A door panel welding system and a welding method using the same

Abstract

The present invention relates to the technical field of plastic processing. The present invention provides a door panel welding system and a welding method using the same. The door panel welding system includes a door panel, a welding part, an intelligent clamping module, a welding module, a quality inspection module, an intelligent control module, and an abnormal handling module. The intelligent clamping module collects the shape data of the transported door panel, analyzes the door panel according to the shape data to form an analysis result, and adaptively adjusts the clamping posture and adsorption pressure of the door panel according to the analysis result; the welding module welds the assembled and abutted door panel and welding part to form a welded combination; the quality inspection module inspects the 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 handling module sorts out and picks out the abnormal welded combination formed by welding according to the evaluation result.

Description

Technical Field

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

[0002] In the common structure of current automotive door panels, automotive door panels are mostly composed of multiple plastic parts combined together, and different processes are used to fix the multiple plastic parts into one body, and ultrasonic welding is one of the processes. The ultrasonic welding process converts 50 / 60 Hz current into 15, 20, 35 or 40 KHz electrical energy through an ultrasonic generator. The converted high-frequency electrical energy is converted into mechanical motion of the same frequency again through a transducer, and then the mechanical motion is transmitted to the welding head through a horn device 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 by friction to melt the plastic.

[0003] For example, an ultrasonic welding die for automotive door panels disclosed in Chinese Patent CN213412962U realizes the support for the inner buckle structure of the automotive door panel through an inverted buckle mechanism, thereby realizing the automatic clamping of plastic parts. However, it ignores the fine control of the combined abutment between workpieces, resulting in the defect that the welding process is suspended and the welding quality is reduced.

[0004] In addition, the following defects also exist in the prior art:

[0005] 1. In traditional plastic door panel welding technologies, such as single ultrasonic welding or hot melt welding methods, when facing the complex geometric structure of the door panel (such as multiple arc surfaces, irregular edges), the positioning of the welding points is often not accurate enough. It is difficult to dynamically adjust the position of the welding head, resulting in uneven welding or misalignment, reducing the welding quality, especially being particularly obvious when dealing with complex structures with high precision requirements.

[0006] 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 production requirements of high beats.

[0007] 3. Existing production lines mostly adopt manual or off-line methods to detect the welding quality, resulting in defects such as high error rate and inability to provide real-time feedback of data after detection.

[0008] 4. The existing clamping mechanisms have poor adaptability to the complex shapes of door panels. Especially in structures with multiple arc surfaces or non-planar designs, it is impossible to ensure that the welded parts are always in a tightly fitting state. As a result, suspension and misalignment may occur during the welding process, thereby affecting the welding quality.

[0009] In order to solve the problems commonly existing in the art, such as poor adaptive clamping ability, poor evaluation ability, low intelligence level, poor welding speed regulation ability, and inability to adaptively adjust according to welded parts, the present invention is made. Summary of the Invention

[0010] The object of the present invention is to propose a door panel welding process method in view of the current deficiencies.

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

[0012] A door panel welding system, the door panel welding system includes a server, a door panel, and a welded part, the door panel welding system further includes an intelligent clamping module, a welding module, a quality inspection module, an intelligent control module, and an abnormal handling module, and the server is respectively connected to the intelligent clamping module, the welding module, the quality inspection module, the intelligent control module, and the abnormal handling module;

[0013] The intelligent clamping module collects the shape data of the transported door panel, analyzes the door panel according to the shape data to form an analysis result, and adaptively adjusts the clamping posture and adsorption pressure of the door panel according to the analysis result; the welding module welds the assembled and abutted door panel and welded part to form a welded combination; the quality inspection module inspects the 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 handling module sorts out and picks out the abnormally welded combination formed by welding according to the evaluation result;

[0014] Among them, the intelligent clamping module includes a shape acquisition unit, a posture analysis unit, a flexible fixture unit, and a dynamic pressure control unit. The shape acquisition unit collects 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 fixture 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 fixture unit according to the analysis result.

[0015] 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 panel and welded part;

[0016] Among them, the welding module is arranged on the transportation path of the door panel and the welded part, and a welding station is arranged in the transportation path. The welding module welds the door panel and the welded part assembled into the welding station.

[0017] Optionally, the quality inspection module includes an ultrasonic inspection unit and a quality evaluation unit. The ultrasonic inspection unit collects weld data formed by welding the door panel and the welded part, and the quality evaluation unit evaluates the weld based on the weld data to form an evaluation result;

[0018] Among them, the quality inspection module is arranged on one side of the transportation path and inspects the welding quality of the door panel after being welded by the welding module.

[0019] Optionally, the abnormal handling module includes a sorting unit and a feedback unit. The sorting unit sorts out unqualified welded assemblies according to the evaluation result, and the feedback unit numbers the abnormally welded assemblies sorted out and feeds them back to the manager;

[0020] Among them, the abnormal handling module is arranged in the welding station and sorts out abnormally welded assemblies.

[0021] Optionally, the posture analysis unit calculates the shape index S of the door panel according to the shape data and the following formula shape :

[0022] ;

[0023] In the formula, 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;

[0024] If the shape index S of the door panel shape exceeds the welding monitoring threshold Range set by the system, adjustments to the flexible fixture unit and the dynamic pressure control unit are triggered.

[0025] Optionally, the flexible fixture unit includes a sliding member, a contact member, and an adjustment member. The sliding member adjusts the positions of the contact member and the adjustment member. The contact member contacts the surface of the door panel, and the adjustment member linearly adjusts the lifting height of the door panel according to the analysis result;

[0026] The sliding member includes a sliding track, at least two sliding driving mechanisms, and at least two sliding seats. At least two sliding seats are slidably connected to the sliding track, and at least two sliding driving mechanisms are correspondingly arranged on at least two sliding seats and drive at least two sliding seats to slide along the extension direction of the sliding track;

[0027] Among them, the contact member and the adjustment member are arranged on at least two of the sliding seats.

[0028] Optionally, the shape acquisition unit includes an acquisition probe and a data memory. The acquisition probe is arranged on both sides of the transportation path of the welded part and acquires image data of the transported door panel, and the data memory stores the image data of the door panel acquired by the acquisition probe.

[0029] In addition, the present invention also provides a method for welding door panels, which includes the following steps:

[0030] S1. Transport the door panel to be welded and the welded part through the transportation path and transfer them to the welding station;

[0031] S2. During the transportation of the door panel, collect the shape data of the transported welded part through the intelligent clamping module, analyze the door panel according to the shape data to form an analysis result, and adaptively adjust the clamping posture and adsorption pressure of the door panel according to the analysis result;

[0032] S3. Weld the assembled and abutted door panel and welded part through the welding module to form a weld;

[0033] S4. Collect the weld data formed by welding through the quality inspection module and evaluate the weld according to the weld data to form an evaluation result;

[0034] S5. Sort out the abnormal welding assemblies according to the evaluation result through the abnormal handling module to generate a production line, so as to retain the normal welding assemblies;

[0035] S6. Distinguish the normal welding assemblies and abnormal welding assemblies and transport them to different subsequent process workshops.

[0036] Optionally, the method for welding door panels further includes: in step S6, attach different RFID tags to the distinguished and transported normal welding assemblies and abnormal welding assemblies;

[0037] Among them, the RFID tags have independent and distinguishable identification information.

[0038] Optionally, the method for welding door panels further includes: in step S1, transport the door panel to be welded step by step through the area where the intelligent clamping module is located, and linearly adjust the welding posture of the assembled door panel through the intelligent clamping module.

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

[0040] 1. Through the mutual cooperation of the welding module and the quality inspection module, the weld quality can be immediately detected after welding, ensuring that the welding depth, width, and fusion degree meet the requirements, ensuring that the welding quality of the entire system is traceable, and reducing the inflow of defective products into the next process.

[0041] 2. Through the mutual cooperation of 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 deviation during welding, guaranteeing high welding precision of the whole system, reducing welding misalignment, and improving the weld quality.

[0042] 3. Through the mutual cooperation of the quality inspection module and the intelligent control module, the welding quality data can be real-time fed back to the control system, and the welding parameters can be automatically adjusted according to the weld quality, ensuring that the whole system has the ability of adaptive adjustment, improving the welding stability, and reducing the human intervention.

[0043] 4. Through the mutual cooperation of the intelligent control module and the exception handling module, the abnormal data detected during the welding process can trigger the re-welding or rejection mechanism, preventing defective door panels and welded assemblies from entering the next process, ensuring that the whole system has high reliability and intelligent decision-making ability, and improving the production quality and efficiency.

[0044] 5. Through the mutual cooperation of the intelligent clamping module, the welding module, the quality inspection module, the intelligent control module, and the 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, the weld quality can be accurately identified by quality inspection and fluctuation analysis after welding, and the abnormal welded assemblies can be intelligently rejected or re-welded, ensuring that the whole system has high precision, high stability, and intelligent regulation ability, thereby improving the consistency of welding quality, reducing the defective rate, and increasing the production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

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

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

[0047] Figure 2 It is a schematic block diagram of the intelligent clamping module of the present invention.

[0048] Figure 3 It is a schematic block diagram of the welding module of the present invention.

[0049] Figure 4 It is a schematic block diagram of the quality inspection module of the present invention.

[0050] Figure 5 It is a schematic structural diagram of the quality inspection module and the exception handling module of the present invention.

[0051] 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.

[0052] Figure 7 is Figure 6 An enlarged schematic view of part A in

[0053] Figure 8 A top view schematic of the welding station, main conveyor belt, and auxiliary conveyor belt of the present invention.

[0054] Figure 9 is Figure 8 An enlarged schematic view of part B in

[0055] Figure 10 A partial sectional view schematic of the welding station, main conveyor belt, and auxiliary conveyor belt of the present invention.

[0056] Figure 11 is Figure 10 An enlarged schematic view of part C in

[0057] Figure 12 A structural schematic of the welding module, intelligent clamping module, door panel, and welded part of the present invention.

[0058] Figure 13 A structural schematic of the quality inspection module, door panel, welded part, and intelligent clamping module of the present invention.

[0059] Figure 14 is Figure 12 An enlarged schematic view of part D in

[0060] Figure 15 is Figure 13 An enlarged schematic view of part E in

[0061] Figure 16 A structural schematic of the negative pressure adsorption sub-component of the present invention.

[0062] Explanation of reference numerals: 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 acquisition unit; 9, robotic arm; 10, welding generator; 11, upright seat; 12, sliding track; 13, adjustment airbag; 14, adsorption cavity; 15, door panel; 16, abutting rod; 17, vision collector; 18, ultrasonic probe; 19, moving seat; 20, moving wheel; 21, moving track; 22, vacuum generator; 23, adsorption hole; 24, vacuum pipeline; 25, sliding seat; 26, welded part. Detailed implementation manners

[0063] The following are specific embodiments to illustrate the implementation manners of the present invention. Those skilled in the art can understand the advantages and effects of the present invention from the content disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the spirit of the present invention. Additionally, the drawings of the present invention are only for simple schematic illustration and are not drawn according to actual dimensions, which is hereby stated in advance. The following embodiments will further detail the related technical content of the present invention, but the disclosed content is not intended to limit the protection scope of the present invention.

[0064] Embodiment 1: According to Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 、 Figure 7 、 Figure 8 、 Figure 9 、 Figure 10 、 Figure 11 、 Figure 12 、 Figure 13 、 Figure 14 、 Figure 15 、and Figure 16 , this embodiment provides a door panel welding system. The door panel welding system includes a server, a door panel 15, and a welding part 26. The door panel welding system further includes an intelligent clamping module, a welding module, a quality inspection module, an intelligent control module, and an exception handling module. The server is respectively connected to the intelligent clamping module, the welding module, the quality inspection module, the intelligent control module, and the exception handling module, and stores the intermediate data and process data of the intelligent clamping module, the welding module, the quality inspection module, the intelligent control module, and the exception handling module in the database of the server for querying and calling;

[0065] The intelligent clamping module collects the 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 welding part 26 to form a welded combination; the quality inspection module inspects the weld data formed by the 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 exception handling module sorts out and picks out the abnormally welded combination formed by the welding according to the evaluation result;

[0066] The door panel welding system further includes a central processing unit, which is respectively connected to the intelligent clamping module, the welding module, the quality inspection module, the intelligent control module, and the exception handling module in a controlled manner, and centrally controls the intelligent clamping module, the welding module, the quality inspection module, the intelligent control module, and the exception handling module based on the central processing unit, and stores the control data of the central processing unit in the database to improve the welding efficiency and welding precision of the entire system.

[0067] In addition, the door panel welding system further includes two main conveyor belts 2, a sub-conveyor belt 3, and a welding station 7 (as shown in the dashed box). The two main conveyor belts 2 respectively transport the door panels 15 to be welded and the welding parts 26. Among them, the main conveyor belt 2 and the sub-conveyor belt 3 are symmetrically arranged on both sides of the welding station 7, and the sub-conveyor belt 3 transports the welded and qualified welding combination to the next subsequent process. Figure 10 At the same time, in this embodiment, the intelligent clamping module, the welding module, the quality inspection module, and the intelligent control module are all arranged in the welding station 7.

[0068] At the same time, in this embodiment, the intelligent clamping module, the welding module, the quality inspection module, and the intelligent control module are all arranged in the welding station 7.

[0069] In addition, the door panels 15 and the welding parts 26 transported by the two main conveyor belts 2 are set to be in a synchronous transportation state, that is, the two transported door panels 15 and the welding parts 26 are transported synchronously, enter the welding station 7 together, and the door panels 15 are clamped and adsorbed by the intelligent clamping module.

[0070] Among them, the intelligent clamping module includes a shape acquisition unit 8, a posture analysis unit, a flexible fixture 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 fixture unit adaptively adjusts the clamping posture (or called "welding posture") of the door panel 15 according to the analysis result. The dynamic pressure control unit adjusts the adsorption pressure of the flexible fixture unit according to the analysis result.

[0071] 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 parts 26.

[0072] Among them, the welding module is arranged on the transportation path of the door panel and the welding parts 26, and a welding station 7 is arranged in the transportation path. The welding module welds the welding parts 26 assembled into the welding station 7.

[0073] As Figure 6As shown, the welded part 26 is placed on one side end face of the door panel 15 (manually placed on one side end face of the door panel according to actual needs).

[0074] The welding unit includes a welding generator 10, an ultrasonic welding head, a welding controller, and a cooler. The cooler cools the welding material. The welding controller controls the welding parameters of the ultrasonic welding head. The welding generator 10 provides the energy required for welding.

[0075] Among them, the welding parameters include but are not limited to the following: welding time, welding power, amplitude, and pressure.

[0076] 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 fixture unit, and parameters such as welding time, power, amplitude, and pressure are set by the welding controller. Subsequently, the welding generator 10 provides ultrasonic energy, drives the ultrasonic welding head to align with the welding area, and applies appropriate pressure to ensure close contact of the welding surface. During welding execution, the ultrasonic welding head vibrates at a high frequency, generating frictional heat at the welding interface, melting and diffusing the materials to fuse. The welding controller adjusts the power, amplitude, and welding time in real time according to the feedback data to optimize the welding quality. After welding is completed, the ultrasonic stops, the system continues to apply pressure and starts the cooler, and the weld between the welded part 26 and the door panel 15 is cured by air cooling to prevent thermal deformation. Finally, the welding pressure is released, and the weld is evaluated by ultrasonic non-destructive testing by the quality inspection module to ensure that the weld is complete, without cracks and defects. If the inspection is qualified, it enters the next process. If it is unqualified, the abnormal handling module is triggered for repair welding or rejection.

[0077] The posture adjustment unit includes a robotic arm 9, a posture operator, and a visual collector 17. The visual collector 17 collects image data of the welding unit and the welded part 26. The posture operator controls the robotic arm 9 according to the image data collected by the visual collector 17;

[0078] Among them, the welding unit is arranged at the execution end of the robotic arm 9 and drives the welding unit to adjust at the welding position of the welded part 26 (adjust around the side wall of the welded part so as to weld the welded part 26 on the door panel 15), improving the flexibility and reliability of the welding position of the welding unit.

[0079] In addition, adjusting the positions of the welded part 26 and the welding unit through the image data collected by the visual collector 17 is a technology mastered and mature by those skilled in the art, so in this embodiment, it will not be elaborated one by one.

[0080] Optionally, the quality inspection module includes an ultrasonic inspection unit and a quality evaluation unit. The ultrasonic inspection unit collects weld data formed by welding between the welded part 26 and the door panel 15, and the quality evaluation unit evaluates the weld based on the weld data to form an evaluation result;

[0081] Among them, the quality inspection module is arranged on one side of the transportation path and inspects the welding quality between the welded part 26 and the door panel 15 after being welded by the welding module.

[0082] The ultrasonic inspection unit includes an ultrasonic inspection component, a moving component and a abutting component. The abutting component adjusts the position of the ultrasonic inspection component so that the ultrasonic inspection component abuts against the welding position. The ultrasonic inspection component collects the welding data of the welding position between the welded part 26 and the door panel 15. The moving component adjusts the positions of the abutting component and the ultrasonic inspection component so that the positions of the abutting component and the ultrasonic inspection component can be adjusted to inspect different positions of the welding position between the welded part 26 and the door panel 15.

[0083] Among them, the ultrasonic inspection component includes an ultrasonic probe 18, an ultrasonic signal generator, and a data buffer. The ultrasonic probe 18 emits ultrasonic signals to the welding position and receives the reflected signals inside the weld. The ultrasonic signal generator generates ultrasonic signals with a specific frequency and emits them to the weld area through the ultrasonic probe 18. The data buffer stores the ultrasonic signals emitted and reflected at the weld position.

[0084] The abutting component includes a vertical seat 11, an abutting rod 16, an abutting driving mechanism, and an extension detection piece. The vertical seat 11 is in a 7 - shape. One end of the vertical seat 11 is connected to one side of the welding station 7, and the other end of the vertical seat 11 extends upward towards the welding station 7. One end of the abutting rod 16 is drivingly connected to the abutting driving mechanism to form an abutting part. The abutting part is arranged at one end of the vertical seat 11 and extends upward towards the welding station 7. The other end of the abutting rod 16 is connected to the ultrasonic inspection unit so that the ultrasonic inspection unit can collect the weld data of the weld; the extension detection piece detects the extension amount of the abutting 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.

[0085] The moving member includes a moving track 21, a moving driving mechanism, a moving seat 19, and at least two moving wheels 20. The moving seat 19 is slidably connected to the moving track 21. The moving track 21 is arranged in the length direction of the welding station 7 and extends along the length direction. The moving driving mechanism is arranged on the moving seat 19 and drives at least two of the moving wheels 20 to slide along the sliding direction of the moving track 21.

[0086] Wherein, the vertical seat 11 is arranged on the moving seat 19 and moves along with the movement of the moving seat 19.

[0087] In this embodiment, the weld data includes but is not limited to the following: the 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 detection area weld,i ;

[0088] The quality evaluation unit obtains the weld data collected by the ultrasonic detection unit and calculates the weld evaluation index S of the i-th detection area according to the following formula weld,i :

[0089] ;

[0090] In the formula, is the weld volume / area ratio of the i-th detection area, is the shape stability factor of the i-th detection area, and its value is calculated according to the following formula:

[0091] ;

[0092] In the formula, D weld,i is the weld depth of the i-th detection area, W weld,i is the weld width of the i-th detection area, and T weld,i is the weld thickness of the i-th detection area.

[0093] In addition, the weld volume V of the i-th detection area weld,i is calculated according to the following formula (in this embodiment, the weld is approximately a columnar molten pool and is approximated as a cylinder):

[0094] ;

[0095] In the formula, D weld,i is the weld depth of the i-th detection area, and W weld,i is the weld width of the i-th detection area.

[0096] The projected area A of the weld weld,iCalculate according to the following formula:

[0097] ;

[0098] In the formula, W weld,i is the weld width of the i-th detection area, and T weld,i is the weld thickness of the i-th detection area.

[0099] If the weld evaluation index S weld of the i-th detection area exceeds the quality qualified threshold Qpass set by the system, the weld geometric shape of the i-th detection area is stable and the welding quality is qualified;

[0100] If the weld evaluation index S weld of the i-th detection area is lower than the quality qualified threshold Qpass set by the system, the weld geometric instability phenomenon occurs in the i-th detection area and the welding quality is poor.

[0101] Among them, the quality qualified threshold Qpass set by the system is set by the system or the manager according to the actual process of the current plastic door panel production and the process requirements. This is a well-known technical means in the art, so in this embodiment, it will not be elaborated one by one.

[0102] Through the mutual cooperation of the welding module and the quality detection module, the weld quality can be detected immediately after welding, ensuring that the welding depth, width, and fusion degree meet the requirements, ensuring that the welding quality of the entire system is traceable, and reducing the inflow of defective products into the next process.

[0103] Optionally, the abnormal handling module includes a sorting unit and a feedback unit. The sorting unit sorts out the unqualified welding assemblies according to the evaluation results, and the feedback unit numbers the sorted out abnormal welding assemblies and feeds them back to the manager;

[0104] Among them, the abnormal handling module is arranged in or at the rear end of the welding station 7, and sorts out the abnormal welding assemblies.

[0105] The sorting unit includes a sorting rod 6, a sorting driving 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 drivingly connected to the sorting driving 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.

[0106] Among them, the sorting rod 6 is set as a pneumatic telescopic type, and under the push of the sorting rod 6, the unqualified welding assemblies are pushed onto the sorting conveyor belt 4.

[0107] In addition, the qualified welded assemblies are transported to the next process via the auxiliary conveyor belt 3. Here, the next process specifically refers to the subsequent processes of further processing or deep processing of the door panels, which are well-known technical means in the art and thus will not be elaborated one by one in this embodiment.

[0108] 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 onto the unqualified welded assemblies and provide feedback to the manager, enabling the on-site manager to attach the corresponding RFID tag for unqualified (i.e., unqualified RFID tag) to the unqualified welded assemblies.

[0109] Through the mutual 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, preventing defective door panels 15 and welded part 26 assemblies from entering the next process, ensuring that the entire system has high reliability and intelligent decision-making capabilities, and improving production quality and efficiency.

[0110] Optionally, the shape acquisition unit 8 includes a collection probe and a data memory. The collection probe is arranged on both sides of the transportation path of the door panel 15 and acquires the image data of the transported door panel 15. The data memory stores the image data of the door panel 15 acquired by the collection probe.

[0111] In this embodiment, after the image data of the door panel 15 is acquired, the image data is preprocessed through image processing technology to obtain the shape data corresponding to the door panel 15.

[0112] Among them, the shape data includes the contour information of the door panel 15, the curvature distribution K, and the shape symmetry coefficient S.

[0113] 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 :

[0114] ;

[0115] In the formula, 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.

[0116] In this embodiment, the shape data of the door panel 15 is obtained, the edge data of the door panel 15 is extracted using the edge detection algorithm, and the contour point coordinates (x i , y i ) are obtained. At the same time, the edge points are fitted to form a smooth contour of the door panel 15.

[0117] Among them, based on the contour point cloud information in the image data, the contour complexity L is calculated according to the following formula:

[0118] ;

[0119] In the formula, 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 (vector representation form), is the coordinate of the (i + 1)-th 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 of the i-th point on the contour of the door panel 15 (numerical representation form), (x i+1 , y i+1 ) is the coordinate of the (i + 1)-th point.

[0120] The curvature K of the door panel 15 is calculated according to the following formula:

[0121] ;

[0122] In the formula, 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-order derivative of the contour point of the door panel 15, x i ’’ , y i ’’ is the second-order derivative of the contour point of the door panel 15.

[0123] The shape symmetry coefficient S of the door panel 15 is calculated according to the following formula:

[0124] ;

[0125] In the formula, 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 the point i on the contour of the door panel 15 to the geometric center point.

[0126] Among them, the geometric center coordinate vector of the door panel 15 is determined according to the following formula:

[0127] ;

[0128] In the formula, 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.

[0129] The adaptability correction coefficient α(A) is calculated according to the following formula:

[0130] ;

[0131] In the formula, A is the adaptability factor, and its value satisfies:

[0132] ;

[0133] In the formula, 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.

[0134] If the shape index S of the door panel 15 shape exceeds the welding monitoring threshold Range set by the system, the adjustment of the flexible fixture unit and the dynamic pressure control unit is triggered.

[0135] If the shape index S of the door panel 15 shape is lower than the welding monitoring threshold Range set by the system, it indicates that the current states of the flexible fixture unit and the dynamic pressure control unit meet the system requirements.

[0136] Among them, the welding monitoring threshold Range set by the system is set by the system or the administrator according to the actual process of the current plastic door panel being produced and the process requirements, and is input through the man-machine interface. This is a well-known technical means for those skilled in the art, so in this embodiment, it will not be elaborated one by one.

[0137] Through the mutual cooperation of 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 deviation during welding, guaranteeing high welding precision of the entire system, reducing welding misalignment, and improving the weld quality.

[0138] Through the mutual cooperation of the quality detection module and the intelligent control module, the welding quality data can be real-time fed back to the control system, and the welding parameters can be automatically adjusted according to the weld quality, ensuring that the entire system has the ability of adaptive adjustment, improving the welding stability, and reducing human intervention.

[0139] Optionally, the flexible fixture unit includes a sliding member, a contact member, and an adjustment member. The sliding member adjusts the positions of the contact member and the adjustment member. The contact member contacts the surface of the door panel 15, and the adjustment member linearly adjusts the lifting height of the door panel 15 according to the analysis result;

[0140] The sliding member includes a sliding track 12, at least two sliding driving mechanisms, and at least two sliding seats 25. The at least two sliding seats 25 are slidably connected to the sliding track 12. The at least two sliding driving 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 extending direction of the sliding track 12.

[0141] Wherein, the contact member and the adjustment member are arranged on the at least two sliding seats 25.

[0142] The contact member includes a contact protrusion, anti-slip lines arranged on the contact protrusion, and a negative pressure adsorption sub-member. The anti-slip lines are arranged at equal intervals along the contact surface between the contact protrusion and the door panel 15. The negative pressure adsorption sub-member is arranged in the contact protrusion and forms a negative pressure adsorption with the contact end surface of the door panel 15, so as to realize the contact with the door panel 15.

[0143] Wherein, the contact member is arranged on the adjustment member.

[0144] The negative pressure adsorption sub-member includes an adsorption cavity 14, a vacuum pipeline 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 at least one adsorption hole 23 is provided on the side wall of the adsorption cavity 14. The 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 the at least one adsorption hole 23 is the same as the contact end surface of the door panel 15. One end of the vacuum pipeline 24 is connected to the vacuum generator 22, and the other end of the vacuum pipeline 24 is connected to the vacuum generator 22. The microporous adsorption membrane is arranged on the contact end surface between the contact protrusion and the door panel 15. The vacuum sensor is arranged in the adsorption cavity 14.

[0145] In addition, a vacuum regulating valve is provided on the vacuum pipeline 24.

[0146] The specific adsorption process includes: the vacuum generator 22 (vacuum pump or Venturi negative pressure generator) is started to start pumping air. The vacuum pipeline 24 is connected to the adsorption cavity 14, the air is pumped away, and the pressure in the cavity drops. The vacuum sensor monitors the negative pressure state to ensure that the set adsorption threshold is reached.

[0147] The contact surface of the door panel 15 fits against the contact protrusion, and the negative pressure of the adsorption cavity 14 is transmitted to the door panel 15 through the adsorption hole 23 to form an adsorption effect. The microporous adsorption membrane controls the air flow uniformity to prevent the door panel 15 from deforming due to excessive local adsorption force.

[0148] The vacuum pressure sensor detects the current negative pressure value:

[0149] If the negative pressure reaches the set range (e.g., -60 kPa), the subsequent adsorption contact operation is continued. If the negative pressure is lower than the safety threshold, automatic compensation is triggered (adjust the working state of the vacuum generator 22).

[0150] Among them, the vacuum regulating valve controls the magnitude of the negative pressure to prevent the door panel 15 from deforming due to excessive adsorption force.

[0151] 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 part. The adjustment part is arranged on the sliding seat 25, and the electronic pressure relief valve is arranged on the adjustment airbag 13 and is internally communicated with the adjustment airbag 13;

[0152] Among them, in the state of pressure relief, the electronic pressure relief 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 bulged state to the dry original state.

[0153] At the same time, the electronic pressure relief valve realizes the pressure relief control of the adjustment airbag 13 under the control of the central processing unit.

[0154] The specific working process of the flexible fixture unit is as follows:

[0155] Transport the door panel 15 to be welded and the welding part 26 to the welding station 7. At this time, the flexible fixture unit performs flexible hijacking and limiting on the door panel in the welding station 7. Among them, the sliding member adjusts the positions 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, so as to drive the adjustment contact member and the adjustment member to move). Then, the vacuum generator 22 is started, and a negative pressure is generated in the adsorption cavity 14 through the vacuum pipeline 24 to form an adsorption effect to ensure the stable fixation of the door panel 15. Then, the air pump in the adjustment member inflates the adjustment airbag 13 to linearly lift the door panel 15 to the optimal welding position. At the same time, the electronic pressure relief valve makes fine adjustments according to the instructions of the central controller to ensure the accurate alignment of the door panel 15. During the welding process, the negative pressure adsorption and the adjustment airbag 13 jointly maintain the stability of the door panel 15. The vacuum sensor monitors the state in real time and performs automatic compensation. After the welding is completed, the vacuum generator 22 is turned off, the electronic pressure relief valve releases the gas in the airbag, and the fixture returns to the initial state. At the same time, the reverse inflation method can be selected to accelerate the separation of the door panel 15 to ensure the smooth release of the door panel 15 and the entry into the next process.

[0156] The flexible fixture unit further includes a contact analysis sub-unit. The contact analysis sub-unit calculates the inflation volume V of the adjustment airbag according to the analysis result (shape index S shape ) and according to the following formula air:

[0157] ;

[0158] Wherein, V0 is the initial inflation volume set by the system, S shape is the shape index, and Range is the welding monitoring threshold set by the system.

[0159] The contact analysis sub-unit transmits the calculated adjusted airbag inflation volume V air to the central processing unit, and controls the inflator through the central processing unit, so that the adjusted airbag can flexibly adjust the posture of the door panel 15.

[0160] The dynamic pressure control unit obtains the shape index S shape , and calculates the negative pressure adsorption force P according to the following formula vacuum :

[0161] ;

[0162] Wherein, P0 is the set maximum negative pressure adsorption capacity, which is set according to the performance of the vacuum generator, α is the negative pressure adjustment coefficient, the value of which is set by the system and input from the man-machine interface; S shape is the shape index, A contact is the contact area between the fixture and the door panel 15, and its value is obtained according to the actual contact situation between the contact protrusion and the door panel 15.

[0163] When the dynamic pressure control unit determines the negative pressure adsorption force P vacuum , it is transmitted to the central processing unit, and the central processing unit controls the vacuum generator and the vacuum regulating valve to achieve precise control of the negative pressure adsorption force P vacuum .

[0164] In addition, in this embodiment, the value-taking trend of the negative pressure adjustment coefficient α is as follows:

[0165] When α is relatively small (such as 0.2 - 0.4): it is applicable to the door panel 15 with a flat, large area and regular shape, and does not require high negative pressure. When α is relatively large (such as 0.7 - 1.0): it is applicable to the door panel 15 with a small area, irregular shape and easy to slide, and requires a higher adsorption force.

[0166] Meanwhile, 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 and large-area door panel 15 (such as the outer plastic shell 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 part), the negative pressure adjustment coefficient α = 0.5; 3) In the scenario of a door panel 15 with a curvature (such as the trunk lid of a car), 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.

[0167] In addition, the present invention also provides a method for welding door panels, which includes the following steps:

[0168] S1. Transport the door panel 15 to be welded and the welding part 26 through a transport path and transfer them to a welding station;

[0169] S2. During the transportation of the door panel 15, collect the shape data of the transported door panel 15 through an intelligent clamping module, analyze the door panel 15 based on the shape data to form an analysis result, and adaptively adjust the clamping posture and adsorption pressure of the door panel 15 according to the analysis result;

[0170] S3. Weld the assembled and abutted door panel 15 and the welding part through a welding module to form a weld;

[0171] S4. Collect the weld data formed by welding through a quality inspection module and evaluate the weld based on the weld data to form an evaluation result;

[0172] S5. Sort out and pick out abnormal welding assemblies through an exception handling module according to the evaluation result to retain normal welding assemblies;

[0173] S6. Distinguish the normal welding assemblies and the abnormal welding assemblies and transport them to different subsequent process workshops.

[0174] Optionally, the method for welding door panels further includes: in step S6, attaching different RFID tags to the distinguished and transported normal welding assemblies and abnormal welding assemblies;

[0175] Among them, the RFID tags have independent and distinguishable identification information.

[0176] Optionally, the method for welding door panels 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.

[0177] Through the mutual cooperation of the intelligent clamping module, welding module, quality inspection module, intelligent control module, and abnormal handling module, the door panel can be accurately positioned and adaptively clamped before welding. During the welding process, the welding parameters can be adjusted in real time. After welding, quality inspection and fluctuation analysis can accurately identify the weld quality, and the abnormal welded part assemblies can be intelligently removed or repaired by welding, 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 increasing production efficiency.

[0178] Embodiment 2: This embodiment should be understood as including all the features of any one of the foregoing embodiments and further improved. According to Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Figure 9 , Figure 10 , Figure 11 , Figure 12 , Figure 13 , Figure 14 , Figure 15 , and Figure 16 , it is further that the quality inspection module further includes a quality fluctuation analysis unit. The quality fluctuation analysis unit analyzes the welding data of an entire welding position according to the quality evaluation index to form a quality result, and triggers a warning prompt according to the quality result.

[0179] Wherein, the quality fluctuation analysis unit obtains the weld evaluation index S of the i-th detection area weld,i , and calculates the weld quality index S of the whole weld according to the following formula weld,total :

[0180] ;

[0181] In the formula, S weld,i is the weld evaluation index of the i-th detection area, and M is the number of detection areas into which the weld is divided.

[0182] The quality fluctuation analysis unit obtains the weld quality index S of the whole weld weld,total , and calculates the standard deviation of the weld quality according to the following formula :

[0183] ;

[0184] In the formula, S weld,i is the weld evaluation index of the i-th detection area, and M is the number of detection areas into which the weld is divided.

[0185] If the following conditions are met: , a yellow warning is triggered, and the manager or operator is prompted to check the welding parameters;

[0186] If the following conditions are met: , a red warning is triggered, indicating that the welding quality seriously fails to meet the standards, and the welding process needs to be adjusted or the equipment needs to be maintained.

[0187] Through the mutual cooperation of the quality assessment unit and the quality fluctuation analysis unit, the welding quality can not only be judged in real time through the single-pass weld assessment index, but also the quality fluctuation trend of the entire weld area can be analyzed, ensuring that the entire system can accurately detect the weld quality and predict in advance the changes in welding stability, improving welding consistency and production reliability.

[0188] The content disclosed above is only the preferred feasible embodiment of the present invention, and does not limit the protection scope of the present invention. Therefore, all equivalent technical changes made by using the content of the specification and drawings of the present invention are included in the protection scope of the present invention. In addition, with the development of technology, the elements therein can be updated.

Claims

1. A door panel welding system, the door panel welding system comprising a server, a door panel, and a welding part, characterized in that, The door panel welding system further includes an intelligent clamping module, a welding module, a quality inspection module, an intelligent control module, and an exception handling module. The server is respectively connected to the intelligent clamping module, the welding module, the quality inspection module, the intelligent control module, and the exception handling module; The intelligent clamping module collects the shape data of the door panels being transported and calculates the shape index S of the door panels based on the shape data shape , and adaptively adjusts the clamping posture and adsorption pressure of the door panels according to the shape index; the welding module welds the assembled and abutted door panels and welding parts to form a welded combination; the quality inspection module collects the weld data after welding and forms an evaluation result and a weld evaluation index S according to the weld data weld ; the intelligent control module controls the welding module and the intelligent clamping module according to the evaluation result, and the abnormal handling module sorts out the abnormal welded combinations formed by welding according to the evaluation result; Among them, the intelligent clamping module includes a shape acquisition unit, a posture analysis unit, a flexible fixture 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 based on the shape data to form an analysis result. The flexible fixture unit adaptively adjusts the clamping posture of the door panel according to the analysis result. The dynamic pressure control unit adjusts the adsorption pressure of the flexible fixture unit according to the analysis result. 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 exceeds the welding monitoring threshold Range set by the system, an adjustment to the flexible fixture unit and the dynamic pressure control unit is triggered; The flexible fixture unit includes a sliding member, a contact member, and an adjustment member. The sliding member adjusts the positions of the contact member and the adjustment member. The contact member contacts the surface of the door panel, and the adjustment member linearly adjusts the lifting height of the door panel according to the analysis result; The contact member includes contact protrusions, anti-slip lines provided on the contact protrusions, and a negative pressure adsorption sub-member. The anti-slip lines are arranged at equal intervals along the contact surface between the contact protrusions and the door panel; the negative pressure adsorption sub-member is arranged in the contact protrusions and forms a negative pressure adsorption with the contact end surface of the door panel, so as to realize the contact with the door panel. The contact member is arranged on the adjustment member; the negative pressure adsorption sub-member includes an adsorption cavity, a vacuum pipeline, a vacuum regulating valve, a vacuum generator, a microporous adsorption membrane, and a vacuum sensor. The adsorption cavity is arranged in the contact protrusions, and at least one adsorption hole is provided on the side wall of the adsorption cavity. At least one adsorption hole penetrates the inner wall of the adsorption cavity and communicates with the external environment. The setting direction of at least one adsorption hole is the same as the contact end surface of the door panel. One end of the vacuum pipeline is connected to the vacuum generator, and the other end of the vacuum pipeline is connected to the vacuum generator. The microporous adsorption membrane is arranged on the contact end surface between the contact protrusions and the door panel.

2. The door panel welding system according to claim 1, wherein 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 panel and the welding part; Among them, the welding module is arranged on the transportation path of the door panel and the welding part, and a welding station is arranged in the transportation path. The welding module welds the door panel and the welding part assembled into the welding station.

3. The door panel welding system according to claim 2, wherein, The quality inspection module includes an ultrasonic inspection unit and a quality evaluation unit. The ultrasonic inspection unit collects the weld data formed by welding the door panel and the welding part, and the quality evaluation unit evaluates the weld according to the weld data to form an evaluation result; Among them, the quality inspection module is arranged on one side of the transportation 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, wherein The exception handling module includes a sorting unit and a feedback unit. The sorting unit sorts out the unqualified welding assemblies according to the evaluation result, and the feedback unit numbers the sorted out abnormal welding assemblies and feeds them back to the manager; Among them, the exception handling 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 sliding member includes a sliding track, at least two sliding driving mechanisms, and at least two sliding seats. The at least two sliding seats are slidably connected to the sliding track. The at least two sliding driving mechanisms are correspondingly arranged on the at least two sliding seats and drive the at least two sliding seats to slide along the extending direction of the sliding track; Wherein, the contact member and the adjustment member are arranged on the at least two sliding seats.

6. The door panel welding system according to claim 5, wherein The shape acquisition unit includes an acquisition probe and a data memory. 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 memory stores the image data of the door panel acquired by the acquisition probe.

7. A method for welding a door panel, according to the door panel welding system described in claim 6, characterized in that, The door panel welding method includes the following steps: S1. Transport the door panel to be welded and the welded parts through the transportation path and transfer them to the welding station; S2. During the transportation of the door panel, acquire the shape data of the transported welded parts through the intelligent clamping module, analyze the door panel according to the shape data to form an analysis result, and adaptively adjust the clamping posture and adsorption pressure of the door panel according to the analysis result; S3. Weld the assembled and abutted door panel and welded parts through the welding module to form a weld; S4. Acquire the weld data formed by welding through the quality inspection module and evaluate the weld according to the weld data to form an evaluation result; S5. Sort and pick out the abnormal welding assemblies through the abnormal handling module according to the evaluation result to generate a line, so as to retain the normal welding assemblies; S6. Distinguish the normal welding assemblies and the abnormal welding assemblies and transport them to different subsequent process workshops.

8. The door panel welding method according to claim 7, characterized in that, The door panel welding method further includes: in step S6, attach different RFID tags to the distinguished and transported normal welding assemblies and abnormal welding assemblies; Wherein, the RFID tags have independent and distinguishable identification information.

9. The door panel welding method according to claim 8, wherein The door panel welding method further includes: in step S1, transport the door panel to be welded step by step into the area where the intelligent clamping module is located and linearly adjust the welding posture of the assembled door panel through the intelligent clamping module.

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