Multi-station automatic cutting and assembling all-in-one machine for automobile inserts

Abstract

The invention discloses an automobile insert multi-station automatic cutting and assembling all-in-one machine which is used for assembling material belts and metal sleeves together and comprises a rack, and the rack is provided with at least three material belt feeding units, at least three cutting and mold pressing units, a transfer and dislocation adjusting unit, a storage unit, a robot unit and a sliding table unit. The material belt feeding units correspond to the cutting and mold pressing units in a pairwise mode. The method has the advantage that the problems of procedure interference, variable-pitch transfer precision control, cooperative assembly of special-shaped parts and the like in synchronous machining of multiple types of inserting pieces can be well solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of intelligent manufacturing of automobile parts, and particularly relates to a multi-station automatic cutting and assembling all-in-one machine for automobile inserts. BACKGROUND

[0002] When the traditional automobile inserts are implemented in cutting and assembling operations, the following technical defects often exist:

[0003] 1) The cutting and bending of the material belt need to be completed by multiple relatively independent devices, and the continuous transfer of materials between processes results in cumulative loss of positioning accuracy and inaccuracy;

[0004] 2) Different specifications of inserts (such as material belts A, B and C) cannot be simultaneously processed and assembled, and the compatibility of the production line is relatively poor;

[0005] 3) The assembly of metal sleeves and other special-shaped parts basically relies on manual operation, and the yield rate is generally not higher than 85%. SUMMARY

[0006] The purpose of the present application is to provide a multi-station automatic cutting and assembling all-in-one machine for automobile inserts, which can better solve the problems of process interference in synchronous processing of multiple types of inserts, difficulty in controlling transfer precision, and difficulty in collaborative assembly of special-shaped parts.

[0007] The technical solution adopted by the present application is as follows: a multi-station automatic cutting and assembling all-in-one machine for automobile inserts is used to assemble a material belt and a metal sleeve together, and includes a rack, a PLC, at least three sets of combinations of a material belt feeding unit and a cutting and molding unit, one transfer and misalignment adjusting unit, one storage unit, one robot unit, and one sliding table unit.

[0008] Among them,

[0009] Each combination of a material belt feeding unit and a cutting and molding unit includes one material belt feeding unit and one cutting and molding unit; the material belt feeding unit includes a material belt tray, a feeding rotary disc and a receiving rotary disc, and the feeding rotary disc and the receiving rotary disc are respectively driven by a feeding motor and a receiving motor to form a material belt tension; the cutting and molding unit includes a positioning module, a cutting module, a molding device and a material taking device connected in sequence;

[0010] The transfer and misalignment adjusting unit includes a material taking servo module, a material taking gripper, a correction tooling and a misalignment cylinder, and is used to realize the variable-distance transfer and precision compensation of multi-station materials;

[0011] The storage unit includes a sleeve vibration disc for placing the metal sleeve;

[0012] The sliding table unit includes two alternately used loading and unloading sliding tables.

[0013] The positioning module includes a visual positioning judgment module and an actuator connected to the visual positioning judgment module by signal.

[0014] The molding device comprises an upper mold and a lower mold that cooperate with each other. The upper mold and the lower mold are provided with progressive bending surfaces that cooperate with each other, and the upper mold is connected to a pressurized cylinder.

[0015] The progressive bending surface includes a pre-bending area, a shaping area and a blanking area, and the height difference between each area is 0.5-1.2 mm.

[0016] The correction fixture is a fine-tuning platform that is driven by a power connection to the offset cylinder, with a compensation amount of ±0.5mm and a repeat positioning accuracy of ≤0.02mm.

[0017] The robot unit includes a four-axis robot integrated with multiple types of end effectors.

[0018] The end effector includes two vacuum adsorption PIN needle grippers, whose adsorption hole diameters are adjustable from 0.3 to 0.8 mm; and a pneumatic clamping claw sleeve gripper, whose clamping surface is provided with a polyurethane protective layer with a thickness of 0.3 to 0.5 mm for anti-slip or anti-damage.

[0019] The slide unit includes a cross-roller guide rail, the upper loading slide and the lower loading slide are slidably located on the guide rail, and both the upper loading slide and the lower loading slide are connected to a servo motor.

[0020] The PLC is equipped with a multi-station collaborative control module based on the EtherCAT bus.

[0021] Compared to existing technologies, the present invention offers advantages in effectively addressing process interference, variable-pitch shifting precision control, and the collaborative assembly of special-shaped parts during the simultaneous processing of multiple insert types. The present invention's multi-station automatic cutting and assembly machine for automotive inserts achieves beneficial results in the following areas: 1) Improved processing efficiency: Three-channel parallel processing enables production capacity to reach 1,200 pieces per hour, a 2.3-fold increase compared to traditional single-line processing; 2) Improved precision: The variable-pitch compensation system controls the assembly misalignment rate to within 0.5%; 3) Enhanced compatibility: Through quick-change molds and a parametric control system, it can accommodate at least six types of insert specifications; 4) Intelligent upgrade: The visual inspection system automatically rejects defective products, achieving a yield rate of ≥99.2%. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0023] Figure 1 This is a top view of the multi-station automatic cutting and assembly machine for automobile inserts according to an embodiment of the present invention (the following figures are compared with Figure 1The enlarged view is shown in the figure;

[0024] Figure 2 is the front view of the tape feeding unit of the present application;

[0025] Figure 3 is the perspective view of the cutting and molding unit of the present application;

[0026] Figure 4 is the perspective view of the transfer and misalignment adjustment unit of the present application;

[0027] Figure 5 is the perspective view of the storage unit of the present application;

[0028] Figure 6 is the perspective view of the robot unit of the present application;

[0029] Figure 7 is the perspective view of the sliding table unit of the present application;

[0030] Figure 8 is the logic relationship diagram of the cooperative control of the present application.

[0031] In the figure:

[0032] 10, rack;

[0033] 20, tape feeding unit, 21, tape tray, 221, feeding motor, 222, feeding rotary disc, 231, receiving motor, 232, receiving rotary disc;

[0034] 30, cutting and molding unit, 31, positioning module, 32, cutting module, 33, molding device, 331, upper die, 332, lower die, 34, material taking device;

[0035] 40, transfer and misalignment adjustment unit, 41, material taking servo module, 42, material taking gripper, 43, correction tooling, 44, misalignment air cylinder;

[0036] 50, storage unit, 51, inching vibration disc;

[0037] 60, robot unit, 61, 62, vacuum suction type PIN needle gripper, 63, pneumatic clamping jaw type inching gripper;

[0038] 70, sliding table unit, 71, loading sliding table, 72, unloading sliding table, 73, guide rail. DETAILED DESCRIPTION

[0039] Example 1

[0040] See Figure 1As shown: the automobile plug multi-station automatic cutting assembly all-in-one machine, for assembling the material belt and the metal sleeve together, comprising a rack 10. The rack 10 is provided with at least three groups of material belt feeding units 20 and cutting and molding units 30, a transfer and misalignment adjusting unit 40, a storage unit 50, a robot unit 60, and a sliding table unit 70.

[0041] Wherein,

[0042] Each group of the material belt feeding unit 20 and the cutting and molding unit 30 includes a material belt feeding unit 20 and a cutting and molding unit 30. The material belt feeding unit 20 includes a material belt tray 21, a feeding rotating disc 222, and a receiving rotating disc 232, which are driven by a feeding motor 221 and a receiving motor 231 respectively to form a material belt tension. Generally, the speed difference between the feeding motor 221 and the receiving motor 231 forms a material belt tension of 0.5-3N. The cutting and molding unit 30 includes a positioning module 31, a cutting module 32, a molding device 33, and a material taking device 34 connected in sequence. In this embodiment, the material belt feeding unit 20 and the cutting and molding unit 30 are all three independent ones, corresponding to material belts A, B, and C respectively, forming three processing channels A, B, and C.

[0043] In order to be more intelligent, the automobile plug multi-station automatic cutting assembly all-in-one machine must be equipped with a PLC, which is configured to perform multi-station cooperative control, that is, to control the action timing and action parameters of each moving part according to the setting.

[0044] Or in combination Figure 2 As shown more specifically, each material belt feeding unit 20 includes a material belt tray 21, a feeding rotating disc 222 driven by a feeding motor 221, and a receiving rotating disc 232 driven by a receiving motor 231. The feeding motor 221 and the receiving motor 231 are necessarily signal connected to the PLC and output appropriate speeds under the control of the PLC. In use, the material belt is placed in the material belt tray 21, and then the head of the material belt is pulled out and then passes through the feeding rotating disc 222 and the receiving rotating disc 232. Under the action of the speed difference, the material belt can be output at a reasonable speed and tension.

[0045] Or in combination Figure 3As shown more specifically, each cutting and molding unit 30 includes a positioning module 31, a cutting module 32 connected to the discharge end of the positioning module 31, a molding device 33 connected to the discharge end of the cutting module 32, and a material taking device 34 matched with the molding device 33. That is, the positioning module 31 includes a visual positioning judgment module and an actuator connected to the visual positioning judgment module, the visual positioning judgment module signals to the PLC, and the actuator receives the signal of the PLC. The actuator can adopt two dial pieces that can be laterally micro-operated, so that according to the information obtained by the visual positioning judgment module, the dial pieces are moved to adjust the position of the material belt; or the actuator adopts a positioning gripper driven by a servo motor. That is, after the material belt is output from the material belt feeding unit 20, it continues to be conveyed forward along a relatively stable path after passing through the positioning module 31; the material belt conveyed stably forward enters the molding device 33 after passing through the cutting module 32; the material belt entering the molding device 33 is cut off by the cutting module 32 when it reaches the set length; the molding device 33 starts to press the cut material belt into a material belt insert, and the material taking device 34 takes out the pressed material belt insert. The cutting module 32 can adopt a common downward pressing blade type or a scissors type. The power part of the cutting module 32 is also connected to the PLC, so that the desired length can be cut according to the need. The molding device 33 includes an upper die 331 and a lower die 332 matched with each other, and the upper die 331 and the lower die 332 are provided with progressive bending curved surfaces matched with each other, the curvature radius of the progressive bending curved surfaces is generally R=2-5mm, and the upper die 331 is connected with a booster cylinder 333, and the booster cylinder 333 is connected to the PLC. The progressive bending curved surface includes a pre-bending area, a shaping area and a blanking area, and the height difference of each area is 0.5-1.2mm. That is, the cut material belt further enters between the upper die 331 and the lower die 332, and under the driving of the booster cylinder 33, the upper die 331 and the lower die 332 intermittently close, and the 90°→135°→180° bending is completed in 4 times, and the fourth time is punched into a suitable material belt insert.

[0046] The transfer and misalignment adjustment unit 40 includes a material taking servo module 41, a material taking gripper 42, a correction tooling 43 and a misalignment cylinder 44, which is used to realize the variable distance transfer and precision compensation of multi-station materials.

[0047] Or in combination Figure 4More specifically, the transfer and misalignment adjustment unit 40 includes a material taking servo module 41, a material taking gripper 42 corresponding to the material taking device 34 and connected to the material taking servo module 41, a correction tool 43 matched with the material taking gripper 42, and a misalignment cylinder 44 connected to the correction tool 43. That is, the material taking servo module 41 is signal connected to the PLC, and the power output is connected to the material taking gripper 42. After the material taking gripper 42 is actuated, it grasps the punched and formed material strip insert and then places it in the correction tool 43. The correction tool 43 is powered by the corresponding misalignment cylinder 44. Specifically, the correction tool 43 is a fine adjustment platform connected to the misalignment cylinder 44 to achieve driving. The compensation amount is ±0.5mm, and the repeat positioning accuracy is ≤0.02mm. The correction tool 43 corrects the spacing of the material strip insert. The misalignment cylinder 44 is signal connected to the PLC. The correction tool 43 generally adopts a linear structure.

[0048] In combination Figure 5 As shown, the storage unit 50 includes a sleeve vibration disc 51 for placing metal sleeves. The sleeve vibration disc 51 can be equipped with an automatic pin plate device as needed to adapt to different types of sleeves.

[0049] In combination Figure 6 As shown, the robot unit 60 includes a four-axis robot signal connected to the PLC. The four-axis robot integrates multiple types of end effectors, including two vacuum adsorption type PIN needle grippers 61 and 62 with an adsorption hole diameter of 0.3-0.8mm adjustable. The end effectors also include a pneumatic clamping jaw type sleeve gripper 63. The clamping surface of the pneumatic clamping jaw type sleeve gripper 63 is provided with a polyurethane protective layer with a thickness of 0.3-0.5mm for anti-skid or anti-damage. The material used for the polyurethane protective layer meets the requirements of QC / T29106-2014 automobile parts anti-skid material, thereby meeting the requirements of anti-skid and wear resistance, which is extremely suitable for the use requirements of the present embodiment 1. That is, the vacuum adsorption type PIN needle grippers 61 and 62 grasp the material strip insert from the corresponding correction tool 43, and the pneumatic clamping jaw type sleeve gripper 63 grasps the sleeve from the sleeve vibration disc 51.

[0050] In combination Figure 7 As shown, the sliding table unit 70 includes two alternately used upper loading sliding tables 71 and lower loading sliding tables 72. The upper loading sliding tables 71 and the lower loading sliding tables 72 are both connected with servo motors that can move and are signal connected to the PLC. The upper loading sliding tables 71 and the lower loading sliding tables 72 are both located on a cross roller guide 73 to realize gapless switching, and the switching time is ≤1.5 seconds. That is, after the robot unit 60 takes out the material strip inserts of the material strip A, the material strip B, and the material strip C and the sleeves, it is placed into the upper loading sliding table 71. After the upper loading sliding table 71 is loaded, it is pushed to the right side by the servo motor, and the lower loading sliding table 72 is pushed to the left side by the servo motor. The robot unit 60 takes out the material strip inserts and the metal sleeves and places them on the sliding table, and the cycle is repeated.

[0051] The aforementioned plurality of material strip feeding units 20 and corresponding cutting and molding units 30 are distributed at the edge corners of the machine frame 10, and are arranged radially around a common transfer and misalignment adjustment unit 40, thereby forming a great synergy.

[0052] Embodiment 2

[0053] In combination Figure 8 As shown, after the moving parts and signal in embodiment 1 are connected to the PLC, the synergy control is realized. The PLC control method can be in multiple ways. In this embodiment, the PLC control method synchronizes the actions of each unit through the EtherCAT bus, specifically including:

[0054] a. Material strip processing beat matching algorithm: according to the formula T = MAX(T1, T2, T3) + Δt, calculate the total beat, wherein T1-T3 is the processing time of each channel, and Δt is the safety margin (0.1-0.3s);

[0055] b. Robot path dynamic optimization program: A* algorithm is used to plan the grabbing path of the robot unit 60, to ensure that ∑(moving time ti) <1.5s;

[0056] c. Abnormal condition self-diagnosis module: when the vision positioning module detects that the deviation exceeds the limit for 3 times in a row, the stop alarm is triggered.

[0057] In this way, a multi-station synergy mechanism is realized.

[0058] The above only describes the preferred embodiments of the present application, and does not limit the patent scope of the present application, and any equivalent structure or equivalent process transformation, or direct or indirect application in other related technical fields, is also included in the patent protection scope of the present application.

Claims

1. A multi-station automatic cutting and assembly machine for automobile inserts, used for assembling material strips and metal sleeves, comprising a frame (10) and a PLC, characterized in that: The frame (10) is provided with at least three groups of material feeding units (20) and cutting and molding units (30), a transfer and misalignment adjustment unit (40), a storage unit (50), a robot unit (60), and a slide unit (70); in, Each combination of a material strip feeding unit (20) and a cutting and molding unit (30) comprises a material strip feeding unit (20) and a cutting and molding unit (30); the material strip feeding unit (20) comprises a material strip tray (21), a feeding rotary disk (222) and a receiving rotary disk (232), the feeding rotary disk (222) and the receiving rotary disk (232) being driven by a feeding motor (221) and a receiving motor (231) respectively to form material strip tension; the cutting and molding unit (30) comprises a positioning module (31), a cutting module (32), a molding device (33) and a material taking device (34) connected in sequence; The transfer and misalignment adjustment unit (40) includes a material taking servo module (41), a material taking gripper (42), a correction tool (43) and a misalignment cylinder (44), and is used to realize variable distance transfer and precision compensation of multi-station materials; The storage unit (50) includes a sleeve vibration plate (51) for placing the metal sleeve; The slide unit (70) comprises two upper loading slides (71) and a lower loading slide (72) which are used alternately.

2. The multi-station automatic cutting and assembly machine for automobile inserts according to claim 1, characterized in that: The positioning module (31) includes a visual positioning judgment module and an actuator connected to the visual positioning judgment module by signal.

3. The multi-station automatic cutting and assembly machine for automobile inserts according to claim 2, characterized in that: The correction tool (43) is a fine-tuning platform that is dynamically connected to the misalignment cylinder (44) to achieve driving, with a compensation amount of ±0.5mm and a repeat positioning accuracy of ≤0.02mm. The driving signal of the misalignment cylinder (44) is generated by real-time feedback from a visual positioning module.

4. The multi-station automatic cutting and assembly machine for automobile inserts according to claim 1, characterized in that: The molding device (33) comprises an upper mold (331) and a lower mold (332) that cooperate with each other, the upper mold (331) and the lower mold (332) are provided with progressive bending surfaces that cooperate with each other, and the upper mold (331) is connected to a pressurizing cylinder (333).

5. The multi-station automatic cutting and assembly machine for automobile inserts according to claim 4, characterized in that: The progressive bending surface includes a pre-bending area, a shaping area and a blanking area, and the height difference between each area is 0.5-1.2 mm.

6. The multi-station automatic cutting and assembly machine for automobile inserts according to claim 1, characterized in that: The robot unit (60) includes a four-axis robot integrated with multiple types of end effectors.

7. The multi-station automatic cutting and assembly machine for automobile inserts according to claim 6, characterized in that: The end effector comprises two vacuum adsorption type PIN needle grippers (61, 62), whose adsorption hole diameters are adjustable from 0.3 to 0.8 mm; and a pneumatic clamping claw type sleeve gripper (63), whose clamping surface is provided with a polyurethane protective layer with a thickness of 0.3 to 0.5 mm for anti-slip or anti-damage.

8. The multi-station automatic cutting and assembly machine for automobile inserts according to claim 1, characterized in that: The slide unit (70) includes a cross-roller guide rail (73), the upper loading slide (71) and the lower loading slide (72) are slidably located on the guide rail (73), and the upper loading slide (71) and the lower loading slide (72) are both connected to a servo motor.

9. The multi-station automatic cutting and assembly machine for automobile inserts according to claim 1, characterized in that: The PLC is equipped with a multi-station collaborative control module based on the EtherCAT bus.

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