Full-automatic flexible production line for aluminum veneers

Abstract

The invention discloses a full-automatic flexible production line for aluminum veneers. Comprising a master control system, a double-station feeding manipulator, an automatic wire drawing machine, a first automatic upender, a first material transfer manipulator, an automatic bending center, a second material transfer manipulator, an automatic welding machine, a reinforcing rib placing robot, a third material transfer manipulator, a nut locking robot, an automatic laser welding robot and a second automatic upender. And a fourth material transferring manipulator, an automatic polishing robot and a double-station discharging manipulator. According to the full-automatic flexible aluminum veneer production line, a traditional aluminum veneer production and manufacturing process is changed, and the full-automatic flexible aluminum veneer production line is formed by combining automatic type selection, transformation, upgrading and configuration according to existing production equipment. Compared with a traditional production line, the number of workers is reduced from 24 to 3-4, the annual productivity is improved from 21 thousand m < 2 > to 31 thousand m < 2 >, and the productivity is improved by 47.6%.

Description

Technical Field

[0001] The present invention relates to a fully automatic flexible production line for aluminum veneers, belonging to the technical field of building material aluminum veneer processing. Background Art

[0002] Aluminum veneer is a building decoration material, which has many characteristics such as good public welfare, corrosion resistance, high strength, easy to clean, recyclable, etc. The production and manufacturing of aluminum veneer is to process the aluminum veneer into the required shape and size through processes such as numerical punching and cutting of raw materials, bending forming, assembly, welding, and grinding.

[0003] In the traditional aluminum veneer sheet metal processing line, each process operates independently. The processing and turnover of aluminum plates rely on a large number of production workers. The welding and grinding processes are seriously polluted and have a greater impact on the health of workers. The degree of automation of each production process is low, and the production process, quality, and efficiency largely depend on the skill level and experience of workers. In addition, aluminum veneers are non-standard customized parts, making it very difficult to automate the production of aluminum veneers.

[0004] CN 201910774692.8 discloses a fully automatic laser processing production line for aluminum veneer uncoiling and blanking. The aluminum veneer only involves the automatic processing production of uncoiling and blanking, and does not involve the full-automatic production of aluminum veneer.

[0005] How to improve the automation level, efficiency, and quality of aluminum veneer processing is particularly important. Summary of the Invention

[0006] The purpose of the present invention is to propose a fully automatic flexible production line for aluminum veneers in order to solve the automation of aluminum veneer processing, improve the production efficiency and processing quality of aluminum veneers.

[0007] The technical solution implemented by the present invention is as follows: A fully automatic flexible production line for aluminum veneers includes a total control system, a double-station loading manipulator, an automatic wire drawing machine, a first automatic turning machine, a first material transfer manipulator, an automatic bending center, a second material transfer manipulator, an automatic spot welder, a stiffener placing robot, a third material transfer manipulator, a lock nut robot, an automatic laser welding robot, a second automatic turning machine, a fourth material transfer manipulator, an automatic grinding robot, and a double-station unloading manipulator.

[0008] The overall control system is installed on the main console; the double-station loading manipulator and the automatic wire drawing machine are installed in the automatic loading and wire drawing area; the first automatic turning machine, the first material transfer manipulator, and the automatic bending center are installed in the automatic bending area; the second material transfer manipulator and the automatic stud welding machine are installed in the stud automatic welding station; the stiffener placing robot is installed in the stiffener automatic placing station; the third material transfer manipulator and the nut locking robot are installed in the nut automatic locking station; the automatic laser welding robot is installed in the stiffener and panel laser welding station; the second automatic turning machine, the fourth material transfer manipulator, and the automatic grinding robot are installed in the welding spot grinding workstation; the double-station unloading manipulator is installed in the automatic unloading workstation.

[0009] All equipment for the automated production of aluminum single panels is installed on the fully automatic flexible production line for aluminum single panels; the main console, the automatic loading and wire drawing area, the automatic bending area, the stud automatic welding station, the stiffener automatic placing station, the nut automatic locking station, the stiffener and panel laser welding station, the welding spot grinding workstation, and the automatic unloading workstation are connected by transmission lines between areas, between an area and a station, and between stations.

[0010] The overall control system uses PLC centralized control, integrates servo drive, Modbus TCP protocol communication, and an industrial flat panel human-machine interface to coordinately control each process; the system has unit activation permission management, is equipped with a dual human-machine interface of an operation console computer and an industrial flat panel, and can display the equipment status, parameters, and fault codes in real time. The PLC issues instructions to each execution unit through a high-speed bus, synchronously integrates a safety interlock mechanism to ensure that the production rhythm is accurately controllable, and at the same time reserves an industrial Internet of Things interface to be compatible with the factory-level data acquisition and remote monitoring requirements; it also synchronously integrates the full-process management of work orders, supports manually / automatically generating work order numbers and binding parameter templates, realizes the drag-and-drop sorting, priority adjustment, and progress tracking of work orders, and supports automatically associating the program relationship comparison table through the product size to match equipment parameters.

[0011] The communication method between the overall control system and each process single machine uses Modbus TCP as the communication protocol, and the software platform is a self-developed software platform to complete the issuance and collection of parameters and information; each process single machine needs to feedback the following information to the overall control system: when starting, the single machine feedbacks whether it can run, when running, the single machine feedbacks the running status, and when ending, the workstation collects the running and processing information and generates a report. The control program of the overall control system's flexible production line is as follows: New program → Select the process equipment required for this program → Parameter input: CAD drawing, length, width, thickness, material, stiffening method → Confirm the work order programming and operation mode to complete the programming; New work order → Input basic information, including work order name, quantity, start and completion time → Select a pre-programmed procedure → Confirm the input information → Complete the creation of the new work order → Return to the production interface and select the work order to be produced → Confirm production → Each device feeds back the current status → Adjust the problematic device according to the feedback → Normal production → The work order is automatically recognized and stopped when completed, or a changeover work order is set in advance and automatically switched after the current work order is completed.

[0012] The hardware of the master control system includes a computer, an industrial flat double human-machine interface, an integrated servo drive mechanism, an industrial Internet of Things interface, and a high-speed data bus; the software includes a data acquisition module, a PLC control module, a parameterization management module, a work order management module, an equipment management module, and a production execution module; the master control system is connected to the industrial flat double human-machine interface, the integrated servo drive mechanism, and the control ends of the equipment in each area and station through the high-speed data bus, and real-time displays the equipment status, parameters, and fault codes; the work order module classifies work orders into six categories according to status: to be produced, in production, paused, cancelled, completed, and in changeover; the work order management module displays the cumulative number of work orders and the cumulative number of workpieces; the work order module realizes the drag-and-drop sorting, priority adjustment, and progress tracking of work orders, and supports matching equipment parameters by automatically associating the program relationship comparison table through the product size; the parameterization management module realizes the dynamic maintenance of templates, the batch distribution of parameters, and abnormal distribution can be manually retried and the status is feedback in real-time; the production execution module supports one-key start / pause to switch work orders and synchronously records the completion data.

[0013] The master control system supports manual input or automatic generation of work order numbers by time. The work order needs to be bound to a parameter template and contains information such as production quantity, planned start time, and estimated completion time. The successfully created work orders are displayed in the work order list and are sorted by the planned start time by default. Workers can drag and drop to sort for priority production and support querying data such as production time, completion time, and completion quantity through the work order number. The received but uncompleted order information is displayed in a list form, and all uncompleted orders for the current day are displayed by default, and support sorting by the planned start time and priority.

[0014] The automatic loading and wire drawing area adjusts the last fine grinding process to the first wire drawing process to solve the problems in the design of the fine grinding process and improve the grinding efficiency and quality, and ensure the quality and effect of subsequent fluorocarbon spraying; the double-station loading manipulator and the automatic wire drawing machine are in the automatic loading and wire drawing area to perform surface wire drawing treatment on the aluminum single panel; the AGV car sends the aluminum single panel to the specified position, and the double-station loading manipulator immediately grabs the aluminum single panel to realize the automatic loading process. The aluminum single panel then enters the automatic wire drawing machine through the conveyor belt for surface wire drawing treatment, and the treated aluminum single panel is sent to the automatic bending area; the automatic wire drawing machine supports stepless speed regulation from 0 to 10 m / min, and the surface wire drawing roughness is controlled within the range of 1-2 μm, and is equipped with a dust collection system to ensure no residue.

[0015] The automatic bending area bends and forms the aluminum single panel entering the automatic bending area; after the aluminum single panel is wire-drawn, it is turned over by the first automatic material turning machine and sent into the automatic bending center by the first material transfer manipulator for bending and forming; the bent and formed aluminum single panel is sent into the buffer station by the first material transfer manipulator; the bending accuracy of the bending center is ±0.5° and ±0.1mm / m; the equipment is linked with the master control system through the Modbus TCP protocol to realize automatic parameter programming and operation status monitoring, support quick die change within 2 minutes and production line changeover within 5 minutes; equipped with robot loading and unloading stations and on-site programming workstations, meeting the requirement that the 8-knife processing beat ≤ 60s, and having functions such as automatic compensation of bending parameters, fault feedback and process data interaction.

[0016] The stud automatic welding station welds aluminum studs on the aluminum single panel; the bent and formed aluminum single panel is taken out from the buffer station by the second material transfer manipulator and placed into the automatic stud welder, and the automatic stud welder welds the aluminum single panel; the automatic stud welder of the stud automatic welding station consists of a robot loading and unloading unit, an intelligent nail feeding and welding module and a digital control platform, meeting the high-precision welding requirements of M6×15 welding studs; the system integrates an automatic nail feeding mechanism, a multi-gun collaborative energy storage welder and a full-steel frame T-shaped groove positioning platform, supports the six-axis robot to grab the workpiece and automatically position and clamp it, generates the welding point program through CAD drawing import, and realizes precise welding with a center offset of ±0.3mm, a straightness of ±0.3mm / m and a perpendicularity of 0.3mm; the welding gun is equipped with a dual-capacitor group for dynamic switching, can adjust the downward pressure / compression speed, and real-time detects the in-place state of the stud, and automatically pauses in case of abnormality; there is no blackening / deformation during the welding process, the back bulge < 0.1mm, no defects after painting, and the tensile strength of a single nail ≥ 1000N; the system interacts with the master control through the Modbus TCP protocol, transmits the equipment status, fault alarm and parameter feedback in real time, supports a high-speed beat of 40 nails / minute, realizes changeover in 5 minutes, is equipped with an independently developed upper computer system, is compatible with office information interaction, and ensures high flexibility and fully automatic continuous production.

[0017] The stiffener automatic placement station places stiffeners on the aluminum single panel; the aluminum single panel after nailing is sent into the stiffener automatic placement station by the second material transfer manipulator for the placement and assembly of stiffeners; the stiffener placement robot of the stiffener automatic placement station uses the robot to grab the aluminum single panel to the servo positioning tooling table, combines the displacement sensor to detect and correct the skew to ensure the assembly accuracy; configures 5 material carts, which are respectively grabbed and installed by the six-axis robot and the three-axis truss manipulator, detects the front and back of the material through external sensors, and the abnormal parts are automatically stored temporarily; the stiffener automatic placement station is integrated and controlled by the PLC, coordinates the robot, the servo transplanting platform and the whole line interaction, is equipped with AB station servo positioning, electric cylinders and a safety protection system, is compatible with the master control protocol docking, and realizes high-speed and precise assembly and risk control.

[0018] The nut automatic locking station locks nuts onto the aluminum studs of the aluminum single panel; the aluminum single panel after stiffener assembly is sent into the nut automatic locking station by the third material transfer manipulator; the nut automatic locking station integrates a truss mechanical structure, a vision positioning unit, an intelligent electric screwdriver tightening unit, a servo positioning tooling, and a buffer feeding mechanism. The vision positioning unit has an anti-light interference detection function to ensure accurate positioning even in a complex factory light environment; the intelligent electric screwdriver tightening unit can flexibly adjust and monitor the tightening force in real time according to the nut size and material to avoid damage, with a repeatability accuracy of ±3° to ±5°, adjustable torque and rotation speed, and complete locking result data recording; the buffer feeding mechanism has a function of detecting the presence or absence of nuts in a single discharge, is equipped with a display screen for real-time monitoring, and cooperates with the buffer mechanism to reduce the robot's idle travel and speed up the cycle, ensuring uninterrupted feeding. It supports the Modbus TCP protocol to achieve two-way communication with the master control system; the system automatically adjusts the product tooling position through servo drive, completes the locking of the stiffener centered in the length and width directions, is equipped with a display screen for real-time monitoring of operation data, and has a three-color light fault alarm; the tightening process has full data traceability, the buffer mechanism reduces the robot's idle travel, and the changeover time is <5 minutes.

[0019] The stiffener and panel laser welding station welds and reinforces the gaps at the four corners of the folded edges of the aluminum single panel and the joints between the stiffeners and the folded edges; the aluminum single panel after stiffener assembly is sent into the stiffener and panel laser welding station by the third material transfer manipulator for welding and reinforcing the gaps at the four corners of the folded edges of the panel surface and the diagonal welding at the joints between the stiffeners and the folded edges, and after welding, it is sent into the solder joint grinding workstation by the third material transfer manipulator; the automatic laser welding robot of this laser welding workstation consists of a double-arc welding robot, a double floor track, a servo transfer table, and a laser positioning system, integrating a gun cleaning device and a PLC master control to achieve full-automatic welding of the aluminum plate stiffeners and the corner welds. The robot is equipped with a collision avoidance sensor, and the welding power supply supports ultra-low spatter, which can reduce 90% of the weld spatter and the intermittent bridging welding process.

[0020] The solder joint grinding workstation grinds the welds and riveting positions of the aluminum veneer; after welding, the aluminum veneer is turned over by the second automatic turning machine, and after turning over, it is sent to the automatic grinding machine by the fourth material transfer manipulator; the automatic grinding robot of the solder joint grinding workstation includes two six-axis robots, integrating high-precision force control grinding and intelligent dust removal functions; the six-axis robot is equipped with a 300N force control compensator to achieve multi-segment force control dynamic adjustment from 5N to 300N and gravity compensation, and is equipped with two electric spindles to achieve a single weld mark grinding cycle of 3 seconds. The double six-station hybrid tool magazine includes a sandpaper tearing and pasting mechanism and an in-position detection sensor. The dust-proof cover design meets the consumable reserve for 2 hours of continuous operation, and the tool change success rate is fed back in real time; the automatic grinding robot supports the parameterized start-stop of the rivet mark grinding mode according to the plate thickness and the servo positioning tooling. The bottom is integrated with a flared dust collection + side dust extraction pipeline, and the dust recovery rate is ≥99%. The wet filter device is embedded in the dust removal room through the PLC control cabinet and the Modbus TCP protocol for collaborative control. The room body is designed with negative pressure, and the external dust concentration <1mg / m³; the robot is equipped with an IP54 protective suit and pipeline package, and is equipped with a touch screen to monitor the status / alarms in real time and a three-color light warning.

[0021] The automatic blanking workstation uses a double-station blanking manipulator to send the ground aluminum veneer from the material transfer manipulator to the transfer platform. After manual inspection, the double-station blanking manipulator performs blanking and stacking, completing the entire automatic production line process of the aluminum veneer; the double-station blanking manipulator automatically sorts products based on the manual inspection results through the blanking and stacking system and stacks them vertically. The stacking quantity and layout are dynamically adapted to the robot arm reach range. It is equipped with a 5-meter travel ground rail to achieve large-range operation, meeting the requirements of efficient and accurate automatic sorting and stacking.

[0022] The process route of the automated processing and manufacturing of aluminum veneers in the present invention: Manual startup (AGV feeding) → Automatic wire drawing of aluminum plates (automatic wire drawing machine with loading and unloading manipulators) → Automatic bending (four-meter automatic bending machine) → Automatic riveting welding (dual tool heads operation) → Automatic feeding of stiffeners (coordinated material picking and placing by truss and robotic arm) → Automatic nut locking (robot vision positioning) → Automatic laser welding (robot welding the four corners and diagonal of the stiffeners on the plate surface, laser positioning) → Automatic grinding (grinding solder joints and rivet marks, dual positioning by vision and laser) → Manual full inspection → Automatic stacking (AGV picking and placing).

[0023] The beneficial effects of the present invention are that by changing the traditional production and manufacturing process of aluminum veneers, and combining with the existing production equipment, through automation selection, transformation, upgrading and configuration, a fully automatic flexible production line for aluminum veneers is formed. After production, compared with the traditional production line, the number of workers is reduced from 24 to 3 - 4, and the annual production capacity is increased from 210,000 square meters to 310,000 square meters, with a production capacity increase of 47.6%. Description of the Drawings

[0024] Figure 1It is the layout plan of a full-automatic flexible production line for aluminum veneers of the present invention; Figure 2 It is the layout diagram of a full-automatic flexible production line for aluminum veneers of the present invention on the production line; Figure 3 It is the equipment layout diagram of the general control console and the automatic loading and wire drawing area; Figure 4 It is the equipment layout diagram of the automatic bending area; Figure 5 It is the equipment layout diagram of the stud automatic welding station; Figure 6 It is the equipment layout diagram of the stiffener automatic placement station; Figure 7 It is the equipment layout diagram of the nut automatic locking station; Figure 8 It is the equipment layout diagram of the stiffener and panel laser welding station; Figure 9 It is the equipment layout diagram of the welding spot grinding workstation; Figure 10 It is the equipment layout diagram of the automatic blanking workstation; Figure 11 It is the structural schematic diagram of the aluminum veneer product; In the figure, 1 is the general control console; 2 is the automatic loading and wire drawing area; 3 is the automatic bending area; 4 is the buffer station; 5 is the stud automatic welding station; 6 is the stiffener automatic placement station; 7 is the nut automatic locking station; 8 is the stiffener and panel laser welding station; 9 is the welding spot grinding workstation; 10 is the manual full inspection station; 11 is the automatic blanking workstation; 12 is the general control system; 13 is the double-station loading manipulator; 14 is the automatic wire drawing machine; 15 is the first automatic material turning machine; 16 is the first material transfer manipulator; 17 is the automatic bending center; 18 is the second material transfer manipulator; 19 is the automatic welding machine; 20 is the stiffener placement robot; 21 is the third material transfer manipulator; 22 is the nut locking robot; 23 is the automatic laser welding robot; 24 is the second automatic material turning machine; 25 is the fourth material transfer manipulator; 26 is the automatic grinding robot; 27 is the double-station blanking manipulator; 101 is the stiffener; 102 is the welding stud; 103 is the nut; 104 is the bending place. Specific embodiments

[0025] As Figure 1 shown, the layout plan of the installation positions of the equipment of a full-automatic flexible production line for aluminum veneers in this embodiment includes, along the production process flow, the general control console 1, the automatic loading and wire drawing area 2, the automatic bending area 3, the buffer station 4, the stud automatic welding station 5, the stiffener automatic placement station 6, the nut automatic locking station 7, the stiffener and panel laser welding station 8, the welding spot grinding workstation 9, the manual full inspection station 10, and the automatic blanking workstation 11.

[0026] AsFigure 2 As shown, it is the layout diagram of the production equipment of a fully automatic flexible production line for aluminum single panels in this embodiment. The production equipment includes: The general control system 12 is installed on the general console 1, as Figure 3 shown; The double-station loading manipulator 13 and the automatic wire drawing machine 14 are installed in the automatic loading and wire drawing area 2, as Figure 3 shown; The first automatic turning machine 15, the first material transfer manipulator 16 and the automatic bending center 17 are installed in the automatic bending area 3, as Figure 4 shown; The second material transfer manipulator 18 and the automatic stud welding machine 19 are installed at the stud automatic welding station 5. As Figure 5 shown; The stiffener placing robot 20 is installed at the stiffener automatic placing station 6, as Figure 6 shown; The third material transfer manipulator 21 and the nut locking robot 22 are installed at the nut automatic locking station 7, as Figure 7 shown; The automatic laser welding robot 23 is installed at the stiffener and panel laser welding station 8, as Figure 8 shown; The second automatic turning machine 24 is installed at the welding point grinding workstation 9, as Figure 8 shown; The fourth material transfer manipulator 25 and the automatic grinding robot 26 are installed at the welding point grinding workstation 9, as Figure 8 shown; The double-station unloading manipulator 27 is installed at the automatic unloading workstation 11, as Figure 10 shown.

[0027] The automated processing and manufacturing process route of the aluminum single panel in this embodiment: Manual start (general console) → AGV car feeding → Robotic arm loading (double-station loading manipulator) → Automatic wire drawing (automatic wire drawing machine) → Aluminum plate turning (first automatic turning machine) → Material transfer (first material transfer manipulator) → Automatic bending (automatic bending center) → Material transfer (first material transfer manipulator) → Buffer station (ensuring continuous production of subsequent workstations when adjusting the plate type) → Material transfer (second material transfer manipulator) → Automatic stud welding (automatic stud welding machine) → Material transfer (second material transfer manipulator) → Automatic stiffener feeding (stiffener placing robot) → Material transfer (third material transfer manipulator) → Automatic nut locking (nut locking robot) → Material transfer (third material transfer manipulator) → Automatic laser welding (automatic laser welding robot) → Material transfer (third material transfer manipulator) → Automatic turning (second automatic turning machine) → Material transfer (fourth material transfer manipulator) → Automatic grinding (automatic grinding robot) → Material transfer (fourth material transfer manipulator) → Manual full inspection → Automatic stacking (double-station unloading manipulator) → AGV car receiving.

[0028] The structure diagram of the aluminum single panel product in this embodiment is as Figure 11As shown, the finished aluminum single panel includes stiffeners 101, stud welds 102, nuts 103, and bends 104, all of which are related to the automated processing and manufacturing process of the aluminum single panel in this embodiment.

[0029] The master control system 1 of this embodiment is installed on the master console 12, and the master control system 1 coordinates and controls each process. The master control system 1 adopts PLC centralized control, integrating servo drive, Modbus TCP protocol communication, and an industrial flat panel human-machine interface. The master control system 1 coordinates the efficient collaborative operation between each production process and production equipment through a modular architecture, supports automatic / manual (maintenance) dual modes. In the automatic mode, unmanned operation of the whole process is realized based on the preset protocol logic; in the manual mode, a single motor can be independently controlled for debugging or maintenance. The master control system 1 has unit activation permission management (inactive equipment is prohibited from operation), is equipped with a dual human-machine interface of an operation console computer and an industrial flat panel, and displays the equipment status, parameters, and fault codes in real time. The PLC issues instructions to each execution unit through a high-speed bus, and synchronously integrates a safety interlock mechanism (such as emergency stop, motion interference detection) to ensure that the production rhythm is accurately controllable. At the same time, an industrial Internet of Things interface is reserved to be compatible with the factory-level data acquisition and remote monitoring requirements. Synchronously integrate the whole-process management of work orders, support manual / automatic generation of work order numbers and binding parameter templates (including product models, sizes, program numbers, etc.), realize work order drag-and-drop sorting, priority adjustment, and progress tracking (real-time display of production quantity / time), and support automatic association of program relationship comparison tables through product sizes to match equipment parameters (such as bending machines, welding robots). The parameterized management module realizes dynamic maintenance of templates and batch issuance of parameters (adapted to equipment such as wire drawing machines, robots, etc.). Abnormal issuance can be manually retried and the status can be fed back in real time; the production execution module supports one-key start / pause switching of work orders and synchronously records the completion data.

[0030] In this embodiment, the double-station loading manipulator 13 and the automatic wire drawing machine 14 are installed in the automatic loading and wire drawing area 2 to perform surface wire drawing treatment on the aluminum single panel. In this embodiment, the last fine grinding process is adjusted to the first wire drawing process to solve the problems in the design of the fine grinding process and improve the grinding efficiency and quality, ensuring the quality and effect of subsequent fluorocarbon spraying. The AGV cart transports the aluminum single panel to the designated position, and then the double-station loading manipulator 13 grabs the aluminum single panel to realize the automatic loading process. The aluminum single panel then enters the automatic wire drawing machine 14 through the conveyor belt for surface wire drawing treatment, and the treated aluminum single panel is sent to the automatic bending area 3. The double-station loading manipulator 13 integrates functions of raw material positioning and material shortage alarm. The loading system is responsible for positioning the sheet material, while the robot is responsible for grabbing. The automatic wire drawing machine 14 supports stepless speed regulation from 0 to 10 m / min, the surface wire drawing roughness is controlled within the range of 1 - 2 μm, and is equipped with a dust collection system to ensure no residue. The equipment interacts with the master control system through the Modbus TCP protocol, can automatically receive product parameters (including thickness adaptive servo lifting ±0.1 mm), feedback the operating status and fault alarms, and has a built-in grinding head life monitoring system, supporting quick die change within 5 minutes. The width of the aluminum plate is adjustable, there are no texture defects after painting, and the die change downtime ≤ 5 minutes.

[0031] In this embodiment, the first automatic material turning machine 15, the first material transfer manipulator 16, and the automatic bending center 17 are installed in the automatic bending area 3 to perform bending and forming on the aluminum single panel. After the wire drawing treatment of the aluminum single panel, it is turned over by the first automatic material turning machine 15 and then sent into the automatic bending center 17 by the first material transfer manipulator 16 for bending and forming. The bent and formed aluminum single panel is sent into the buffer station 4 by the first material transfer manipulator 16. The bending accuracy of this bending center is ±0.5°, ±0.1 mm / m. The equipment is linked with the master control system through the Modbus TCP protocol to realize automatic parameter programming (including material, size, compensation process, etc.) and operating status monitoring, supporting quick die change within 2 minutes and production line changeover within 5 minutes. It is equipped with a robot loading and unloading station and an on-site programming workstation, meeting the requirement that the processing cycle of 8 cuts ≤ 60 s, and having functions of automatic compensation of bending parameters, fault feedback, and process data interaction to ensure production continuity and precision stability.

[0032] The second material transfer manipulator 18 and the automatic stud welding machine 19 of this embodiment are installed at the stud automatic welding station 5 to perform stud welding on the aluminum single board. The bent and formed aluminum single board is taken out from the buffer station 4 by the second material transfer manipulator 18 and placed into the automatic stud welding machine 19, and the automatic stud welding machine 19 performs automatic stud welding on the aluminum single board. The automatic stud welding machine 19 at the stud automatic welding station 5 is composed of a robot loading and unloading unit, an intelligent stud feeding and welding module, and a digital control platform, meeting the high-precision welding requirements of M6×15 welding studs. The system integrates an automatic stud feeding mechanism, a multi-gun collaborative energy storage welding machine, and a full-steel frame T-slot positioning platform (laid with insulating anti-sparkling plates), supports the six-axis robot to grab the workpiece and automatically position and clamp it, generates a welding point program through CAD drawing import, and realizes precise welding with a center offset of ±0.3mm, a straightness of ±0.3mm / m, and a perpendicularity of 0.3mm. The welding gun is equipped with a dual-capacitor group for dynamic switching, can adjust the downward pressure / clamping speed, and real-time detects the in-place state of the stud, and automatically pauses in case of abnormality; there is no blackening / deformation during the welding process, the back bulge is <0.1mm, there is no defect after painting, and the tensile strength of a single stud is ≥1000N. The system interacts with the master control through the Modbus TCP protocol, transmits the device status, fault alarm, and parameter feedback in real time, supports a high-speed beat of 40 studs / minute, can complete tool change in 5 minutes, is equipped with an independently developed upper computer system, is compatible with office information interaction, and ensures high flexibility and fully automatic continuous production.

[0033] The stiffener placement robot 20 of this embodiment is installed at the stiffener automatic placement station 6 to place the stiffener 101 on the aluminum single board according to the drawing requirements. The aluminum single board after stud welding is sent into the stiffener automatic placement station 6 by the second material transfer manipulator 18 for the placement and assembly of the stiffener. The stiffener placement robot 20 at the stiffener automatic placement station 6 uses the robot to grab the aluminum single board to the servo positioning tooling table, combines the displacement sensor to detect and correct the skew to ensure the assembly accuracy; configures 5 material carts (3 for supplying short stiffeners of 600 - 1500mm; 2 for supplying long stiffeners of 2500 - 4000mm), which are respectively grabbed and installed by the six-axis robot and the three-axis truss manipulator, detects the front and back of the material through an external sensor, and automatically stores the abnormal parts temporarily. The workstation is integrated and controlled by the PLC, coordinates the robot, the servo transplanting platform and the whole line interaction, is equipped with AB station servo positioning, electric cylinders and a safety protection system, is compatible with the master control protocol docking, and realizes high-speed and precise assembly and risk control.

[0034] In this embodiment, the third material transfer manipulator 21 and the nut locking robot 22 are installed at the nut automatic locking station 7, and rely on visual positioning to lock nuts on the aluminum studs of the aluminum single panel. The aluminum single panel after stiffener assembly is sent into the nut automatic locking station 6 by the third material transfer manipulator 21. This nut automatic locking station 6 integrates a truss mechanical structure, a visual positioning unit (anti-light interference detection), an intelligent electric screwdriver tightening unit (adapting to M6 nuts, torque / speed adaptive adjustment), a servo positioning tooling and a buffer feeding mechanism (automatic detection + continuous feeding), and supports two-way communication with the master control system through the Modbus TCP protocol (including parameter distribution, status feedback and fault alarm). The system automatically adjusts the product tooling positioning through servo drive, completes the locking of the stiffener in the center of the length and width directions, is equipped with a display screen to monitor the operation data in real time, and has a three-color light fault alarm; the whole process of tightening is fully traceable (waveform recording / export / upload), the buffer mechanism reduces the robot's idle stroke, and the changeover time < 5 minutes, ensuring high-precision, high-beat and full-process automated operation.

[0035] In this embodiment, the automatic laser welding robot 23 is installed at the stiffener and panel laser welding station 8 to weld and reinforce the gaps at the four corners of the folded edges of the aluminum single panel and the joints between the stiffeners and the folded edges. The aluminum single panel after stiffener assembly is sent into the stiffener and panel laser welding station 8 by the third material transfer manipulator 21 for welding and reinforcing the gaps at the four corners of the folded edges of the panel surface and the diagonal welding at the joints between the stiffeners and the folded edges. After welding, it is sent into the welding point grinding workstation 9 by the third material transfer manipulator 21. The automatic laser welding robot 23 of this laser welding workstation consists of a double-arc welding robot, a double ground rail, a servo transfer table and a laser positioning system, and integrates a gun cleaning device and a PLC master control to realize the full-automatic welding of the aluminum plate stiffeners and the corner welds. The robot is equipped with anti-collision sensors and digital bus communication. The welding power supply supports ultra-low spatter (reducing by 90%) and gap bridging processes. The workstation interacts with the master control through the Modbus TCP protocol (including parameter distribution, status feedback and fault alarm), is configured with three-color lights, safety light curtains (fence ≥ 1.2m), and emergency stop interlocks, meets the positioning accuracy requirement of ±0.1mm, conforms to the IP54 protection standard, and realizes efficient, low heat deformation and fully protected automated welding production.

[0036] In this embodiment, the second automatic blank turning machine 24, the fourth material transfer manipulator 25 and the automatic grinding robot 26 are installed at the welding point grinding workstation 9, and the automatic grinding robot 26 grinds the welds and rivet positions of the aluminum single plate. After welding, the aluminum single plate is turned over by the second automatic blank turning machine 24, and after turning over, it is sent into the automatic grinding robot 26 by the fourth material transfer manipulator 25. The welding point grinding workstation 9 in this embodiment takes two six-axis robots as the core, integrating high-precision force control grinding and intelligent dust removal functions. The six-axis robot is equipped with a 300N force control compensator to achieve multi-segment force control dynamic adjustment and gravity compensation of 5 - 300N, and is equipped with a double electric spindle to achieve a single welding mark grinding beat of 3 seconds. The double six-station hybrid tool magazine includes a sandpaper tearing and pasting mechanism and an in-position detection sensor. The dust-proof cover design meets the consumable reserve for 2 hours of continuous operation, and the tool change success rate is fed back in real time. It supports the parameterized start-stop rivet mark grinding mode for plate thickness and the servo positioning tooling (±0.5mm adaptive clamping). The bottom is integrated with a flared dust collection + side dust extraction pipeline, and the dust recovery rate is ≥99%. It is coordinated with the wet filtration device (7.5kW explosion-proof fan / spray + filter ball double-stage filtration / 300mm air suction port) in the dust removal room through the PLC control cabinet and the Modbus TCP protocol. The room body is designed with negative pressure (rolling door seal + bottom dust extraction), and the external dust concentration < 1mg / m³. The automatic grinding robot is equipped with an IP54 protective clothing and a pipeline package, and is equipped with a touch screen to monitor the status / alarm in real time, and a three-color light warning, meeting the requirements of dust negative pressure collection, safety interlock and remote maintenance.

[0037] In this embodiment, the double-station blanking manipulator 27 is installed at the automatic blanking workstation 11. The ground aluminum single plate is sent into the transfer platform by the fourth material transfer manipulator 25. After being detected by the manual full inspection station 10, it is blanked and stacked by the double-station blanking manipulator 27, completing the entire automatic production line process of the aluminum single plate. In this embodiment, the double-station blanking manipulator 27 automatically sorts products and stacks them vertically through the robot blanking and stacking system based on the manual inspection results (OK / NG). The stacking quantity and layout are dynamically adapted to the robot arm reach range. It is equipped with a 5-meter travel ground rail to achieve large-range operation, meeting the requirements of efficient and precise automatic sorting and stacking.

Claims

1. A fully automatic flexible production line for aluminum single plates, characterized in that, The production line includes a total control system, a double-station loading manipulator, an automatic wire drawing machine, a first automatic material turning machine, a first material transfer manipulator, an automatic bending center, a second material transfer manipulator, an automatic stud welding machine, a stiffener placing robot, a third material transfer manipulator, a nut locking robot, an automatic laser welding robot, a second automatic material turning machine, a fourth material transfer manipulator, an automatic grinding robot, and a double-station unloading manipulator; The total control system is installed on the main console; the double-station loading manipulator and the automatic wire drawing machine are installed in the automatic loading and wire drawing area; the first automatic material turning machine, the first material transfer manipulator, and the automatic bending center are installed in the automatic bending area; the second material transfer manipulator and the automatic stud welding machine are installed in the stud automatic welding station; the stiffener placing robot is installed in the stiffener automatic placing station; the third material transfer manipulator and the nut locking robot are installed in the nut automatic locking station; the automatic laser welding robot is installed in the stiffener and panel laser welding station; the second automatic material turning machine, the fourth material transfer manipulator, and the automatic grinding robot are installed in the welding point grinding workstation; the double-station unloading manipulator is installed in the automatic unloading workstation; All equipment for the automatic production of aluminum single panels is installed on the fully automatic flexible production line for aluminum single panels; the main console, the automatic loading and wire drawing area, the automatic bending area, the stud automatic welding station, the stiffener automatic placing station, the nut automatic locking station, the stiffener and panel laser welding station, the welding point grinding workstation, and the automatic unloading workstation are connected by transmission lines between areas, between areas and stations, and between stations; The total control system uses PLC centralized control. The PLC issues instructions to each execution unit through a high-speed bus, synchronously integrates a safety interlock mechanism to ensure accurate control of the production rhythm, and at the same time reserves an industrial Internet of Things interface to be compatible with factory-level data collection and remote monitoring requirements; synchronously integrates the full-process management of work orders, supports manual / automatic generation of work order numbers and binding parameter templates, realizes drag-and-drop sorting, priority adjustment, and progress tracking of work orders, and supports automatic association of equipment parameters through the product size with the program relationship comparison table; The communication method between the total control system and each single machine of each process. The communication protocol uses Modbus TCP, and the software platform is a self-developed software platform to complete the issuance and collection of parameters and information; each single machine of each process shall feedback the following information to the total control system: whether the single machine can run when starting, the running state of the single machine when running, and the workstation collects the running and processing information and generates a report when ending; The control program of the total control system flexible production line is as follows: New program → Select the process equipment to be used in this program → Parameter input: CAD drawing, length and width, thickness, material, stiffening method → Confirm the work order programming and operation mode; Create a new work order → Enter basic information, including work order name, quantity, start and completion times → Select a pre-programmed procedure → Confirm the entered information → Complete creating the new work order → Return to the production interface and select the work order to be produced → Confirm production → Each device feeds back the current status → Adjust the problematic device according to the feedback → Normal production → The work order is automatically recognized and stopped when completed, or a production change work order is set in advance and automatically switched after the current work order is completed.

2. The fully automatic flexible production line for aluminum veneers according to claim 1, wherein The hardware of the master control system includes a computer, an industrial flat panel dual human-machine interface, an integrated servo drive mechanism, an industrial Internet of Things interface, and a high-speed data bus; the software includes a data acquisition module, a PLC control module, a parameterization management module, a work order management module, an equipment management module, and a production execution module; the master control system is connected to the control terminals of the industrial flat panel dual human-machine interface, the integrated servo drive mechanism, and the devices in each area and station through the high-speed data bus, and real-time displays the device status, parameters, and fault codes; the work order module classifies work orders into six categories according to status: to be produced, in production, paused, cancelled, completed, and in production change; the work order management module displays the cumulative number of work orders and the cumulative number of workpieces; the work order module realizes work order drag-and-drop sorting, priority adjustment, and progress tracking, and supports automatically associating the program relationship comparison table through product dimensions to match device parameters; the parameterization management module realizes dynamic template maintenance and batch parameter distribution, and for abnormal distribution, it can be manually retried and the status can be feedback in real time; the production execution module supports one-key start / pause to switch work orders and synchronously records the completion data.

3. The fully automatic flexible production line for aluminum single plates according to claim 1, characterized in that, The automatic loading and wire drawing area adjusts the last fine grinding process to the first wire drawing process to solve the problems in the design of the fine grinding process and improve the grinding efficiency and quality, ensuring the quality and effect of subsequent fluorocarbon spraying; the double-station loading manipulator and the automatic wire drawing machine in the automatic loading and wire drawing area perform surface wire drawing treatment on the aluminum single panel; the AGV cart transports the aluminum single panel to the designated position, and the double-station loading manipulator immediately grabs the aluminum single panel to realize the automatic loading process; the aluminum single panel then enters the automatic wire drawing machine through the conveyor belt for surface wire drawing treatment, and the treated aluminum single panel is sent to the automatic bending area; the automatic wire drawing machine supports stepless speed regulation from 0 to 10 m / min, and the surface wire drawing roughness is controlled within the range of 1 - 2 μm, and is equipped with a dust collection system to ensure no residue.

4. The fully automatic flexible production line for aluminum veneers according to claim 1, characterized in that, The automatic bending area bends and forms the aluminum single panel entering the automatic bending area; after the aluminum single panel is wire drawn, it is turned over by the first automatic turning machine and sent into the automatic bending center for bending and forming by the first material transfer manipulator; the bent and formed aluminum single panel is sent to the buffer station by the first material transfer manipulator; the bending accuracy of the bending center is ±0.5°, ±0.1 mm / m; the equipment is linked with the master control system through the Modbus TCP protocol to realize automatic parameter programming and operation status monitoring, supports quick die change within 2 minutes and production line changeover within 5 minutes; is equipped with a robot loading and unloading station and a on-site programming workstation, meets the requirement that the 8-knife processing beat ≤ 60 s, and has functions such as automatic bending parameter compensation, fault feedback, and process data interaction.

5. The fully automatic flexible production line for aluminum veneers according to claim 1, characterized in that, The automatic stud projection welding station performs projection welding of aluminum studs on the aluminum single panel. The bent and formed aluminum single panel is taken out from the buffer station by the second material transfer manipulator and placed into the automatic projection welder, and the automatic projection welder performs automatic stud welding on the aluminum single panel. The automatic projection welder of the automatic stud projection welding station consists of a robot loading and unloading unit, an intelligent stud feeding and welding module, and a digital control platform, meeting the high-precision welding requirements of M6×15 welding studs. The system integrates an automatic stud feeding mechanism, a multi-gun collaborative energy storage welder, and a full-steel frame T-slot positioning platform, supporting the six-axis robot to grab the workpiece and automatically position and clamp it. The welding point program is generated through CAD drawing import, realizing precise welding with a center offset of ±0.3mm, a straightness of ±0.3mm / m, and a perpendicularity of 0.3mm. The welding gun is equipped with a dual-capacitor group for dynamic switching, adjustable downward pressure / compression speed, and real-time detection of the stud in-place state, with automatic pause in case of abnormality. There is no blackening / deformation during the welding process, the back bulge is <0.1mm, there are no defects after painting, and the tensile strength of a single stud is ≥1000N. The system interacts with the master control through the Modbus TCP protocol, transmitting the device status, fault alarm, and parameter feedback in real time, supporting a high-speed beat of 40 studs / minute, and realizing tool change in 5 minutes. It is equipped with an independently developed upper computer system, compatible with office information interaction, ensuring high flexibility and fully automatic continuous production.

6. The fully automatic flexible production line for aluminum veneers according to claim 1, wherein The automatic stiffener placement station places stiffeners on the aluminum single panel. The aluminum single panel after stud welding is sent into the automatic stiffener placement station by the second material transfer manipulator for the placement and assembly of stiffeners. The stiffener placement robot of the automatic stiffener placement station uses the robot to grab the aluminum single panel to the servo positioning tooling table, combines with the displacement sensor to detect and correct the skew, ensuring the assembly accuracy. It is equipped with 5 material carts, which are respectively grabbed and installed by the six-axis robot and the three-axis gantry manipulator. The front and back of the material are detected by external sensors, and abnormal parts are automatically stored temporarily. The automatic stiffener placement station is integrated and controlled by the PLC, coordinating the robot, the servo transplanting platform, and the whole line interaction, equipped with AB station servo positioning, electric cylinders, and a safety protection system, compatible with the master control protocol docking, realizing high-speed and precise assembly and risk control.

7. The full-automatic flexible production line for aluminum single plates according to claim 1, characterized in that, The automatic nut locking station locks nuts on the aluminum studs of the aluminum single panel. The aluminum single panel after stiffener assembly is sent into the automatic nut locking station by the third material transfer manipulator. The automatic nut locking station integrates a gantry mechanical structure, a vision positioning unit, an intelligent electric screwdriver tightening unit, a servo positioning tooling, and a buffer feeding mechanism, supporting two-way communication with the master control system through the Modbus TCP protocol. The system automatically adjusts the product tooling position through servo drive, completes the centering lock of the stiffener in the length and width directions, is equipped with a display screen to monitor the operation data in real time, and has a three-color light for fault alarm. The whole process of tightening is fully traceable, and the buffer mechanism reduces the empty stroke of the robot, with a tool change time <5 minutes.

8. The fully automatic flexible production line for aluminum single plates according to claim 1, wherein The reinforcing rib and panel laser welding station welds and reinforces the gaps at the four corners of the folded edges of the aluminum single panel and the joints between the reinforcing ribs and the folded edges; after the assembly of the reinforced aluminum single panel is completed, it is sent into the reinforcing rib and panel laser welding station by the third material transfer manipulator for welding the gaps at the four corners of the panel folded edges and diagonal welding reinforcement at the joints between the reinforcing ribs and the folded edges. After welding, it is sent into the solder joint grinding workstation by the third material transfer manipulator; the automatic laser welding robot of this laser welding workstation consists of a double-arc welding robot, a double floor track, a servo transfer table and a laser positioning system, integrating a gun cleaning device and a PLC master control to realize the full-automatic welding of the aluminum plate reinforcing ribs and the corner welds.

9. The fully automatic flexible production line for aluminum veneers according to claim 1, wherein, The solder joint grinding workstation grinds the welds and rivet positions of the aluminum single panel; the aluminum single panel after welding is turned over by the second automatic turning machine and then sent into the automatic grinding robot by the fourth material transfer manipulator; the automatic grinding robot of the solder joint grinding workstation includes two six-axis robots, integrating high-precision force control grinding and intelligent dust removal functions; the six-axis robots are equipped with a 300N force control compensator to realize multi-segment force control dynamic adjustment of 5 - 300N and gravity compensation, and are equipped with double electric spindles to achieve a single welding mark grinding cycle of 3 seconds. The double six-station hybrid tool magazine includes a sandpaper tearing and pasting mechanism and an in-position detection sensor. The dust-proof cover design meets the consumable reserve for 2 hours of continuous operation, and the tool change success rate is feedback in real time; the automatic grinding robot supports the parameterized start and stop of the rivet mark grinding mode for the plate thickness and the servo positioning tooling. The bottom is integrated with a flared dust collection + side dust extraction pipeline, and the dust recovery rate is ≥99%. It is coordinated with the wet filtering device embedded in the dust removal room through the PLC control cabinet and the Modbus TCP protocol. The room body is designed with negative pressure, and the external dust concentration < 1mg / m³; the robot is equipped with an IP54 protective suit and a pipeline package, and is equipped with a touch screen to monitor the status / alarms in real time and a three-color light warning.

10. The full-automatic flexible production line for aluminum single plates according to claim 1, wherein, The automatic blanking workstation is composed of a double-station blanking manipulator. The ground aluminum single panel is sent into the transfer platform by the material transfer manipulator, and after manual inspection, it is blanked and stacked by the double-station blanking manipulator to complete the entire automatic production line process of the aluminum single panel; the double-station blanking manipulator automatically sorts the products based on the manual inspection results through the blanking and stacking system and stacks them vertically. The stacking quantity and layout are dynamically adapted to the robot arm reach range, and it is equipped with a 5-meter travel floor track to achieve large-range operation, meeting the requirements of efficient and accurate automatic sorting and stacking.

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