Automobile carpet punching machine

Abstract

The invention discloses an automotive carpet punching machine, and relates to the technical field of automotive trim processing equipment. The punching machine comprises a rack, a feeding mechanism, a punching mechanism, a waste hopper, a positioning mechanism and a control system. The feeding mechanism is arranged at the input end of the rack and used for achieving automatic and continuous conveying of automobile carpet raw materials. The punching mechanism is installed in the middle of the machine frame and can accurately complete punching forming of carpets of different vehicle models. The positioning mechanism ensures the position precision of the carpet raw materials in the punching process through the combination of visual identification and laser positioning; and the control system adopts a PLC (Programmable Logic Controller) which is electrically connected with the feeding mechanism, the punching mechanism, the waste recovery mechanism and the positioning mechanism respectively, so that automatic operation and parameter adjustment of the equipment are realized. The automatic punching machine solves the problems that a traditional punching machine is low in die changing efficiency, poor in punching precision and tedious in waste treatment, has the advantages of being high in automation degree, stable in punching quality and wide in application range, and can remarkably improve the production efficiency and the machining quality of automobile carpets.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile interior part processing equipment, in particular to an automobile carpet punching machine. BACKGROUND

[0002] As an important part of automobile interior, the shape of automobile carpet needs to be accurately matched with the structure of automobile chassis, and the size and hole position (such as seat mounting hole, throttle / brake pedal avoidance hole, etc.) of the carpet of different vehicle models are significantly different, so the processing precision and forming consistency are extremely high. At present, the punching processing of automobile carpet mainly depends on traditional hydraulic punching machines or manual punching equipment. Such equipment has the following problems in actual application:

[0003] 1. Low die changing efficiency: the die and the machine body of the traditional punching machine are fixedly connected by bolts. When changing the punching die of different vehicle models, the operator needs to manually disassemble multiple bolts, which is tedious and time-consuming, resulting in long equipment downtime and difficulty in meeting the production needs of multiple vehicle models in small batches.

[0004] 2. Poor punching precision: the existing equipment mainly relies on manual positioning or simple mechanical positioning. The carpet raw material is prone to deviation during conveying and punching, and the punching die is prone to deviation in punching position due to guide error during long-term use, resulting in rough edges of the carpet, inaccurate hole position and other problems, which affects the product qualification rate.

[0005] 3. Low automation degree: the feeding, positioning and punching processes of the traditional equipment need to be operated manually, which is low in production efficiency, and the stability of manual operation is easily affected by the experience and fatigue of the operator, resulting in large fluctuations in product quality.

[0006] In view of the above problems, it is urgent to design an automobile carpet punching machine with high automation degree, convenient die changing, high punching precision and automatic waste recycling to meet the efficient and accurate production needs of the automobile interior industry. SUMMARY

[0007] The purpose of the present application is to provide an automobile carpet punching machine to solve the problems raised in the background.

[0008] In order to achieve the above object, the present application provides the following technical scheme: The automobile carpet punching machine comprises a rack, a feeding mechanism, a punching mechanism, a waste hopper, a positioning mechanism and a control system; the feeding mechanism is arranged at the input end of the rack and comprises a feeding support, a driving feeding roller, a driven feeding roller, a servo motor, a sliding seat, a lifting cylinder, a guide slide rod and a planetary reducer; the feeding support is fixed to the rack, the driving feeding roller and the driven feeding roller are arranged in parallel in the feeding support, the driven feeding roller is installed in the sliding seat, the sliding seat is connected to the feeding support through the lifting cylinder and the guide slide rod to form an up-down sliding structure; the servo motor is connected to the driving feeding roller through the planetary reducer; the punching mechanism is installed in the middle of the rack and comprises a die mounting seat, a punching die assembly, a driving assembly and a guide assembly; the die mounting seat is divided into an upper die seat and a lower die seat, the lower die seat is fixed to the rack, and the upper die seat is connected to the lower die seat through the guide assembly; the punching die assembly comprises a lower die and an upper die, the upper die is detachably connected to the upper die seat through a quick locking structure, and the lower die is installed on the lower die seat; the driving assembly adopts a servo hydraulic cylinder, the cylinder body of the servo hydraulic cylinder is fixed to the top of the rack, and the piston rod is fixed to the upper die seat; the waste hopper is located below the punching mechanism, the upper side of the waste hopper is open and faces the lower die seat, and the waste hopper forms a pull-out structure in the rack; the positioning mechanism comprises a visual positioning assembly, the visual positioning assembly comprises an industrial camera, a ring light source and an image processor, the industrial camera is installed at the top of the rack, the image processor is electrically connected to the industrial camera, and the ring light source is arranged around the lens of the industrial camera; the control system comprises a PLC controller and a touch screen; the PLC controller is electrically connected to the feeding mechanism, the punching mechanism and the positioning mechanism; the touch screen is electrically connected to the PLC controller and is used for displaying parameters and operation control.

[0009] Preferably, the quick locking structure comprises a positioning pin arranged at the bottom of the upper die seat, an elastic clamping block and a pneumatic switch, the top of the upper die is provided with a positioning hole and a clamping groove corresponding to the positioning pin and the elastic clamping block, and the pneumatic switch controls the expansion and contraction of the elastic clamping block to realize the installation and dismounting of the upper die.

[0010] Preferably, the surfaces of the driving feeding roller and the driven feeding roller are wrapped with rubber anti-skid layers, and the surfaces of the rubber anti-skid layers are provided with diamond patterns.

[0011] Preferably, the control system further comprises a remote communication module, the remote communication module is electrically connected to the PLC controller and supports communication with a factory MES system.

[0012] Preferably, polyurethane blade edge protection sleeves are arranged at the edges of the lower die and the upper die.

[0013] Preferably, the guide assembly comprises a guide column and a linear bearing, the guide column is fixed to the lower die seat, and the linear bearing is embedded in the upper die seat.

[0014] Preferably, adjustable feet are arranged at the bottom of the rack, and transparent dustproof covers are arranged on the surfaces of the adjustable feet.

[0015] Preferably, the control system further comprises an emergency stop button arranged on both sides of the rack and the side of the touch screen, for emergency power-off.

[0016] Preferably, the positioning mechanism further comprises a laser positioning assembly, the laser positioning assembly comprising at least two laser emitters mounted on both sides of the upper die holder, the laser beams emitted by the laser emitters being vertically projected onto the surface of the lower die.

[0017] Preferably, the output end of the rack is provided with a tension adjusting mechanism, the tension adjusting mechanism comprising a tension sensor and a conveying belt, the tension sensor being arranged between the driving feeding roller and the punching mechanism.

[0018] Compared with the prior art, the present application has the following advantages:

[0019] (1) High die changing efficiency: the punching mechanism adopts a quick locking structure, the elastic clamping block cooperates with the clamping groove of the upper die through pneumatic switch control, the upper die is quickly disassembled and installed, the die changing time is greatly shortened, the production flexibility of the equipment is significantly improved, and the production demand of multiple vehicle types is met.

[0020] (2) High punching precision: the positioning mechanism combines visual recognition and laser positioning, the visual positioning assembly can detect the position deviation of the carpet in real time and feed back to the control system, the control system adjusts the servo motor of the feeding mechanism to realize automatic correction of the position of the carpet; at the same time, the guide assembly of the punching mechanism ensures the vertical movement of the upper die, avoids die deviation, improves punching precision, and greatly improves product qualification rate.

[0021] (3) Convenient waste treatment: through punching down pressure work, the punching waste can automatically fall into the waste hopper, which is convenient for waste collection and treatment, reduces the labor intensity of the operator, maintains the cleanliness of the workshop environment, and meets the environmental protection production requirements.

[0022] (4) High automation degree: the PLC controller is used to integrate feeding, positioning, punching and other processes to realize automatic operation of the whole process of the equipment, the operator only needs to set parameters through the touch screen, the production efficiency is greatly improved compared with traditional equipment, and the product quality stability is higher. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 is a schematic diagram of the three-dimensional structure of the present application;

[0024] Figure 2 is a schematic diagram of the three-dimensional structure of the present application;

[0025] Figure 3 is a schematic diagram of the three-dimensional structure of the present application;

[0026] Figure 4 is a schematic diagram of the rack structure of the present application;

[0027] Figure 5 Structure diagram of the feeding mechanism of the present application;

[0028] Figure 6 Structure diagram of the punching mechanism of the present application;

[0029] Figure 7 Structure diagram of the punching mechanism of the present application;

[0030] Figure 8 Structure diagram of the upper die holder of the present application;

[0031] Figure 9 Structure diagram of the waste hopper and the frame of the present application.

[0032] In the figure: 1, frame; 11, adjustable foot; 12, dustproof cover; 2, feeding mechanism; 21, feeding support; 22, driving feeding roller; 23, driven feeding roller; 24, servo motor; 25, sliding seat; 26, lifting cylinder; 27, guide slide rod; 28, planetary reducer box; 3, punching mechanism; 31, upper die holder; 32, lower die holder; 33, servo hydraulic cylinder; 34, guide column; 35, lower die; 36, upper die; 37, polyurethane blade edge protection sleeve; 38, quick locking structure; 4, waste hopper; 5, positioning mechanism; 51, industrial camera; 52, ring light source; 53, image processor; 6, control system; 61, PLC controller; 62, touch screen; 63, emergency stop button; 7, tension adjusting mechanism. DETAILED DESCRIPTION

[0033] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0034] Please refer to Figures 1-9 The present application provides the technical solution: the automobile carpet punching machine, comprising a frame 1, a feeding mechanism 2, a punching mechanism 3, a waste hopper 4, a positioning mechanism 5 and a control system 6.

[0035] The frame 1 is used as the support base of the equipment, which is made of high-strength steel by welding, and the adjustable foot 11 is arranged at the bottom of the frame for adjusting the levelness of the equipment. The surface of the frame 1 is covered with a transparent dustproof cover 12, which is convenient for the operator to observe the internal running state of the equipment.

[0036] The feeding mechanism 2 is arranged at the input end of the rack 1, and comprises a feeding support 21, a driving feeding roller 22, a driven feeding roller 23, a servo motor 24, a sliding seat 25, a lifting cylinder 26, a guide slide rod 27 and a planetary reduction box 28. The feeding support 21 is fixed to the rack 1, the driving feeding roller 22 and the driven feeding roller 23 are arranged in parallel in the feeding support 21, the driven feeding roller 23 is installed in the sliding seat 25, the sliding seat 25 forms an up-down sliding structure in the feeding support 21 through the lifting cylinder 26 and the guide slide rod 27, and the distance between the driven feeding roller 23 and the driving feeding roller 22 can be adjusted according to the thickness of the carpet. The servo motor 24 is of Mitsubishi HG-KR43J type, is in transmission connection with the driving feeding roller 22 through the planetary reduction box 28, and is used to drive the driving feeding roller 22 to rotate, so that the carpet raw material is quantitatively conveyed.

[0037] Further, the surfaces of the driving feeding roller 22 and the driven feeding roller 23 are wrapped with rubber anti-skid layers, and the surfaces of the rubber anti-skid layers are provided with rhombic lines, so that the friction between the roller body and the carpet raw material can be increased, the slipping phenomenon in the feeding process can be prevented, and the feeding precision is ensured.

[0038] The punching mechanism 3 is installed in the middle of the rack 1, and comprises a die mounting seat, a punching die assembly, a driving assembly and a guide assembly. The die mounting seat is divided into an upper die seat 31 and a lower die seat 32, the lower die seat 32 is fixed to the rack 1, and the upper die seat 31 is in sliding connection with the lower die seat 32 through the guide assembly. The punching die assembly comprises a lower die 35 and an upper die 36, the upper die 36 is detachably connected with the upper die seat 31 through a quick locking structure 38, and the lower die 35 is installed on the lower die seat 32. The driving assembly is of a servo hydraulic cylinder 33 of HOB125*100 type, the cylinder body of the servo hydraulic cylinder 33 is fixed to the top of the rack 1, the piston rod is fixed to the upper die seat 31, and the servo hydraulic cylinder 33 is used to drive the upper die seat 31 to move the upper die 36 up and down, so that the punching action is realized.

[0039] Further, the quick locking structure 38 comprises a positioning pin arranged at the bottom of the upper die seat 31, an elastic clamping block and a pneumatic switch of SMCVQ110U type, and the upper die 36 is correspondingly provided with a positioning hole and a clamping groove at the top. When the die is replaced, the elastic clamping block can be controlled to stretch and retract through the pneumatic switch, so that the quick installation and dismounting of the upper die 36 can be completed.

[0040] Further, the guide assembly comprises a guide column 34 and a linear bearing, the guide column 34 is fixed to the lower die seat 32, and the linear bearing is embedded in the upper die seat 31, so that the upper die 36 can move in the vertical direction during the punching process, and the die deviation is avoided.

[0041] Further, polyurethane blade edge protection sleeves 37 are arranged at the edges of the lower die 35 and the upper die 36, so that the die blade edge can be prevented from being damaged in the non-working state, and the risk that the operator is cut by the blade edge when replacing the die is reduced.

[0042] The waste hopper 4 is located below the punching mechanism 3, and the upper side of the waste hopper 4 is opened to face the lower die seat 32, so that the waste punched down falls freely into the waste hopper 4, facilitating the collection of the waste. The waste hopper 4 is formed as a pull-out structure in the rack 1, facilitating the centralized cleaning work of the waste.

[0043] The positioning mechanism 5 comprises a visual positioning assembly, which comprises an industrial camera 51 of Basler acA1300-30gc type, a resolution of 1296*966, a ring light source 52 of CCSLED-RI2-50 type, and an image processor 53 of Advantech ARK-3500 type. The industrial camera 51 is installed on the top of the rack 1, with the lens facing the surface of the carpet raw material. The ring light source 52 is arranged around the lens of the industrial camera 51, for providing uniform white light illumination with adjustable brightness. The image processor 53 is electrically connected with the industrial camera 51. By collecting the positioning marks on the surface of the carpet, such as the pre-printed positioning points or edge profiles, the deviation between the actual position of the carpet and the preset position is calculated, and the deviation signal is fed back to the control system 6.

[0044] Further, the positioning mechanism 5 further comprises a laser positioning assembly, which comprises at least two laser emitters with a power of 5mW and a wavelength of 650nm, installed on both sides of the upper die seat 31. The laser beams emitted by the laser emitters are vertically projected onto the surface of the lower die 35, forming positioning light spots, to assist the operator in preliminary positioning during the equipment debugging or manual feeding.

[0045] The control system 6 comprises a PLC controller 61 of Siemens S7-1200CPU1214C type, a touch screen 62 of WELON MT8102iE type, and an emergency stop button 63. The PLC controller 61 is installed on the rack 1, and is electrically connected with the servo motor 24 of the feeding mechanism 2, the lifting cylinder 26, the tension sensor of the tension adjusting mechanism 7, the driving motor of the conveying belt, the servo hydraulic cylinder 33 of the punching mechanism 3, the pneumatic switch of the quick locking structure 38, the industrial camera 51, the image processor 53, and the laser emitters of the positioning mechanism 5, for receiving the signals of the components and outputting control instructions, to realize the automatic operation of the equipment. The touch screen 62 is installed outside the PLC controller 61, for displaying the operation parameters of the equipment, such as the feeding speed, the punching pressure, the punching frequency, and the fault alarm information, while supporting the manual setting of parameters, the selection of die types, and the control of the start and stop of the equipment by the operator.

[0046] Further, the control system 6 further comprises a remote communication module of Siemens CM1243-1 type, which is electrically connected with the PLC controller 61, supports the communication with the factory MES system manufacturing execution system through Ethernet or 4G network, realizes the remote monitoring and production scheduling of the equipment operation data, and facilitates the intelligent management of the factory.

[0047] Further, the control system 6 further comprises an emergency stop button 63, which is a red mushroom button arranged on both sides of the rack 1 and the side of the touch screen 62, used to cut off the power supply of the equipment in emergency to ensure the safety of operation.

[0048] Further, the output end of the rack 1 is provided with a tension adjusting mechanism 7, which comprises a tension sensor model HBMU9C and a conveying belt. The tension sensor is arranged between the driving feeding roller 22 and the punching mechanism 3, used to detect the tension of the carpet raw material in real time, and feed the signal to the control system 6, so as to control the feeding speed of the conveying belt and the feeding mechanism 2 to the carpet through the control system 6, to avoid the carpet from being wrinkled due to excessive or insufficient tension.

[0049] The working process of the embodiment is as follows:

[0050] 1. Equipment debugging: the operator selects the mold parameters of the vehicle model to be processed through the touch screen 62, starts the laser positioning assembly, installs the lower mold 35 on the lower mold seat 32 and calibrates the position through the laser spot; controls the elastic clamping block to retract through the pneumatic switch, positions the matched upper mold 36 through the positioning pin and the upper mold seat 31, and then controls the elastic clamping block to extend to clamp the clamping groove, to complete the mold installation;

[0051] 2. Feeding and feeding: the automobile carpet raw material in roll or sheet shape is placed at the input end of the feeding mechanism 2, the driven feeding roller 23 is driven to descend by the lifting cylinder 26, and the carpet raw material is compressed; the servo motor 24 is started to drive the driving feeding roller 22 to rotate, and the carpet raw material is conveyed to the lower side of the punching mechanism 3;

[0052] 3. Positioning correction: the industrial camera 51 of the visual positioning assembly collects the positioning mark image of the carpet surface, the image processor 53 analyzes and calculates the position deviation of the carpet, and sends the deviation signal to the PLC controller 61; the PLC controller 61 controls the servo motor 24 to fine-tune the feeding speed, corrects the position of the carpet, and ensures the accuracy of the punching position;

[0053] 4. Punching forming: after positioning, the PLC controller 61 controls the servo hydraulic cylinder 33 to start, the piston rod pushes the upper mold seat 31 to drive the upper mold 36 to move downward, and cooperates with the lower mold 35 to complete the punching of the carpet; after punching, the servo hydraulic cylinder 33 drives the upper mold 36 to reset;

[0054] 5. Waste recycling: the waste generated in the punching process falls into the waste hopper 4 through the punching slot of the lower mold 35 and the opening on the lower mold seat 32 for centralized collection, then the waste hopper 4 is pulled out, and the waste is cleaned to the external recycling box;

[0055] 6. Continuous production: after the completion of a single punching, the feeding mechanism 2 continues to convey the carpet raw material, and steps 3-5 are repeated to realize continuous automatic production; if the vehicle type needs to be changed, only the corresponding mold parameters need to be selected through the touch screen 62, and the upper die 36 is replaced through the quick locking structure 38.

[0056] The automobile carpet punching machine of the embodiment has high die changing efficiency, high punching precision and high overall automation degree, can effectively solve the shortcomings of traditional equipment, and is suitable for batch production of various automobile carpets.

[0057] Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art can modify the technical solutions recorded in the foregoing embodiments or make equivalent substitutions for part of the technical features, and any modification, equivalent substitution, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. Car carpet punching and cutting machine, characterized in that, It comprises a frame (1), a feeding mechanism (2), a punching mechanism (3), a waste hopper (4), a positioning mechanism (5) and a control system (6); The feeding mechanism (2) is arranged at the input end of the frame (1), and comprises a feeding bracket (21), an active feeding roller (22), a driven feeding roller (23), a servo motor (24), a sliding seat (25), a lifting cylinder (26), a guide slide bar (27) and a planetary reduction box (28); the feeding bracket (21) is fixed on the frame (1), the active feeding roller (22) and the driven feeding roller (23) are arranged in parallel in the feeding bracket (21), the driven feeding roller (23) is installed in the sliding seat (25), and the sliding seat (25) forms an up and down sliding structure in the feeding bracket (21) through the lifting cylinder (26) and the guide slide bar (27); the servo motor (24) is connected to the active feeding roller (22) through the planetary reduction box (28); The punching mechanism (3) is installed in the middle of the frame (1), and includes a die mounting seat, a punching die assembly, a driving assembly and a guide assembly; the die mounting seat is divided into an upper die seat (31) and a lower die seat (32), the lower die seat (32) is fixed on the frame (1), and the upper die seat (31) is slidably connected to the lower die seat (32) through the guide assembly; the punching die assembly includes a lower die (35) and an upper die (36), the upper die (36) is detachably connected to the upper die seat (31) through a quick locking structure (38), and the lower die (35) is installed on the lower die seat (32); the driving assembly adopts a servo hydraulic cylinder (33), the cylinder body of the servo hydraulic cylinder (33) is fixed on the top of the frame (1), and the piston rod is fixed to the upper die seat (31); The waste hopper (4) is located below the punching mechanism (3), the upper opening of the waste hopper (4) faces the lower die base (32), and the waste hopper (4) forms a pull-out structure within the frame (1); The positioning mechanism (5) includes a visual positioning component, which includes an industrial camera (51), an annular light source (52), and an image processor (53). The industrial camera (51) is installed on the top of the frame (1). The image processor (53) is electrically connected to the industrial camera (51). The annular light source (52) is arranged around the lens of the industrial camera (51). The control system (6) comprises a PLC controller (61) and a touch screen (62); the PLC controller (61) is electrically connected to the feeding mechanism (2), the punching mechanism (3) and the positioning mechanism (5) respectively; the touch screen (62) is electrically connected to the PLC controller (61) and is used for displaying parameters and operating control.

2. The automotive carpet punching and cutting machine according to claim 1, characterized in that: The quick locking structure (38) includes a positioning pin, an elastic block and a pneumatic switch arranged at the bottom of the upper mold base (31); a positioning hole and a slot are correspondingly arranged on the top of the upper mold (36); the pneumatic switch controls the expansion and contraction of the elastic block to realize the installation and removal of the upper mold (36).

3. The automotive carpet punching and cutting machine according to claim 1, characterized in that: The surfaces of the active feeding roller (22) and the driven feeding roller (23) are wrapped with a rubber anti-skid layer, and diamond-shaped patterns are arranged on the surface of the rubber anti-skid layer.

4. The automotive carpet punching and cutting machine according to claim 1, characterized in that: The control system (6) further comprises a remote communication module, which is electrically connected to the PLC controller (61) and supports communication with the factory MES system.

5. The automotive carpet punching and cutting machine according to claim 1, characterized in that: A polyurethane cutting edge protection sleeve (37) is provided on the edges of the lower die (35) and the upper die (36).

6. The automotive carpet punching and cutting machine according to claim 1, characterized in that: The guide assembly comprises a guide column (34) and a linear bearing, wherein the guide column (34) is fixed to the lower die base (32), and the linear bearing is embedded in the upper die base (31).

7. The automotive carpet punching and cutting machine according to claim 1, characterized in that: The bottom of the frame (1) is provided with an adjustable foot (11), and the surface is covered with a transparent dustproof shield (12).

8. The automotive carpet punching and cutting machine according to claim 1, characterized in that: The control system (6) further comprises an emergency stop button (63), which is arranged on both sides of the frame (1) and the side of the touch screen (62) and is used to cut off the power supply in an emergency.

9. The automotive carpet punching and cutting machine according to claim 1, characterized in that: The positioning mechanism (5) further comprises a laser positioning assembly, which comprises at least two laser emitters installed on both sides of the upper mold base (31). The laser beams emitted by the laser emitters are vertically projected onto the surface of the lower mold (35).

10. The automotive carpet punching and cutting machine according to claim 1, characterized in that: The output end of the frame (1) is equipped with a tension adjustment mechanism (7), which includes a tension sensor and a conveyor belt. The tension sensor is arranged between the active feeding roller (22) and the punching mechanism (3).

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