it may cause hanging and dislocation during the welding process, thus affecting the welding quality.

[0008] The present invention is made to solve the common problems in the art, such as poor adaptive clamping ability, poor evaluation ability, low intelligence, poor welding speed control ability, and inability to adaptively adjust according to the weldment. Summary of the invention

[0009] The purpose of the present invention is to propose a door panel welding process method in view of the current shortcomings.

[0010] In order to overcome the shortcomings of the prior art, the present invention adopts the following technical solutions: A door panel welding system, comprising a server, a door panel, and a welding part, the door panel welding system also comprising an intelligent clamping module, a welding module, a quality detection module, an intelligent control module, and an abnormality handling module, the server is respectively connected to the intelligent clamping module, the welding module, the quality detection module, the intelligent control module, and the abnormality handling module; The intelligent clamping module collects shape data of the transported door panels, analyzes the door panels according to the shape data to form analysis results, and adaptively adjusts the clamping posture and adsorption pressure of the door panels according to the analysis results; the welding module welds the assembled and abutted door panels and welded parts to form a welded assembly; the quality inspection module collects weld data formed by welding, and evaluates the welds according to the weld data to form an evaluation result; the intelligent control module controls the welding module and the intelligent clamping module according to the evaluation results, and the abnormal handling module sorts out abnormal welded assemblies formed by welding according to the evaluation results; Among them, the intelligent clamping module includes a shape acquisition unit, a posture analysis unit, a flexible clamp unit and a dynamic pressure control unit, the shape acquisition unit acquires the shape data of the door panel, the posture analysis unit analyzes the door panel according to the shape data to form an analysis result, the flexible clamp unit adaptively adjusts the clamping posture of the door panel according to the analysis result, and the dynamic pressure control unit adjusts the adsorption pressure of the flexible clamp unit according to the analysis result.

[0011] Optionally, the welding module includes a welding unit and a posture adjustment unit, the posture adjustment unit adjusts the welding posture of the welding unit, and the welding unit welds the assembled and abutted door panels and welded parts; The welding module is arranged on a transportation path of the door panels and welded parts, and a welding station is arranged in the transportation path. The welding module welds the door panels and welded parts that enter the welding station for assembly.

[0012] Optionally, the quality detection module includes an ultrasonic detection unit and a quality assessment unit, the ultrasonic detection unit collects weld data formed by welding the door panel and the welded part, and the quality assessment unit assesses the weld according to the weld data to form an assessment result; Wherein, the quality inspection module is arranged on one side of the transport path, and inspects the welding quality of the door panel after being welded by the welding module.

[0013] Optionally, the abnormality handling module includes a sorting unit and a feedback unit, wherein the sorting unit sorts out unqualified welding assemblies according to the evaluation results, and the feedback unit numbers the sorted out abnormal welding assemblies and feeds back to the manager; Wherein, the abnormality processing module is arranged in the welding station and sorts out the abnormal welding assemblies.

[0014] Optionally, the posture analysis unit calculates the shape index S of the door panel according to the shape data and the following formula: shape : ; Where L is the contour complexity, K is the curvature of the door panel, S is the shape symmetry coefficient of the door panel, and α(A) is the adaptability correction coefficient; If the shape index S of the door panel shape If the welding monitoring threshold Range set by the system is exceeded, the adjustment of the flexible clamp unit and the dynamic pressure control unit will be triggered.

[0015] Optionally, the flexible clamp unit includes a sliding member, a contact member and an adjusting member, the sliding member adjusts the positions of the contact member and the adjusting member, the contact member contacts the surface of the door panel, and the adjusting member linearly adjusts the propping-up height of the door panel according to the analysis result; The sliding member comprises a sliding track, at least two sliding drive mechanisms, and at least two sliding seats, the at least two sliding seats are slidably connected to the sliding track, and the at least two sliding drive mechanisms are correspondingly arranged on the at least two sliding seats and drive the at least two sliding seats to slide along the extension direction of the sliding track; Wherein, the contact member and the adjustment member are arranged on at least two of the sliding seats.

[0016] Optionally, the shape acquisition unit includes an acquisition probe and a data storage device, wherein the acquisition probe is arranged on both sides of the transportation path of the weldment and acquires image data of the transported door panel, and the data storage device stores the image data of the door panel acquired by the acquisition probe.

[0017] In addition, the present invention also provides a door panel welding method, which comprises the following steps: S1, transporting the door panels to be welded and the welded parts through the transport path and transferring them to the welding station; S2. During the transportation of the door panels, the shape data of the transported welded parts are collected through the intelligent clamping module, and the door panels are analyzed according to the shape data to form analysis results, and the clamping posture and adsorption pressure of the door panels are adaptively adjusted according to the analysis results; S3, welding the assembled and abutted door panels and welded parts to form a weld seam through a welding module; S4. Collecting weld data formed by welding through the quality inspection module, and evaluating the weld according to the weld data to form an evaluation result; S5. sorting out abnormal welding assemblies from the production line according to the evaluation results through the abnormality processing module to retain normal welding assemblies; S6. Differentiate normal welding assemblies from abnormal welding assemblies and transport them to different subsequent process workshops.

[0018] Optionally, the door panel welding method further comprises: in step S6, attaching different RFID tags to the normal welding assemblies and abnormal welding assemblies that are distinguished and transported; Among them, the RFID tag has independent and distinguishable identification information.

[0019] Optionally, the door panel welding method further includes: in step S1, transporting the door panel to be welded step by step through the area where the intelligent clamping module is located, and linearly adjusting the welding posture of the assembled door panel through the intelligent clamping module.

[0020] The beneficial effects achieved by the present invention are: 1. Through the cooperation between the welding module and the quality inspection module, the weld quality can be inspected immediately after welding is completed to ensure that the welding depth, width and degree of fusion meet the requirements, ensure the traceability of the welding quality of the entire system, and reduce the flow of defective products into the next process.

[0021] 2. Through the cooperation between the intelligent clamping module and the welding module, the door panel can be accurately positioned and the clamping posture can be adaptively adjusted before welding, ensuring that the door panel is stable and without offset during welding, ensuring high welding accuracy of the entire system, reducing welding misalignment, and improving weld quality.

[0022] 3. Through the cooperation of the quality detection module and the intelligent control module, the welding quality data can be fed back to the control system in real time, and the welding parameters can be automatically adjusted according to the weld quality, ensuring that the entire system has adaptive adjustment capabilities, improving welding stability and reducing human intervention.

[0023] 4. Through the cooperation of the intelligent control module and the exception handling module, the abnormal data detected during the welding process can trigger the repair welding or rejection mechanism to prevent defective door panels and welded parts from entering the next process, ensuring that the entire system has high reliability and intelligent decision-making capabilities, and improving production quality and efficiency.

[0024] 5. Through the mutual cooperation of intelligent clamping module, welding module, quality inspection module, intelligent control module and exception handling module, the door panel can be accurately positioned and adaptively clamped before welding. The welding parameters can be adjusted in real time during the welding process. After the welding is completed, the quality inspection and fluctuation analysis can accurately identify the quality of the weld and intelligently remove or re-weld the abnormal welded parts assembly, ensuring that the entire system has high precision, high stability and intelligent control capabilities, thereby improving the consistency of welding quality, reducing the defective rate, and improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present invention can be further understood from the following description in conjunction with the accompanying drawings. The components in the figures are not necessarily drawn to scale, but the emphasis is placed on illustrating the principles of the embodiments. In different views, the same reference numerals designate the same parts.

[0026] Figure 1 It is an overall block diagram of the present invention.

[0027] Figure 2 It is a block diagram of the intelligent clamping module of the present invention.

[0028] Figure 3 It is a block diagram of the welding module of the present invention.

[0029] Figure 4 It is a block diagram of the quality detection module of the present invention.

[0030] Figure 5 It is a structural schematic diagram of the quality detection module and the exception handling module of the present invention.

[0031] Figure 6 It is a front view schematic diagram of the welding station, the main conveyor belt and the auxiliary conveyor belt of the present invention.

[0032] Figure 7 for Figure 6 Enlarged schematic diagram of part A in the middle.

[0033] Figure 8 It is a top view schematic diagram of the welding station, the main conveyor belt and the auxiliary conveyor belt of the present invention.

[0034] Fig. 9 for Figure 8 Enlarged schematic diagram of part B in the middle.

[0035] Fig.10It is a partial cross-sectional schematic diagram of the welding station, the main conveyor belt and the auxiliary conveyor belt of the present invention.

[0036] Fig.11 for Fig.10 Enlarged schematic diagram of part C in the middle.

[0037] Fig.12 It is a structural schematic diagram of the welding module and intelligent clamping module, door panel and welding parts of the present invention.

[0038] Fig.13 It is a schematic structural diagram of the quality inspection module, door panel, welding part and intelligent clamping module of the present invention.

[0039] Fig.14 for Fig.12 Enlarged schematic diagram of part D in the middle.

[0040] Fig.15 for Fig.13 Enlarged schematic diagram of part E in the middle.

[0041] Fig.16 It is a schematic structural diagram of the negative pressure adsorption sub-component of the present invention.

[0042] Explanation of the accompanying drawings: 1. welding station; 2. main conveyor belt; 3. auxiliary conveyor belt; 4. sorting conveyor belt; 5. sorting section; 6. sorting rod; 7. welding station; 8. shape collection unit; 9. robotic arm; 10. welding generator; 11. stand; 12. sliding track; 13. adjustment airbag; 14. adsorption cavity; 15. door panel; 16. abutment rod; 17. visual collector; 18. ultrasonic probe; 19. moving seat; 20. moving wheel; 21. moving track; 22. vacuum generator; 23. adsorption hole; 24. vacuum pipe; 25. sliding seat; 26. welding part. DETAILED DESCRIPTION

[0043] The following is an explanation of the embodiments of the present invention through specific embodiments. Those skilled in the art can understand the advantages and effects of the present invention from the contents disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and the details in this specification can also be modified and changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. In addition, the drawings of the present invention are only simple schematic illustrations and are not depicted according to actual sizes. It is stated in advance. The following embodiments will further explain the relevant technical contents of the present invention in detail, but the disclosed contents are not intended to limit the scope of protection of the present invention.

[0044] Embodiment 1: According to Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Fig. 9 , Fig.10 , Fig.11 , Fig.12 , Fig.13 , Fig.14 , Fig.15 ,as well as Fig.16 The present embodiment provides a door panel welding system, which includes a server, a door panel 15, and a welding piece 26. The door panel welding system also includes an intelligent clamping module, a welding module, a quality detection module, an intelligent control module, and an exception handling module. The server is connected to the intelligent clamping module, the welding module, the quality detection module, the intelligent control module, and the exception handling module, respectively, and stores the intermediate data and process data of the intelligent clamping module, the welding module, the quality detection module, the intelligent control module, and the exception handling module in a database of the server for query and call; The intelligent clamping module collects shape data of the transported door panel 15, analyzes the door panel 15 according to the shape data to form an analysis result, and adaptively adjusts the clamping posture and adsorption pressure of the door panel 15 according to the analysis result; the welding module welds the assembled and abutted door panel 15 and the welded part 26 to form a welded assembly; the quality inspection module collects weld data formed by welding, and evaluates the weld according to the weld data to form an evaluation result; the intelligent control module controls the welding module and the intelligent clamping module according to the evaluation result, and the abnormal processing module sorts out the abnormal welded assembly formed by welding according to the evaluation result; The door panel welding system also includes a central processing unit, which is respectively controlled and connected to the intelligent clamping module, welding module, quality inspection module, intelligent control module, and exception handling module, and centrally controls the intelligent clamping module, welding module, quality inspection module, intelligent control module, and exception handling module based on the central processing unit, and stores the control data of the central processing unit in a database to improve the welding efficiency and welding accuracy of the entire system.

[0045] In addition, the door panel welding system also includes two main conveyor belts 2, an auxiliary conveyor belt 3, and a welding station 7 (such as Fig.10 As shown in the dotted box, the two main conveyor belts 2 respectively transport the door panels 15 to be welded and the welded parts 26, wherein the main conveyor belt 2 and the auxiliary conveyor belt 3 are symmetrically arranged on both sides of the welding station 7, and the auxiliary conveyor belt 3 transports the welded and qualified welding assembly to the next subsequent process.

[0046] At the same time, in this embodiment, the intelligent clamping module, welding module, quality inspection module, and intelligent control module are all arranged in the welding station 7.

[0047] In addition, the door panels 15 and welded parts 26 transported by the two main conveyor belts 2 are set to a synchronous transportation state, that is, the two transported door panels 15 and welded parts 26 are transported synchronously and enter the welding station 7 together, and the door panels 15 are clamped and adsorbed by the intelligent clamping module.

[0048] Among them, the intelligent clamping module includes a shape acquisition unit 8, a posture analysis unit, a flexible clamp unit and a dynamic pressure control unit. The shape acquisition unit 8 acquires the shape data of the door panel 15, the posture analysis unit analyzes the door panel 15 according to the shape data to form an analysis result, the flexible clamp unit adaptively adjusts the clamping posture (or called "welding posture") of the door panel 15 according to the analysis result, and the dynamic pressure control unit adjusts the adsorption pressure of the flexible clamp unit according to the analysis result.

[0049] Optionally, the welding module includes a welding unit and a posture adjustment unit, the posture adjustment unit adjusts the welding posture of the welding unit, and the welding unit welds the two assembled and abutted door panels 15 and the welding piece 26; The welding module is arranged on the transportation path of the door panel and the welded parts 26 , and a welding station 7 is arranged in the transportation path. The welding module welds the welded parts 26 that enter the welding station 7 for assembly.

[0050] like Figure 6 As shown, the welding piece 26 is placed on one end surface of the door panel 15 (manually placed on one end surface of the door panel according to actual needs).

[0051] The welding unit includes a welding generator 10, an ultrasonic horn, a welding controller, and a cooler. The cooler cools the welding material. The welding controller controls the welding parameters of the ultrasonic horn. The welding generator 10 provides energy required for welding.

[0052] The welding parameters include but are not limited to the following: welding time, welding power, amplitude, and pressure.

[0053] In this embodiment, the welding process of the welding unit includes five stages: welding preparation, welding start, welding execution, welding cooling and welding completion. First, the clamping posture (welding posture) of the door panel 15 is fixed and adjusted by the flexible clamp unit, and the welding controller sets parameters such as welding time, power, amplitude and pressure. Subsequently, the welding generator 10 provides ultrasonic energy, drives the ultrasonic horn to align with the welding area, and applies appropriate pressure to ensure that the welding surface is in close contact. When welding is performed, the ultrasonic horn vibrates at a high frequency, generates friction heat at the welding interface, melts the material and diffuses and fuses it, and the welding controller adjusts the power, amplitude and welding time in real time according to the feedback data to optimize the welding quality. After the welding is completed, the ultrasonic wave stops, the system continues to apply pressure and starts the cooler, and accelerates the solidification of the weld between the welded part 26 and the door panel 15 by air cooling to prevent thermal deformation. Finally, the welding pressure is released, and the quality inspection module performs ultrasonic non-destructive testing and evaluation on the weld to ensure that the weld is complete, crack-free and defect-free. If the inspection is qualified, it enters the next process. If it is unqualified, the abnormal processing module is triggered to perform repair welding or rejection.

[0054] The posture adjustment unit includes a robot arm 9, a posture manipulator, and a visual collector 17, wherein the visual collector 17 collects image data of the welding unit and the welded part 26, and the posture manipulator controls the robot arm 9 according to the image data collected by the visual collector 17; Among them, the welding unit is arranged on the execution end of the robot arm 9, and drives the welding unit to adjust the welding position of the welding part 26 (adjust around the side wall of the welding part so that the welding part 26 can be welded to the door panel 15), thereby improving the flexibility and reliability of the welding position of the welding unit.

[0055] In addition, adjusting the position of the welding part 26 and the welding unit by using the image data collected by the visual collector 17 is a mature technology mastered by technicians in this field, so it is not repeated in this embodiment.

[0056] Optionally, the quality detection module includes an ultrasonic detection unit and a quality assessment unit, the ultrasonic detection unit collects weld data formed by welding between the welded part 26 and the door panel 15, and the quality assessment unit assesses the weld according to the weld data to form an assessment result; The quality inspection module is arranged at one side of the transport path, and inspects the welding quality between the welded part 26 and the door panel 15 after being welded by the welding module.

[0057] The ultrasonic detection unit includes an ultrasonic detection component, a moving component and a supporting component. The supporting component adjusts the position of the ultrasonic detection component so that the ultrasonic detection component abuts against the welding position. The ultrasonic detection component collects welding data of the welding position between the welding part 26 and the door panel 15. The moving component adjusts the positions of the supporting component and the ultrasonic detection component so that the positions of the supporting component and the ultrasonic detection component can be adjusted to detect different positions of the welding position between the welding part 26 and the door panel 15.

[0058] The ultrasonic detection component includes an ultrasonic probe 18, an ultrasonic signal generator, and a data buffer. The ultrasonic probe 18 transmits an ultrasonic signal to the welding position and receives a reflected signal inside the weld. The ultrasonic signal generator generates an ultrasonic signal of a specific frequency and transmits it to the weld area through the ultrasonic probe 18. The data buffer stores the ultrasonic signals transmitted and reflected at the weld position.

[0059] The abutment component includes a stand 11, an abutment rod 16, an abutment driving mechanism, and an extension detection member. The stand 11 is in a 7 shape, one end of the stand 11 is connected to one side of the welding station 7, and the other end of the stand 11 extends toward the top of the welding station 7. One end of the abutment rod 16 is driven and connected to the abutment driving mechanism to form an abutment portion, and the abutment portion is arranged at one end of the stand 11 and extends toward the top of the welding station 7. The other end of the abutment rod 16 is connected to the ultrasonic detection unit so that the ultrasonic detection unit can collect weld data of the weld; the extension detection member detects the extension amount of the abutment rod 16 and feeds it back to the central processing unit, and at the same time compares it with the required extension amount through the central processing unit until it is the same as the required extension amount.

[0060] The movable component includes a movable track 21, a movable driving mechanism, a movable seat 19, and at least two movable wheels 20. The movable seat 19 is slidably connected to the movable track 21. The movable track 21 is arranged in the length direction of the welding station 7 and extends along the length direction. The movable driving mechanism is arranged on the movable seat 19 and drives at least two movable wheels 20 to slide along the sliding direction of the movable track 21.

[0061] The stand 11 is disposed on the moving seat 19 and moves along with the movement of the moving seat 19 .

[0062] In this embodiment, the weld data includes but is not limited to the following: weld depth D of the i-th detection area weld,i , the weld width W of the i-th detection area weld,i, the weld thickness T of the i-th inspection area weld,i ; The quality assessment unit obtains the weld data collected by the ultrasonic detection unit and calculates the weld assessment index S of the i-th detection area according to the following formula: weld,i : ; In the formula, is the weld volume / area ratio of the i-th inspection area, is the shape stability factor of the i-th detection area, and its value is calculated according to the following formula: ; Where D weld,i is the weld depth of the i-th inspection area, W weld,i is the weld width of the i-th inspection area, T weld,i is the weld thickness of the i-th inspection area.

[0063] In addition, the weld volume V of the i-th inspection area weld,i The calculation is performed according to the following formula (in this embodiment, the weld is approximately a columnar molten pool, which is approximately a cylinder): ; Where D weld,i is the weld depth of the i-th inspection area, W weld,i is the weld width of the i-th inspection area.

[0064] Projected area of ​​weld A weld,i Calculate according to the following formula: ; Where W weld,i is the weld width of the i-th inspection area, T weld,i is the weld thickness of the i-th inspection area.

[0065] If the weld evaluation index S of the i-th inspection area weld If the quality threshold Qpass set by the system is exceeded, the weld geometry of the i-th inspection area is stable and the welding quality is qualified; If the weld evaluation index S of the i-th inspection area weld If the value is lower than the quality acceptance threshold Qpass set by the system, the weld geometry in the i-th inspection area is unstable and the welding quality is poor.

[0066] Among them, the quality acceptance threshold Qpass set by the system is set by the system or the manager according to the actual process and process requirements of the plastic door panels currently being produced. This is a technical means well known to technicians in this field, so it will not be described in detail in this embodiment.

[0067] Through the cooperation between the welding module and the quality inspection module, the weld quality can be inspected immediately after welding is completed to ensure that the welding depth, width and degree of fusion meet the requirements, ensure the traceability of the welding quality of the entire system, and reduce the flow of defective products into the next process.

[0068] Optionally, the abnormality handling module includes a sorting unit and a feedback unit, wherein the sorting unit sorts out unqualified welding assemblies according to the evaluation results, and the feedback unit numbers the sorted out abnormal welding assemblies and feeds back to the manager; The abnormality processing module is arranged in the welding station 7 or at the rear end, and sorts out abnormal welding assemblies.

[0069] The sorting unit includes a sorting rod 6, a sorting drive mechanism, and a sorting conveyor belt 4. The sorting conveyor belt 4 is arranged on one side of the auxiliary conveyor belt 3, and one end of the sorting rod 6 is driven and connected to the sorting drive mechanism to form a sorting part 5. The sorting part 5 is arranged on the auxiliary conveyor belt 3, and the other end of the sorting rod 6 is arranged in the direction of the sorting conveyor belt 4.

[0070] The sorting rod 6 is pneumatically telescopic, and the unqualified welding assemblies are pushed onto the sorting conveyor belt 4 by the push of the sorting rod 6 .

[0071] In addition, the qualified welded assembly is transported to the next process through the secondary conveyor belt 3. The next process specifically refers to the subsequent door panel reprocessing or deep processing process, which is a technical means well known to those skilled in the art, and thus will not be described in detail in this embodiment.

[0072] The feedback unit includes a feedback device and an indicator light. The feedback device obtains the evaluation result and activates the indicator light. The indicator light is used to project the result onto the unqualified welding assembly and provide feedback to the manager, so that the on-site manager can attach an RFID tag corresponding to the unqualified welding assembly (i.e., an unqualified RFID tag).

[0073] Through the cooperation between the intelligent control module and the exception handling module, the abnormal data detected during the welding process can trigger the repair welding or rejection mechanism, preventing the defective door panel 15 and welded part 26 assembly from entering the next process, ensuring that the entire system has high reliability and intelligent decision-making capabilities, and improving production quality and efficiency.

[0074] Optionally, the shape acquisition unit 8 includes an acquisition probe and a data storage device. The acquisition probe is arranged on both sides of the transportation path of the door panel 15 and acquires image data of the transported door panel 15. The data storage device stores the image data of the door panel 15 acquired by the acquisition probe.

[0075] In this embodiment, after the image data of the door panel 15 is acquired, the image data is pre-processed by image processing technology to obtain shape data corresponding to the door panel 15; The shape data includes contour information, curvature distribution K, and shape symmetry coefficient S of the door panel 15 .

[0076] Optionally, the posture analysis unit calculates the shape index S of the door panel 15 according to the shape data and the following formula: shape : ; Wherein, L is the contour complexity, K is the curvature of the door panel 15, S is the shape symmetry coefficient of the door panel 15, and α(A) is the adaptability correction coefficient; In this embodiment, the shape data of the door panel 15 is obtained, and the edge data of the door panel 15 is extracted using an edge detection algorithm, and the coordinates of the contour points (x i ,y i ), and at the same time, the edge points are fitted to form a smooth door panel 15 contour.

[0077] Wherein, based on the contour point cloud information in the image data, the contour complexity L is calculated according to the following formula: ; Where N is the total number of sampling points on the contour of the door panel 15, is the coordinate of the i-th point on the outline of the door panel 15 (in vector form), is the coordinate of the i+1th point on the contour of the door panel 15, is the Euclidean distance between adjacent contour points, and its value satisfies: , where ( x i ,y i ) is the coordinate (in numerical form) of the i-th point on the contour of the door panel 15, ( x i+1 ,y i+1 ) are the coordinates of the i+1th point.

[0078] The curvature K of the door panel 15 is calculated according to the following formula: ; Where N is the total number of sampling points on the contour of the door panel 15, ( x i ,y i) is the coordinate of the i-th point on the contour of the door panel 15, x i ’ ,y i ’ is the first derivative of the contour point of door panel 15, x i ’’ ,y i ’’ It is the second-order derivative of the contour point of door panel 15.

[0079] The shape symmetry coefficient S of the door panel 15 is calculated according to the following formula: ; Where N is the total number of sampling points on the contour of the door panel 15, is the coordinate of the i-th point on the contour of the door panel 15, is the geometric center coordinate vector of the door panel 15, is the Euclidean distance from point i on the contour of door panel 15 to the geometric center point.

[0080] Among them, the geometric center coordinate vector of the door panel 15 is Determined according to the following formula: ; Where N is the total number of sampling points on the contour of the door panel 15, ( x i ,y i ) is the coordinate of the i-th point on the contour of door panel 15.

[0081] The adaptability correction factor α(A) is calculated according to the following formula: ; Where A is the adaptability factor, and its value satisfies: ; Wherein, L is the contour complexity, K is the curvature of the door panel 15 , and S is the shape symmetry coefficient of the door panel 15 .

[0082] If the shape index S of the door panel 15 shape If the welding monitoring threshold Range set by the system is exceeded, the adjustment of the flexible clamp unit and the dynamic pressure control unit will be triggered.

[0083] If the shape index S of the door panel 15 shape If it is lower than the welding monitoring threshold Range set by the system, it means that the current status of the flexible fixture unit and the dynamic pressure control unit meets the system requirements.

[0084] Among them, the welding monitoring threshold Range set by the system is set by the system or the administrator according to the actual process and process requirements of the plastic door panels currently being produced, and is input through the human-computer interaction interface. This is a technical means well known to technicians in this field, so it will not be described one by one in this embodiment.

[0085] Through the cooperation between the intelligent clamping module and the welding module, the door panel can be accurately positioned and the clamping posture can be adaptively adjusted before welding, ensuring that the door panel is stable and without offset during welding, ensuring high welding accuracy of the entire system, reducing welding misalignment, and improving weld quality.

[0086] Through the cooperation between the quality inspection module and the intelligent control module, the welding quality data can be fed back to the control system in real time, and the welding parameters can be automatically adjusted according to the weld quality, ensuring that the entire system has adaptive adjustment capabilities, improving welding stability and reducing human intervention.

[0087] Optionally, the flexible clamp unit includes a sliding member, a contact member and an adjusting member, the sliding member adjusts the positions of the contact member and the adjusting member, the contact member contacts the surface of the door panel 15, and the adjusting member linearly adjusts the propping height of the door panel 15 according to the analysis result; The sliding member includes a sliding track 12, at least two sliding drive mechanisms, and at least two sliding seats 25, the at least two sliding seats 25 are slidably connected to the sliding track 12, and the at least two sliding drive mechanisms are correspondingly arranged on the at least two sliding seats 25, and drive the at least two sliding seats 25 to slide along the extension direction of the sliding track 12; The contact member and the adjustment member are arranged on at least two of the sliding seats 25 .

[0088] The contact component includes a contact protrusion, an anti-slip pattern arranged on the contact protrusion, and a negative pressure adsorption sub-component, wherein the anti-slip pattern is arranged at equal intervals along the contact surface between the contact protrusion and the door panel 15; the negative pressure adsorption sub-component is arranged in the contact protrusion and forms negative pressure adsorption with the contact end surface of the door panel 15, thereby achieving contact with the door panel 15.

[0089] Wherein, the contact member is arranged on the adjusting member.

[0090] The negative pressure adsorption sub-component includes an adsorption cavity 14, a vacuum pipe 24, a vacuum regulating valve, a vacuum generator 22, a microporous adsorption membrane, and a vacuum sensor. The adsorption cavity 14 is arranged in the contact protrusion and the side wall of the adsorption cavity 14 is provided with at least one adsorption hole 23. At least one adsorption hole 23 penetrates the inner wall of the adsorption cavity 14 and communicates with the external environment. The setting direction of at least one adsorption hole 23 is arranged in the same direction as the contact end face of the door panel 15. One end of the vacuum pipe 24 is connected to the vacuum generator 22, and the other end of the vacuum pipe 24 is connected to the vacuum generator 22. The microporous adsorption membrane is arranged on the contact end face between the contact protrusion and the door panel 15. The vacuum sensor is arranged in the adsorption cavity 14; In addition, a vacuum regulating valve is provided on the vacuum pipe 24 .

[0091] The specific adsorption process includes: the vacuum generator 22 (vacuum pump or Venturi negative pressure generator) is started to extract air. The vacuum pipe 24 is connected to the adsorption chamber 14, the air is extracted, and the pressure in the chamber decreases. The vacuum sensor monitors the negative pressure state to ensure that the set adsorption threshold is reached.

[0092] The contact surface of the door panel 15 fits the contact protrusion, and the negative pressure of the adsorption cavity 14 is transmitted to the door panel 15 through the adsorption holes 23, thereby forming an adsorption effect. The microporous adsorption membrane controls the uniformity of the airflow and prevents the door panel 15 from being deformed due to excessive local adsorption force.

[0093] The vacuum pressure sensor detects the current negative pressure value: If the negative pressure reaches the set range (such as -60 kPa), the subsequent adsorption contact operation will continue. If the negative pressure is lower than the safety threshold, automatic compensation will be triggered (adjusting the working state of the vacuum generator 22).

[0094] The vacuum regulating valve adjusts the negative pressure to prevent the door panel 15 from being deformed due to excessive adsorption force.

[0095] The adjustment member includes an adjustment airbag 13, an air pump, and an electronic pressure relief valve. The air pump (not shown) is connected to the adjustment airbag 13 to form an adjustment portion, and the adjustment portion is disposed on the sliding seat 25. The electronic pressure relief valve is disposed on the adjustment airbag 13 and communicates with the interior of the adjustment airbag 13. In the pressure release state, the electronic pressure release valve is in an open state, and releases the gas in the adjustment airbag 13 to the outside, so that the adjustment airbag 13 returns from the inflated state to the deflated original state.

[0096] At the same time, the electronic pressure relief valve realizes pressure release control of the adjustment airbag 13 based on the control of the central processing unit.

[0097] The specific working process of the flexible clamp unit is as follows: The door panel 15 to be welded and the welded part 26 are transported to the welding station 7. At this time, the flexible clamp unit flexibly holds and limits the door panel in the welding station 7. The sliding member adjusts the position of the contact member and the adjustment member through the sliding track 12 and the driving mechanism to adapt to door panels 15 of different sizes and shapes (the position of the sliding member can be manually adjusted according to the size, thereby driving the adjustment of the contact member and the adjustment member to move). Then, the vacuum generator 22 is started, and the adsorption chamber 14 is negatively pressurized through the vacuum pipe 24 to form an adsorption effect to ensure that the door panel 15 is stably fixed. Next, the air pump in the adjustment member inflates the adjustment airbag 13 to linearly prop up the door panel 15 to the optimal welding position. At the same time, the electronic pressure relief valve is fine-tuned according to the instructions of the central controller to ensure that the door panel 15 is accurately aligned. During the welding process, the negative pressure adsorption and the adjustment airbag 13 jointly maintain the stability of the door panel 15, and the vacuum sensor monitors the status in real time and performs automatic compensation. After welding is completed, the vacuum generator 22 is closed, the electronic pressure relief valve releases the airbag gas, and the fixture returns to the initial state. At the same time, the reverse inflation method can be used to accelerate the separation of the door panel 15 to ensure that the door panel 15 is released smoothly and enters the next process.

[0098] The flexible fixture unit further includes a contact analysis subunit, wherein the contact analysis subunit performs contact analysis based on the analysis result (shape index S shape ), and adjust the airbag inflation volume V according to the following formula air : ; Where V 0 is the initial inflation volume set for the system, S shape is the shape index, and Range is the welding monitoring threshold set by the system.

[0099] The contact analysis subunit calculates the adjusted airbag inflation volume V air The information is transmitted to the central processing unit, and the inflation pump is controlled by the central processing unit, so that the adjustment airbag can flexibly adjust the posture of the door panel 15.

[0100] The dynamic pressure control unit obtains the shape index S shape , and calculate the negative pressure adsorption force P according to the following formula vacuum : ; Where P 0 To set the maximum negative pressure adsorption capacity, according to the performance of the vacuum generator, α is the negative pressure adjustment coefficient, its value is set by the system and input from the human-computer interaction interface; S shape is the shape index, Acontact is the contact area between the clamp and the door panel 15 , and its value is determined by the actual contact situation between the contact protrusion and the door panel 15 .

[0101] When the dynamic pressure control unit determines the negative pressure adsorption force P vacuum After that, it is transmitted to the central processor, and the vacuum generator and the vacuum regulating valve are controlled by the central processor to achieve the negative pressure adsorption force P vacuum Precise control.

[0102] In addition, in this embodiment, the value trend of the negative pressure adjustment coefficient α is: When α is small (such as 0.2~0.4): it is suitable for flat, large-area, regularly shaped door panels 15, and does not require high negative pressure. When α is large (such as 0.7~1.0): it is suitable for small-area, irregular, easy-to-slide door panels 15, and requires higher adsorption force.

[0103] At the same time, in this embodiment, an example of the value of the negative pressure adjustment coefficient α is provided, specifically: 1) in the scenario of a flat, large-area door panel 15 (such as a plastic shell outer panel of a car door), the negative pressure adjustment coefficient α=0.3; 2) in the scenario of a small-sized regular door panel 15 (such as a plastic interior decoration part), the negative pressure adjustment coefficient α=0.5; 3) in the scenario of a curved door panel 15 (such as a car trunk lid), the negative pressure adjustment coefficient α=0.7; 4) in the scenario of an ultra-small-area door panel 15 (such as fasteners and bracket parts), the negative pressure adjustment coefficient α=1.0.

[0104] In addition, the present invention also provides a door panel welding method, which comprises the following steps: S1, transporting the door panel 15 to be welded and the welded part 26 through a transport path and transferring them to a welding station; S2. During the transportation of the door panel 15, the shape data of the transported door panel 15 is collected through the intelligent clamping module, and the door panel 15 is analyzed according to the shape data to form an analysis result, and the clamping posture and adsorption pressure of the door panel 15 are adaptively adjusted according to the analysis result; S3, welding the assembled and abutted door panels 15 and the welding parts to form a weld seam through a welding module; S4. Collecting weld data formed by welding through the quality inspection module, and evaluating the weld according to the weld data to form an evaluation result; S5. sorting out abnormal welding assemblies from the production line according to the evaluation results through the abnormality processing module to retain normal welding assemblies; S6. Differentiate normal welding assemblies from abnormal welding assemblies and transport them to different subsequent process workshops.

[0105] Optionally, the door panel welding method further comprises: in step S6, attaching different RFID tags to the normal welding assemblies and abnormal welding assemblies that are distinguished and transported; Among them, the RFID tag has independent and distinguishable identification information.

[0106] Optionally, the door panel welding method further includes: in step S1, transporting the door panel 15 to be welded step by step through the area where the intelligent clamping module is located, and linearly adjusting the welding posture of the assembled door panel through the intelligent clamping module.

[0107] Through the mutual cooperation of the intelligent clamping module, welding module, quality inspection module, intelligent control module, and exception handling module, the door panel can be accurately positioned and adaptively clamped before welding, and the welding parameters can be adjusted in real time during the welding process. After the welding is completed, the quality inspection and fluctuation analysis can accurately identify the quality of the weld and intelligently remove or re-weld the abnormal welded parts assembly, ensuring that the entire system has high precision, high stability and intelligent control capabilities, thereby improving the consistency of welding quality, reducing the defective rate, and improving production efficiency.

[0108] Embodiment 2: This embodiment should be understood to include all the features of any of the above embodiments, and further improve upon them. Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Fig. 9 , Fig.10 , Fig.11 , Fig.12 , Fig.13 , Fig.14 , Fig.15 ,as well as Fig.16 , and the quality detection module also includes a quality fluctuation analysis unit, which analyzes the welding data of an entire welding position according to the quality evaluation index to form a quality result, and triggers an early warning prompt according to the quality result.

[0109] The quality fluctuation analysis unit obtains the weld evaluation index S of the i-th detection area. weld,i , and calculate the weld quality index S of the entire weld according to the following formula weld,total : ; In the formula, S weld,i is the weld evaluation index of the ith inspection area, and M is the number of inspection areas into which the weld is divided.

[0110] The quality fluctuation analysis unit obtains the weld quality index S of the entire weld. weld,total , and the standard deviation of weld quality is calculated according to the following formula : ; In the formula, S weld,i is the weld evaluation index of the ith inspection area, and M is the number of inspection areas into which the weld is divided.

[0111] If satisfied: , a yellow warning is triggered, and the manager or operator is prompted to check the welding parameters; If satisfied: , a red warning is triggered, the welding quality is seriously substandard, and the welding process needs to be adjusted or the equipment needs to be maintained.

[0112] Through the cooperation between the quality assessment unit and the quality fluctuation analysis unit, the welding quality can not only be judged in real time through a single weld assessment index, but also the quality fluctuation trend of the entire weld area can be analyzed, ensuring that the entire system can not only accurately detect weld quality, but also predict changes in welding stability in advance, thereby improving welding consistency and production reliability.

[0113] The contents disclosed above are only preferred feasible embodiments of the present invention, and do not limit the protection scope of the present invention. Therefore, all equivalent technical changes made using the contents of the present invention specification and drawings are included in the protection scope of the present invention. In addition, the elements therein can be updated as technology develops.

Claims

1. A door panel welding system, comprising a server, a door panel, and a welding part, characterized in that: The door panel welding system also includes an intelligent clamping module, a welding module, a quality detection module, an intelligent control module, and an abnormality handling module, and the server is connected to the intelligent clamping module, the welding module, the quality detection module, the intelligent control module, and the abnormality handling module respectively; The intelligent clamping module collects shape data of the transported door panels, analyzes the door panels according to the shape data to form analysis results, and adaptively adjusts the clamping posture and adsorption pressure of the door panels according to the analysis results; the welding module welds the assembled and abutted door panels and welded parts to form a welded assembly; the quality inspection module collects weld data formed by welding, and evaluates the welds according to the weld data to form an evaluation result; the intelligent control module controls the welding module and the intelligent clamping module according to the evaluation results, and the abnormal handling module sorts out abnormal welded assemblies formed by welding according to the evaluation results; Among them, the intelligent clamping module includes a shape acquisition unit, a posture analysis unit, a flexible clamp unit and a dynamic pressure control unit, the shape acquisition unit acquires the shape data of the door panel, the posture analysis unit analyzes the door panel according to the shape data to form an analysis result, the flexible clamp unit adaptively adjusts the clamping posture of the door panel according to the analysis result, and the dynamic pressure control unit adjusts the adsorption pressure of the flexible clamp unit according to the analysis result.

2. The door panel welding system according to claim 1, characterized in that: The welding module includes a welding unit and a posture adjustment unit, wherein the posture adjustment unit adjusts the welding posture of the welding unit, and the welding unit welds the assembled and abutted door panels and welded parts; The welding module is arranged on a transportation path of the door panels and welded parts, and a welding station is arranged in the transportation path. The welding module welds the door panels and welded parts that enter the welding station for assembly.

3. The door panel welding system according to claim 2, characterized in that: The quality detection module includes an ultrasonic detection unit and a quality assessment unit, wherein the ultrasonic detection unit collects weld data formed by welding the door panel and the welded part, and the quality assessment unit assesses the weld according to the weld data to form an assessment result; Wherein, the quality inspection module is arranged on one side of the transport path, and inspects the welding quality of the weld after being welded by the welding module.

4. The door panel welding system according to claim 3, characterized in that: The abnormality handling module includes a sorting unit and a feedback unit. The sorting unit will sort out unqualified welding assemblies according to the evaluation results, and the feedback unit will number the sorted out abnormal welding assemblies and feedback them to the manager. Wherein, the abnormality processing module is arranged in the welding station, and sorts out the abnormal welding assemblies.

5. The door panel welding system according to claim 4, characterized in that: The posture analysis unit calculates the shape index S of the door panel according to the shape data and the following formula shape : ； Where L is the contour complexity, K is the curvature of the door panel, S is the shape symmetry coefficient of the door panel, and α(A) is the adaptability correction coefficient; If the shape index S of the door panel shape If the welding monitoring threshold Range set by the system is exceeded, the adjustment of the flexible clamp unit and the dynamic pressure control unit will be triggered.

6. The door panel welding system according to claim 5, characterized in that: The flexible clamp unit includes a sliding member, a contact member and an adjusting member, wherein the sliding member adjusts the positions of the contact member and the adjusting member, the contact member contacts the surface of the door panel, and the adjusting member linearly adjusts the propping height of the door panel according to the analysis result; The sliding member comprises a sliding track, at least two sliding drive mechanisms, and at least two sliding seats, the at least two sliding seats are slidably connected to the sliding track, and the at least two sliding drive mechanisms are correspondingly arranged on the at least two sliding seats and drive the at least two sliding seats to slide along the extension direction of the sliding track; Wherein, the contact member and the adjustment member are arranged on at least two of the sliding seats.

7. The door panel welding system according to claim 6, characterized in that: The shape acquisition unit includes an acquisition probe and a data storage device. The acquisition probe is arranged on both sides of the transportation path of the door panel and acquires image data of the transported welded parts. The data storage device stores the image data of the door panel acquired by the acquisition probe.

8. A door panel welding method, according to the door panel welding system of claim 7, characterized in that: The door panel welding method comprises the following steps: S1, transporting the door panels to be welded and the welded parts through the transport path and transferring them to the welding station; S2. During the transportation of the door panels, the shape data of the transported welded parts are collected through the intelligent clamping module, and the door panels are analyzed according to the shape data to form analysis results, and the clamping posture and adsorption pressure of the door panels are adaptively adjusted according to the analysis results; S3, welding the assembled and abutted door panels and welded parts to form a weld seam through a welding module; S4. Collecting weld data formed by welding through the quality inspection module, and evaluating the weld according to the weld data to form an evaluation result; S5. sorting out abnormal welding assemblies from the production line according to the evaluation results through the abnormality processing module to retain normal welding assemblies; S6. Differentiate normal welding assemblies from abnormal welding assemblies and transport them to different subsequent process workshops.

9. The door panel welding method according to claim 8, characterized in that: The door panel welding method further comprises: in step S6, attaching different RFID tags to the normal welding assemblies and abnormal welding assemblies that are distinguished and transported; Among them, the RFID tag has independent and distinguishable identification information.

10. The door panel welding method according to claim 9, characterized in that: The door panel welding method further includes: in step S1, the door panel to be welded is transported step by step into the area where the intelligent clamping module is located, and the welding posture of the assembled door panel is linearly adjusted by the intelligent clamping module.

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