Steering wheel switch detection equipment

Abstract

The invention relates to the technical field of steering wheel detection, in particular to a steering wheel switch detection device, which comprises a frame body provided with a working table top and a mounting part, and a display screen and an electric control box are arranged on the mounting part; the base is arranged on the working table, and a supporting component used for placing a steering wheel is arranged on the base; the detection unit comprises a material code scanning identification module, a product code scanning tracing module, a screw counting module and a switch function detection module, and the detection unit is used for generating a corresponding detection signal; the control system is electrically connected with the detection unit and the electric cabinet and used for receiving and processing the detection signals, controlling the assembly process based on a preset assembly operation sequence and logic, achieving process confirmation and missed process mistake proofing through the detection signals and / or operator confirmation and outputting alarm information when abnormity is detected. All-directional and automatic quality control in the steering wheel switch assembling process is achieved, and the product percent of pass is remarkably increased.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of steering wheel detection, and more particularly, to a steering wheel switch detection device. BACKGROUND

[0002] As a key component in the automobile driving control system, the assembly quality of the steering wheel directly affects the operation safety and use comfort of the whole vehicle. At present, in the assembly process of the steering wheel assembly, especially the installation of the direction key assembly, manual operation is generally relied on. Although the traditional manual assembly method meets the basic production needs to a certain extent, with the increasing requirements of the automobile manufacturing industry on product quality, production efficiency and intelligent level, its disadvantages are increasingly apparent.

[0003] Firstly, manual assembly lacks unified operation standards and is easily affected by the skill level and working state of the operator, resulting in unstable assembly quality and poor product consistency. Especially in the flexible production mode of multiple varieties and small batches, the operator needs to frequently switch the assembly objects, which is prone to cause quality problems such as misassembly and missing assembly, and seriously affects the factory qualified rate of the product.

[0004] Secondly, there is a lack of effective error-proofing mechanism in the current steering wheel key assembly process. For example, in the material taking and assembly links, different models or specifications of switch assemblies are easily confused, leading to incorrect installation. At the same time, due to the lack of automatic detection means, problems such as missing screws, position deviation and key function failure cannot be immediately found after assembly, and can only be found in the subsequent quality inspection stage, resulting in increased rework cost and affecting the overall production rhythm.

[0005] In addition, the existing assembly process usually does not have data recording and product traceability capability, and cannot effectively track the assembly process of each steering wheel assembly. Once a quality accident occurs, it is difficult to quickly locate the root cause of the problem, and is not conducive to subsequent quality improvement and responsibility tracing. In the face of the current development trend of intelligent manufacturing, the traditional assembly method has been difficult to meet the higher requirements of modern automobile manufacturing on informatization, digitization and automation.

[0006] Therefore, there is an urgent need for a steering wheel key assembly tool with reasonable structure, high function integration, multiple detection and error-proofing functions, to improve assembly efficiency, ensure assembly quality, and realize data management and product traceability in the assembly process, and promote the development of steering wheel assembly towards automation and intelligence. SUMMARY

[0007] Therefore, the purpose of the present application is to provide a steering wheel detection device, which realizes omnidirectional and automatic quality control of the steering wheel switch assembly process, and significantly improves the product qualified rate.

[0008] To achieve the above object, the present application provides the following technical solutions:

[0009] A steering wheel switch detection device, comprising:

[0010] A frame body having a workbench and a mounting component, the mounting component being provided with a display screen and an electric control box;

[0011] A base disposed on the workbench, the base being provided with a support component for placing a steering wheel;

[0012] A detection unit comprising a material code scanning and recognition module, a product code scanning and tracing module, a screw counting module, and a switch function detection module, the detection unit being configured to generate corresponding detection signals;

[0013] A control system electrically connected to the detection unit and the electric control box, configured to receive and process the detection signals, control the assembly process based on a preset assembly operation sequence and logic, realize process confirmation and error-proofing through detection signals and / or operator confirmation, and output alarm information when an abnormality is detected.

[0014] The present application further provides that the support component comprises at least three support legs arranged around the planned position of the steering wheel, and the support legs are provided with step portions for stabilizing the falling of the steering wheel and accurately positioning the steering wheel.

[0015] The present application further provides that the material code scanning and recognition module is adapted to identify the type and specification of the parts to be assembled by scanning a two-dimensional code, an RFID tag, or other optical identification codes, and to compare and verify the information with the current production work order information, and only when the verification matches, the parts are allowed to enter the subsequent assembly process;

[0016] The product code scanning and tracing module is adapted to generate a unique product serial number for the steering wheel after assembly is completed, and bind the serial number with the material information, key process parameters, operator information, and detection results of each module during the assembly process, and upload the data to a manufacturing execution system.

[0017] The present application further provides that the screw counting module comprises an image recognition device, which is configured to analyze the images of a specified area, count the number of visible screws in the assembly process in real time, and determine whether the positions of the screws are correct.

[0018] The present application further provides that the switch function detection module is configured to apply a preset small current or voltage excitation signal to the specified contact of the switch, and to detect in real time whether the conduction state, resistance value, voltage drop, or signal output waveform of the switch is within the preset qualified parameter range, so as to determine whether the electrical function of the switch key is effective.

[0019] The control system further realizes the missing process error-proofing function, which includes:

[0020] A plurality of key assembly confirmation steps are set, and the completion state of the confirmation steps is achieved by receiving a specific signal from the detection unit and a confirmation input of an operator on the display screen; before receiving a valid confirmation signal of the completion of the current process, the control system will prevent entering the next process operation, and can issue a prompt and a warning through the display screen and the sound and light assembly.

[0021] The control system further includes:

[0022] A data acquisition and processing module is configured to acquire, analyze and store various detection signals and process parameters in real time from the detection unit;

[0023] A process control and logic arbitration module is configured to control the sequential execution of assembly steps, process inter-process and condition judgment, and realize the missing process error-proofing logic according to the preset assembly operation program and logic rules;

[0024] A human-computer interaction management module is responsible for managing the graphical user interface of the display screen, displaying operation guidance, real-time state, detection results, alarm information, and receiving instructions of an operator through a touch screen or an external input device;

[0025] An operation guidance and information presentation module is coupled to the human-computer interaction management module and is configured to dynamically display the graphic steps of the standard operation instruction book, model schematic diagram, key parameter highlight prompt, real-time video feed related to the current operation, teaching video clips or images containing correct and incorrect cases on the display screen, so as to guide and standardize the assembly and detection behavior of the operator; and

[0026] A communication interface module is configured to realize data exchange and instruction communication between the control system and an upper management system.

[0027] The device further integrates a screw tightening torque and angle monitoring module, which is linked with an electric or pneumatic tightening tool, can monitor and record the tightening torque value of each key screw in real time, and compare it with the preset upper and lower limit standard value, and immediately alarm and record the tightening operation that exceeds the qualified range.

[0028] The display screen is a touch industrial tablet computer, which is configured to display the current production order information, standard operation instruction book, running state and detailed detection result data of each detection module, and specific content, location and suggested treatment scheme of abnormal alarm in real time;

[0029] The abnormal alarm information at least includes a visual warning on the display screen and a sound alarm emitted by an independent sound and light alarm, and the control system can automatically lock the device operation or the current workpiece to prevent unqualified products from flowing into the subsequent process when detecting the preset serious assembly error or quality defect.

[0030] Compared with the deficiencies of the prior art, the beneficial effects of the present application are:

[0031] By integrating multiple detection modules such as material code scanning identification, screw counting, switch function detection, and screw tightening torque and angle monitoring, the steering wheel switch assembly process is realized. Full range, automatic quality control, significantly improves product qualification rate; especially important is that the missing process error proofing function set by the control system can monitor and ensure the completion of key assembly steps in real time, fundamentally eliminating omissions and errors in the assembly process, greatly improving the reliability of the production process.

[0032] The device not only can accurately detect the key assembly steps of the steering wheel switch, but also through the product code scanning traceability module, realizes the complete collection, binding and uploading of product data from material to assembly process, and builds an efficient and accurate product traceability system. At the same time, through the man-machine interaction management and operation guidance module, it provides clear and real-time operation guidance and information feedback for operators, improves the manageability and informatization level of the production process. BRIEF DESCRIPTION OF DRAWINGS

[0033] Fig. 1 is a schematic diagram of the three-dimensional structure of the present application;

[0034] Fig. 2 is a schematic diagram of the detection process of the present application;

[0035] Fig. 3 is a schematic diagram of the module of the present application. DETAILED DESCRIPTION

[0036] Reference Figs. 1 to 3 Further description of an embodiment of the steering wheel switch detection device of the present application, including: frame, detection unit and control system.

[0037] Frame: provide support and working space for the whole device, its main components include:

[0038] Workbench: provide a stable platform for placing steering wheel and related detection units.

[0039] Mounting components: fixed on the frame, used for mounting display screen and electric control box.

[0040] Display screen: installed above the mounting component, serving as the human-machine interface, using a touch industrial tablet computer to clearly display information such as operation guidance, real-time status, and test results.

[0041] Electric control box: installed on the side of the mounting component, used to house the mainboard, power module, driver, and terminal of the control system.

[0042] Base: placed on the workbench, used to place the steering wheel to be tested. The support component is located on the base and is used to support and accurately position the steering wheel. The support component includes at least three support legs arranged around the planned position of the steering wheel. The support legs are designed to be adjustable to accommodate different sizes of steering wheels. The support legs are provided with a stepped portion, and the size and angle of the stepped portion are optimized to guide the stable falling of the steering wheel and achieve accurate horizontal and rotational positioning, ensuring the accuracy of subsequent testing.

[0043] Detection unit:

[0044] Material code scanning and recognition module: used to identify the type and specification of the parts to be assembled and compare and verify with the current production work order information. This module uses an industrial-grade code scanning gun or image recognition camera to scan the two-dimensional code, RFID tag, or other optical identification code attached to the parts to be assembled. The scanned information (such as part number, batch number, supplier information, etc.) is transmitted to the control system through the communication interface. After receiving the part information, the control system compares it with the list of parts to be assembled specified in the current production work order. The comparison includes part type, specification, and model. Only when the scanned part information matches the work order information, the control system will allow the part to proceed to the subsequent assembly process. If it does not match, an alarm will be issued to prevent the operator from assembling.

[0045] Product code scanning and tracing module: used to generate a unique traceable information for the steering wheel after assembly. After the steering wheel completes all assembly and testing procedures, the control system will automatically generate a unique product serial number. The serial number can be generated according to pre-set rules, such as combining date, batch, and serial number.

[0046] Data binding and uploading: this module binds all key data collected during the assembly process, including: part information obtained by the material code scanning and recognition module, completion status and timestamp of key procedures, counting results of the screw counting module, detection results (conduction state, resistance value, etc.) of the switch function detection module, tightening parameters of the screw tightening torque and angle monitoring module, and operator information for performing the assembly operation. These data will be bound to the generated product serial number. Then, through the communication interface, these traceable data will be uploaded to the manufacturing execution system (MES), realizing the whole life cycle traceability of the product.

[0047] Screw Counting Module: This module is used to count the number of visible screws during assembly and determine their positions. The core of this module is an image recognition device, which uses a high-resolution industrial camera in combination with appropriate lighting (such as a ring light or a bar light). The camera is fixed above or to the side of the device, allowing it to clearly capture images of specific areas of the steering wheel.

[0048] The specific steps of the image analysis algorithm based on computer vision are as follows:

[0049] Image Acquisition: The industrial camera captures images of the area to be detected.

[0050] Preprocessing: Perform preprocessing operations such as noise reduction and grayscale conversion on the image to enhance image quality.

[0051] Feature Extraction: Use edge detection, morphological operations, or feature point detection algorithms (such as SIFT, SURF) to extract features of screws in the image.

[0052] Template Matching or Object Detection: Match the extracted features with pre-set screw templates, or use deep learning-based object detection algorithms (such as YOLOv5, FasterR-CNN) to detect screws in the image. Count the number of recognized screws, and for each recognized screw, calculate its pixel coordinates in the image and convert them to world coordinates through camera calibration data. Compare the actual position with the pre-set correct screw position to determine whether the screw position is correct. The module outputs the number and position information of the recognized screws. If the number is incorrect or the position deviates beyond the pre-set threshold, an abnormal signal is generated.

[0053] Switch Function Detection Module: This module is used to determine whether the electrical function of the switch on the steering wheel is effective. The module applies a pre-set small current or voltage excitation signal to the specified contacts of the switch to be detected through a dedicated electrical signal generator. The parameters of the excitation signal (voltage value, current value, waveform, frequency, etc.) are set according to the characteristics of different switches, such as applying a 5V DC voltage or a 1mA current pulse.

[0054] The module's electrical signal acquisition device detects the switch's response in real time:

[0055] Conduction State: Detect whether the contacts are normally closed or open to determine whether they are conducting or insulated.

[0056] Resistance Value: Measure the loop resistance value when the switch is closed to determine whether the contact is good. For example, the acceptable resistance value range may be 0-5 Ohms.

[0057] Voltage Drop: Measure the voltage drop across the switch when a current is applied, which indirectly reflects its internal resistance.

[0058] Signal output waveform: For switches with complex output signals (such as digital signals or PWM signals), collect and analyze the output waveform to determine whether the waveform shape, amplitude, frequency, and duty cycle meet the specifications.

[0059] Pass judgment: Compare the collected detection parameters with the pre-set qualified parameter range. For example, if the resistance value is higher than 5 Ohms when the switch is closed, it is judged as unqualified. Only when all detection parameters are within the qualified range, the switch function is judged as effective.

[0060] Screw tightening torque and angle monitoring module: used to monitor the tightening process of key screws. This module is linked with a dedicated electric or pneumatic tightening tool. The tightening tool has a built-in high-precision torque sensor and angle sensor. During the tightening process, the sensor measures and records the tightening torque value and tightening angle value of each key screw in real time. These data are transmitted to the control system through a communication interface (such as Ethernet or fieldbus).

[0061] After receiving the tightening data, the control system compares it with the pre-set upper and lower limit standard values. For example, the qualified torque range of a certain screw may be 1.8 Nm ± 0.2 Nm, and the qualified angle range is 90° ± 10°. If the tightening torque or angle exceeds the qualified range, the control system will immediately trigger an immediate alarm (audible and visual alarm or display screen prompt) and record the detailed information of the abnormal tightening operation (screw position, measured torque, measured angle, time of occurrence, etc.).

[0062] Control system: responsible for receiving and processing detection signals, controlling assembly process, implementing error-proofing and exception handling.

[0063] The control system usually adopts an architecture of industrial programmable logic controller (PLC) combined with industrial computer (IPC) to ensure the stability and flexibility of the system, which includes:

[0064] Data acquisition and processing module: responsible for real-time acquisition of various detection signals, process parameters (such as tightening torque / angle, switch resistance value, etc.), and sensor status signals from all detection units (material scanning code recognition module, product scanning code traceability module, screw counting module, switch function detection module, screw tightening torque and angle monitoring module).

[0065] Data analysis and storage: analyze the collected raw signals and convert them into meaningful data formats. For example, parse the string output by the scanning code gun into part information, and convert the analog signal into digital value. Store the parsed data, which can be stored in local database, file system or uploaded to upper management system through network. The stored data includes real-time data, historical data, and exception records.

[0066] Flow control and logic arbitration module: According to the pre-set assembly operation program and logic rules, control the sequential execution of the entire assembly detection process.

[0067] Step execution and judgment: According to the steps set in the SOP, activate the corresponding detection unit or control the external execution mechanism (such as mechanical arm, clamp, etc., if the equipment is integrated) in turn. Before or at the completion of each process, inter-process and conditional judgment is carried out. For example, whether the material scanning code is passed, whether the number of screws is correct, whether the switch function is qualified, etc.

[0068] Missed process error prevention logic: By setting multiple key assembly confirmation steps. The completion status of these confirmation steps is achieved through the following ways:

[0069] Receive specific signals: Receive specific signals from detection units. For example, the screw counting module reports the correct screw quantity signal, and the switch function detection module reports the switch function qualified signal.

[0070] Operator confirmation input: Receive the operator's confirmation input on the display screen. For example, after the operator completes a certain manual operation, click the "confirm" button on the screen. Before receiving a valid confirmation signal that the current process is completed, the control system will prevent the next process operation. This means that the subsequent detection unit or execution mechanism will not be activated. At the same time, prompts and warnings can be issued through the display screen and sound-light components to remind the operator that the current process is not completed or there is an abnormality.

[0071] Human-computer interaction management module: Responsible for managing the graphical user interface of the display screen.

[0072] Information display: Real-time display of current production order information (product model, batch number, planned production quantity, etc.), graphical and textual steps of standard operating procedures (SOP), model schematic diagram, key parameter highlight prompt, etc., running status of each detection module (whether it is detecting, whether it is detecting, etc.) and detailed detection result data (for example, tightening torque value, switch resistance value, etc.). Specific content of abnormal alarm, location and suggested treatment plan.

[0073] Instruction receiving: Receive the instructions input by the operator through the touch screen or external input devices (such as keyboard, mouse), such as starting / stopping operation, selecting order, confirming operation, etc.

[0074] Operation guidance and information presentation module: Coupled with the human-computer interaction management module, used to dynamically present operation guidance information in various forms on the display screen. The presentation content includes:

[0075] Standard operating procedures (SOP): Display standard operation steps in the form of pictures and text, including text description, schematic diagram, exploded view, etc.

[0076] Model Schematic Diagram: A dynamic model of the steering wheel or component helps operators understand the assembly structure and key positions.

[0077] Key Parameter Highlight: In the job guide or test results, key parameters such as tightening torque values and acceptable ranges are highlighted to remind operators to pay attention.

[0078] Real-time Video Feed: If the device is integrated with a surveillance camera, a real-time video of the work area can be displayed to help operators confirm the operation process.

[0079] Teaching Video Clips or Images: Provide short videos or images that compare correct and incorrect cases to visually guide operators on how to correctly assemble and test, avoiding common mistakes.

[0080] Communication Interface Module: Used to exchange data and communicate instructions between the control system and the upper management system (such as MES, ERP, SCADA system).

[0081] Communication Protocol: Supports multiple industrial communication protocols such as Ethernet / IP, Profinet, ModbusTCP, OPCUA, etc.

[0082] Data Exchange: Upload production data, quality data, device status information, alarm records, etc. to the upper system. Receive production orders, process parameters, software update instructions, etc. issued by the upper system.

[0083] Exceptional Alarm: When the device detects an exception, the control system will output an alarm message. Display the alarm message in a prominent way (such as red background, flashing text, pop-up window) on the display screen, including exception type, location, specific reason and suggested treatment plan. A separate audible and visual alarm is installed in a prominent location on the device, emitting a high-decibel sound alarm and flashing lights to alert operators or managers, and automatically locking the device / workpiece: When detecting a preset serious assembly error or quality defect (for example, key screws are not tightened, safety airbag switch function is abnormal), the control system can automatically lock the device operation (stop subsequent processes) or lock the current workpiece (marked as unqualified, preventing it from flowing out). This effectively prevents unqualified products from flowing into subsequent processes, ensuring product quality.

[0084] The above only describes the preferred embodiments of the present application and does not limit the present application. Those skilled in the art can make usual changes and replacements within the scope of the technical solutions of the present application, which should be included in the protection scope of the present application.

Claims

1. A steering wheel switch detection device, characterized in that: include: The frame has a work surface and a mounting component, wherein a display screen and an electric control box are mounted on the mounting component; A base is placed on the work surface, and the base has a supporting component for placing the steering wheel; The detection unit includes a material code scanning and identification module, a product code scanning and tracing module, a screw counting module, and a switch function detection module. The detection unit is used to generate corresponding detection signals; A control system is electrically connected to the detection unit and the electrical control box, and is used to receive and process the detection signal, control the assembly process based on a preset assembly operation sequence and logic, realize process confirmation and process omission prevention through detection signals and / or operator confirmation, and output alarm information when an abnormality is detected.

2. A steering wheel switch detection device according to claim 1, characterized in that: The support component includes at least three support feet arranged around the planned position of the steering wheel, and the support feet are provided with step portions for the steering wheel to fall stably and be accurately positioned.

3. The steering wheel switch detection device according to claim 2, characterized in that: The material code scanning and identification module is suitable for identifying the type and specifications of the parts to be assembled by scanning QR codes, RFID tags or other optical identification codes, and comparing and verifying them with the current production work order information. Only when the verification matches, the parts are allowed to enter the subsequent assembly process; The product code scanning and tracing module is suitable for generating a unique product serial number for the steering wheel after it is assembled, and binding the serial number with data such as material information, key process parameters, operator information and test results of each module in the assembly process, and uploading it to the manufacturing execution system.

4. A steering wheel switch detection device according to claim 3, characterized in that: The screw counting module includes an image recognition device; the image recognition device analyzes the image of a specified area to perform real-time statistics on the number of screws visible during the assembly process and determine whether their positions are correct.

5. The steering wheel switch detection device according to claim 4, characterized in that: The switch function detection module applies a preset small current or voltage excitation signal to the specified contact of the switch, and detects in real time whether its conduction state, resistance value, voltage drop or signal output waveform is within the preset qualified parameter range to determine whether the electrical function of the switch button is valid.

6. The steering wheel switch detection device according to claim 5, characterized in that: The control system implements the following error-proofing functions: Multiple key assembly confirmation steps are set, and the completion status of the confirmation steps is determined by receiving specific signals from the detection unit and the operator's confirmation input on the display screen; before receiving a valid confirmation signal that the current process is completed, the control system will prevent entry into the next process operation and can issue prompts and warnings through the display screen and sound and light components.

7. The steering wheel switch detection device according to claim 1, characterized in that: The control system includes: A data acquisition and processing module, used to collect, analyze and store various detection signals and process parameters from the detection unit in real time; The process control and logic arbitration module is used to control the sequential execution of assembly steps, perform inter-process and conditional judgments, and implement error-proofing logic for missed processes based on preset assembly procedures and logic rules; A human-computer interaction management module is responsible for managing the graphical user interface of the display screen, displaying operation instructions, real-time status, test results, alarm information, and receiving instructions from the operator through the touch screen or external input device; an operation guidance and information presentation module, coupled to the human-computer interaction management module, for dynamically displaying on the display screen graphic steps of the standard operation instructions, model schematics, key parameter highlighting prompts, real-time video feeds related to the current operation, and instructional video clips or images containing comparisons of correct and incorrect cases, so as to guide and standardize the operator's assembly and inspection behaviors; and The communication interface module is used to realize data exchange and command communication between the control system and the upper management system.

8. The steering wheel switch detection device according to claim 1, characterized in that: The device also integrates a screw tightening torque and angle monitoring module, which is linked to the electric or pneumatic tightening tool. It can monitor and record the tightening torque value of each key screw in real time, and compare it with the preset upper and lower limit standard values. It will immediately alarm and record the tightening operation that exceeds the qualified range.

9. The steering wheel switch detection device according to claim 1, characterized in that: The display screen is a touch-screen industrial tablet computer that displays in real time the current production work order information, standard operating instructions, the operating status of each detection module and detailed detection result data, as well as the specific content of abnormal alarms, the location of occurrence, and the recommended treatment plan; The abnormal alarm information includes at least a visual warning on the display screen and an audible alarm issued by an independent sound and light alarm, and when the control system detects a preset serious assembly error or quality defect, it can automatically lock the equipment operation or the current workpiece to prevent unqualified products from flowing into subsequent processes.

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