Water heater inner container bolt and rubber mat self-adaptive installation system and installation method

Abstract

The invention discloses a water heater inner container bolt and rubber mat self-adaptive mounting system and method.The mounting system comprises an automatic bolt feeding module, an automatic rubber mat feeding module, a profiling arm self-adaptive robot and a visual system; the automatic bolt feeding module and the automatic rubber mat feeding module are installed on one side of the profiling arm self-adaptive robot side by side, and a clamp is installed on a rotating shaft at the tail end of the profiling arm self-adaptive robot. The visual system is a 3D AI visual system and is installed on one side of a clamp at the tail end of the profiling arm self-adaption robot. According to the water heater inner container bolt and rubber mat self-adaptive installation method, the installation system is utilized, the model of an inner container opening is recognized through the visual system, and according to the recognition result, the automatic bolt feeding module and the automatic rubber mat feeding module are controlled to achieve automatic material model switching and matched feeding; and automatic matching, remodeling and mounting of the clamping jaws are automatically achieved, bolts and rubber mats of corresponding models are grabbed for mounting, and the effects of improving efficiency, reducing cost and reducing labor intensity are achieved.

Description

Technical Field

[0001] This invention belongs to the field of water heater inner tank component installation, specifically, it relates to a self-adaptive installation system and method for water heater inner tank bolts and gaskets. Background Technology

[0002] Because the inner tank of a water heater is sintered at high temperature using an enamel process, it is prone to problems such as unevenness at the tank opening, uneven enamel powder, deformation of the tank opening, and inability to effectively identify bolt holes. Therefore, ordinary robotic technology cannot achieve automatic installation of the tank opening bolts and gaskets, and manual installation is required, resulting in high labor intensity, high labor costs, and low efficiency.

[0003] In view of this, the present invention is proposed. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide an adaptive installation system for the inner tank bolts and rubber gaskets of a water heater, which can adaptively match and install the inner tank bolts and rubber gaskets, thereby reducing labor intensity, lowering costs and improving efficiency.

[0005] The second objective of this invention is to provide an adaptive installation method for the bolts and gaskets of the inner tank of a water heater.

[0006] To solve the above-mentioned technical problems, the basic concept of the technical solution adopted by the present invention is as follows:

[0007] The adaptive installation system for water heater inner tank bolts and gaskets includes an automatic bolt feeding module, an automatic gasket feeding module, a contoured adaptive robot arm, and a vision system. The automatic bolt feeding module and the automatic gasket feeding module are installed side by side on one side of the contoured adaptive robot arm. The contoured adaptive robot arm has a gripper mounted on its end-effector. The vision system is a 3D AI vision system, installed on one side of the gripper at the end of the contoured adaptive robot arm.

[0008] On the production line, after the inner tank of the water heater is completed in the previous process, it is transferred to the gasket and bolt installation station. The contour-following adaptive robot adaptively picks up and installs the gasket and bolt that are suitable for the characteristics of the inner tank opening, and installs the gasket and bolt in the inner tank opening. The gasket is fixed by the bolt.

[0009] Because there are various models of water heater inner tanks, in order to make full use of the production line and improve production efficiency, multiple models of inner tanks will be produced on the same production line. Different models of inner tanks have different numbers of bolt holes on the tank opening. Some models of inner tanks have 5 bolt holes on the tank opening, some models have 4 bolt holes on the tank opening, and some models have other numbers of bolt holes on the tank opening. Correspondingly, the shape of the rubber gasket installed on the tank opening is also different.

[0010] To accommodate different models of inner tanks, an adaptive installation system for water heater inner tank bolts and gaskets is implemented. This system includes an automatic bolt feeding module, an automatic gasket feeding module, a contour-following adaptive robot, and a vision system. When the inner tank reaches the gasket and bolt installation station, the vision system first identifies the type of the inner tank opening and the number of bolt holes. Upon successful identification, the information is fed into the control system of the clamp at the end of the contour-following adaptive robot and the automatic bolt and gasket feeding modules. The control system then controls the automatic bolt and gasket feeding modules to automatically switch and match the material types to provide bolts and gaskets suitable for the inner tank opening. After the type matching is complete, the clamp at the end of the contour-following adaptive robot automatically and quickly changes type to match the corresponding bolts and gaskets. The clamp picks up the corresponding bolts and gaskets and installs them at the inner tank opening.

[0011] To address the issue that ordinary robots cannot effectively identify bolt holes in water heater inner tanks after high-temperature sintering via enamel enamel processing, and thus cannot effectively install bolts and gaskets due to unevenness at the tank opening, uneven enamel powder, and deformation of the tank opening, this invention employs a 3D AI vision system installed on the gripper side of the end effector of a contour-following adaptive robot. This 3D AI vision system can effectively identify bolt holes in the inner tank opening, thereby efficiently installing bolts and gaskets.

[0012] Furthermore, the vision system includes a light source and a camera. The light source is a ring light; the camera is located above the light source, both are fixed relative to each other, and its lens is directly facing the central through-hole of the ring light.

[0013] In order to effectively identify the bolt holes of the inner liner, the light source in the vision system is a ring light, which provides a wide range of high-brightness illumination for the camera to take pictures. The camera is located above the light source, and the two are relatively fixed with the lens facing the central through hole of the ring light. Taking pictures through the central through hole of the ring light can more clearly identify the bolt holes around the inner liner.

[0014] Furthermore, the vision system and the gripper are mounted on the same axis at the end of the bionic arm adaptive robot, with the vision system located on one side above the gripper.

[0015] To facilitate the vision system's imaging and identification of the inner liner opening, while also ensuring convenient gripping of bolts and gaskets by the fixture, the vision system and fixture are mounted on the same axis at the end effector of the contouring robot. The vision system is positioned on one side above the fixture. The fixture and the end effector's axis are coaxially aligned, while the vision system is eccentrically aligned with the end effector's axis. This arrangement ensures that the vision system's imaging and identification are not obstructed by the fixture, while also guaranteeing the fixture's movement accuracy. This results in higher efficiency and accuracy in installing gaskets and bolts.

[0016] Furthermore, the fixture includes a gripper cylinder and a gripper. The upper end of the gripper cylinder is connected to the end effector of the contouring arm adaptive robot, and the lower end of the gripper cylinder is connected to the gripper. The gripper can be automatically replaced as needed.

[0017] Since different models of inner liner have different numbers of bolt holes at the liner opening, the shape of the rubber gasket installed at the liner opening is also different. Consequently, the grippers of the clamps required to grasp the bolts and rubber gaskets are also different. In order to adaptively install the rubber gaskets and bolts according to the type of inner liner opening without manual intervention and operation, in this invention, the clamp includes a gripper cylinder and grippers. Through the action of the gripper cylinder, the clamp that does not match the rubber gasket and bolt required by the inner liner opening can be automatically removed, and then the clamp that matches the rubber gasket and bolt required by the inner liner opening can be automatically replaced.

[0018] Furthermore, the adaptive installation system for the water heater inner tank bolts and gaskets of the present invention also includes a clamping jaw stand, on which clamping jaws corresponding to various inner tank port models are placed.

[0019] Since the appropriate clamps need to be installed according to the model of the inner liner opening, and there are many models of inner liner openings to be processed on the same production line, a clamp spare table is needed to store clamps corresponding to various models of inner liner openings, so that the appropriate clamps can be installed when needed.

[0020] Furthermore, the gripper spare table, the automatic bolt feeding module, and the automatic rubber pad feeding module are located on the same side of the contouring arm adaptive robot.

[0021] In order not to hinder the operation of the inner liner on the production line and to facilitate the changing of grippers on the adaptive robot of the contouring arm, the gripper spare table, the automatic bolt feeding module, and the automatic rubber pad feeding module are located on the same side of the adaptive robot of the contouring arm.

[0022] Furthermore, the contour-following adaptive robot can perform seven-axis motion, enabling it to grasp and install bolts and gaskets with higher precision.

[0023] The present invention also provides an adaptive installation method for water heater inner tank bolts and rubber gaskets. Using the above-mentioned adaptive installation system for water heater inner tank bolts and rubber gaskets, the model of the inner tank opening is identified and determined by a vision system. Based on the identification result, the automatic bolt feeding module and the automatic rubber gasket feeding module are controlled to realize automatic switching and matching of material models for feeding. The clamps in the fixture are automatically matched and changed for installation, picking up the corresponding bolts and rubber gaskets and installing them at the inner tank opening.

[0024] Furthermore, by using the 3D AI vision of the vision system, the number of bolts at the inner liner can be determined by taking a picture, which also enables the identification and determination of the model of the inner liner.

[0025] By adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art.

[0026] This invention relates to an adaptive installation system and method for water heater inner tank bolts and gaskets. The installation system includes an automatic bolt feeding module, an automatic gasket feeding module, a contour-following adaptive robot arm, and a vision system. The automatic bolt feeding module and the automatic gasket feeding module are installed side-by-side on one side of the contour-following adaptive robot arm, which has a gripper mounted on its end effector. The vision system is a 3D AI vision system, installed on one side of the gripper at the end effector of the contour-following adaptive robot arm. The method for adaptive installation of water heater inner tank bolts and gaskets...

[0027] This invention utilizes the aforementioned adaptive installation system for water heater inner tank bolts and gaskets. A vision system identifies the model of the inner tank opening. Based on the identification result, the system controls the automatic bolt feeding module and the automatic gasket feeding module to automatically switch and match the material models during feeding. It also automatically matches and changes the clamping jaws in the fixture, picking up the corresponding bolts and gaskets and installing them at the inner tank opening. By employing a 3D AI vision system, the bolt holes at the inner tank opening can be identified more effectively. Combined with the adaptive clamping jaws, this achieves automatic identification, automatic replacement, and automatic gripping and installation, greatly improving installation efficiency, reducing costs, and decreasing the number of installation personnel, thereby reducing labor intensity.

[0028] The specific embodiments of the present invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0029] The accompanying drawings, as part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments and descriptions of the invention are used to explain the invention, but do not constitute an undue limitation of the invention. Obviously, the drawings described below are merely some embodiments, and those skilled in the art can obtain other drawings based on these drawings without creative effort. In the drawings:

[0030] Figure 1 This is a schematic diagram of the self-adaptive installation system for the inner tank bolts and rubber gaskets of the water heater of the present invention;

[0031] Figure 2 This is a schematic diagram of the gripper and vision system at the end of the adaptive robot arm in the adaptive installation system of the water heater inner tank bolts and gaskets of the present invention.

[0032] In the diagram: 1. Automatic bolt feeding module; 2. Automatic rubber pad feeding module; 3. Contouring arm adaptive robot; 4. 3D AI vision system; 41. Camera; 42. Light source; 5. Fixture; 51. Gripper cylinder; 52. Gripper.

[0033] It should be noted that these accompanying drawings and textual descriptions are not intended to limit the scope of the invention in any way, but rather to illustrate the concept of the invention to those skilled in the art by referring to specific embodiments. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0035] In the description of this invention, it should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0036] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0037] Combination Figures 1 to 2 As shown, the adaptive installation system for the inner tank bolts and rubber gaskets of the water heater of the present invention includes an automatic bolt feeding module 1, an automatic rubber gasket feeding module 2, a contour-following adaptive robot 3, and a vision system; the automatic bolt feeding module 1 and the automatic rubber gasket feeding module 2 are installed side by side on one side of the contour-following adaptive robot 3; a clamp 5 is installed on the end shaft of the contour-following adaptive robot 3; the vision system is a 3D AI vision system 4, which is installed on one side of the clamp 5 at the end of the contour-following adaptive robot 3.

[0038] The contour-following adaptive robot 3 can perform seven-axis motion, enabling it to grasp and install bolts and gaskets with higher precision. It also makes it easier to adjust the position and angle of the vision system to photograph and identify the bolt holes at the inner liner opening.

[0039] On the production line, after the water heater's inner tank is completed in the previous process, it is conveyed to the gasket and bolt installation station. A contour-following adaptive robot 3 adaptively picks up and installs the gaskets and bolts suitable for the inner tank's opening characteristics, securing them with the bolts. Because there are various models of water heater inner tanks, to fully utilize the production line and improve efficiency, multiple models of inner tanks are produced on the same line. Different models of inner tanks have different numbers of bolt holes at the opening; some models have 5 bolt holes, some have 4, and some have other numbers. Correspondingly, the shape of the gasket installed at the inner tank opening also differs.

[0040] To accommodate different models of inner tanks, an adaptive installation system for water heater inner tank bolts and gaskets is implemented. This system includes an automatic bolt feeding module 1, an automatic gasket feeding module 2, a contour-following adaptive robot arm 3, and a vision system. When the inner tank reaches the gasket and bolt installation station, the vision system first identifies the type of the inner tank opening and the number of bolt holes. Upon successful identification, the system connects the identification information to the gripper 5 at the end of the contour-following adaptive robot arm 3 and the control systems of the automatic bolt feeding module 1 and the automatic gasket feeding module 2. The control system then controls the automatic bolt feeding module 1 and the automatic gasket feeding module 2 to automatically switch and match the material types to provide bolts and gaskets suitable for the inner tank opening. After the type matching is completed, the control system controls the gripper 5 at the end of the contour-following adaptive robot arm 3 to automatically and quickly change types to match the corresponding bolts and gaskets. The gripper 5 picks up the corresponding bolts and gaskets and installs them at the inner tank opening.

[0041] To address the issue that ordinary robots cannot effectively identify bolt holes in the inner tank after the water heater inner tank is sintered at high temperatures using the enamel process, due to unevenness at the tank opening, uneven enamel powder, and deformation of the tank opening, thus hindering the effective installation of bolts and gaskets, this invention employs a 3D AI vision system 4 installed on one side of the gripper 5 at the end of the contour-following adaptive robot 3. The 3D AI vision system 4 can effectively identify bolt holes in the inner tank opening, thereby efficiently installing bolts and gaskets.

[0042] In order to effectively identify the bolt holes of the inner liner, the light source 42 in the vision system is a ring lamp, which provides a wide range of high-brightness illumination for the camera 41 to take pictures. The camera 41 is located above the light source 42, and the two are relatively fixed with its lens facing the central through hole of the ring lamp. Taking pictures through the central through hole of the ring lamp can more clearly identify the bolt holes around the inner liner.

[0043] To facilitate the vision system's imaging and identification of the inner liner opening, and also to ensure convenient gripping of bolts and rubber gaskets by the clamp 5, the vision system and clamp 5 are mounted on the same rotating shaft at the end of the contouring arm adaptive robot 3. The vision system is located on one side above the clamp 5. The clamp 5 is coaxial with the rotating shaft at the end of the contouring arm adaptive robot 3, while the vision system is eccentrically positioned with the rotating shaft at the end of the contouring arm adaptive robot 3. This arrangement ensures that the vision system's imaging and identification are not obstructed by the clamp 5, and also ensures the movement accuracy of the clamp 5, resulting in higher installation efficiency and accuracy for the rubber gaskets and bolts.

[0044] Because different models of inner liner have different numbers of bolt holes at the liner opening, the shape of the rubber gasket installed at the liner opening also differs. Consequently, the gripper 52 of the clamp 5 required to grasp the bolts and rubber gasket also differs. In order to adaptively install the rubber gasket and bolt according to the type of inner liner opening without manual intervention, in this invention, the clamp 5 includes a gripper 52 cylinder 51 and a gripper 52. The lower end of the gripper 52 cylinder 51 is connected to the gripper 52 via a component. Through the action of the gripper 52 cylinder 51, the clamp 5 that does not match the rubber gasket and bolt required for the inner liner opening can be automatically removed, and then the clamp 5 that matches the rubber gasket and bolt required for the inner liner opening can be automatically replaced.

[0045] The adaptive installation system for the water heater inner tank bolts and gaskets of this invention also includes a clamping jaw stand, on which clamping jaws 52 corresponding to various inner tank opening models are placed. Since it is necessary to install the appropriate clamping jaws 52 according to the inner tank opening model, and a large number of inner tank opening models need to be processed and produced on the same production line, a clamping jaw stand is needed to store clamping jaws 52 corresponding to various inner tank opening models, so that the corresponding clamping jaws 52 can be replaced when needed.

[0046] In order not to hinder the operation of the inner liner on the production line and to facilitate the replacement of the gripper 52 on the contouring arm adaptive robot 3, the gripper spare table is located on the same side of the contouring arm adaptive robot 3 as the bolt automatic feeding module 1 and the rubber pad automatic feeding module 2.

[0047] This invention also provides an adaptive installation method for water heater inner tank bolts and gaskets. Utilizing the aforementioned adaptive installation system, the number of bolts at the inner tank opening is determined by the 3D AI vision system 4, which also identifies the model of the inner tank opening. Upon successful identification, the information is connected to the control system of the clamp 5 at the end of the contour-following adaptive robot 3, as well as the automatic bolt feeding module 1 and the automatic gasket feeding module 2. Based on the identification result, the control system automatically switches and matches the material models of the automatic bolt feeding module 1 and the automatic gasket feeding module 2 to provide bolts and gaskets suitable for the inner tank opening. The control system also automatically matches and installs the grippers 52 in the clamp 5, automatically removing unsuitable grippers 52 and installing suitable grippers 52 to pick up and install the corresponding bolts and gaskets at the inner tank opening.

[0048] This invention relates to an adaptive installation system and method for water heater inner tank bolts and gaskets. By combining front-end 3D AI vision imaging with a contour-following adaptive robot arm and rear-end automatic feeding modules for bolts and gaskets, a comprehensive adaptive installation system and technology for water heater inner tank bolts and gaskets under complex working conditions is established. This system achieves adaptive and automatic installation of water heater inner tank bolts and gaskets, replacing manual installation and achieving efficiency improvement and cost reduction. The adaptive installation method for water heater inner tank bolts and gaskets using this system is an intelligent adaptive assembly technology, offering significant advantages over ordinary industrial robot technology, improving efficiency and reducing costs, with a 100% increase in single-process efficiency.

[0049] This invention relates to an adaptive installation system and method for water heater inner tank bolts and gaskets. The installation system includes an automatic bolt feeding module, an automatic gasket feeding module, a contour-following adaptive robot, and a vision system. The automatic bolt feeding module and the automatic gasket feeding module are installed side-by-side on one side of the contour-following adaptive robot, which has a gripper mounted on its end-effector. The vision system is a 3D AI vision system, installed on the gripper side of the contour-following adaptive robot's end-effector. The adaptive installation method for water heater inner tank bolts and gaskets utilizes the aforementioned adaptive installation system. The vision system identifies and determines the model of the inner tank opening. Based on the identification result, the automatic bolt feeding module and the automatic gasket feeding module automatically switch and match the material model for feeding. The gripper in the fixture automatically matches and changes its type, picking up the corresponding bolts and gaskets and installing them at the inner tank opening. By adopting a 3D AI vision system, the bolt holes of the inner liner can be identified more effectively. Combined with an adaptive gripper, it can achieve adaptive installation with automatic identification, automatic replacement, and automatic gripping. This greatly improves installation efficiency, reduces costs, and reduces the number of installers, thereby reducing the labor intensity of personnel.

[0050] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-described technical content to create equivalent embodiments without departing from the scope of the present invention. The implementation schemes in the above embodiments can also be further combined or replaced. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A self-adaptive installation system for bolts and rubber gaskets in the inner tank of a water heater, characterized in that: This includes an automatic bolt feeding module, an automatic rubber pad feeding module, a contour-following adaptive robot arm, and a vision system; The automatic bolt feeding module and the automatic rubber pad feeding module are installed side by side on one side of the contour-following adaptive robot arm. A contour-following adaptive robot with a gripper mounted on its end effector. The vision system is a 3D AI vision system, installed on one side of the gripper at the end of the contoured adaptive robot arm.

2. The self-adaptive installation system for the water heater inner tank bolts and rubber gaskets according to claim 1, characterized in that: Vision systems, including light sources and cameras, The light source is a ring lamp. The camera is positioned above the light source, with both fixed relative to each other, and its lens is directly facing the central through-hole of the ring light.

3. The self-adaptive installation system for the water heater inner tank bolts and gaskets according to claim 2, characterized in that: The vision system and the gripper are mounted on the same axis at the end of the contoured adaptive robot arm, with the vision system located on one side above the gripper.

4. The self-adaptive installation system for the water heater inner tank bolts and rubber gaskets according to claim 3, characterized in that: The fixture includes a gripper cylinder and a gripper. The upper end of the gripper cylinder is connected to the end-effector of the adaptive robot, and the lower end of the gripper cylinder is connected to the gripper.

5. The self-adaptive installation system for the water heater inner tank bolts and rubber gaskets according to claim 4, characterized in that: The grippers can be automatically replaced as needed.

6. The self-adaptive installation system for the water heater inner tank bolts and rubber gaskets according to claim 5, characterized in that: It also includes a spare gripper table, which has grippers that correspond to various inner liner port models.

7. The self-adaptive installation system for the water heater inner tank bolts and rubber gaskets according to claim 6, characterized in that: The gripper spare table, the automatic bolt feeding module, and the automatic rubber pad feeding module are located on the same side of the contouring arm adaptive robot.

8. The self-adaptive installation system for the water heater inner tank bolts and rubber gaskets according to claim 7, characterized in that: The biomimetic arm adaptive robot can perform seven-axis movements.

9. A self-adaptive installation method for bolts and rubber gaskets in the inner tank of a water heater, characterized in that: Using the adaptive installation system for water heater inner tank bolts and gaskets as described in any one of claims 1-8, the model of the inner tank opening is identified and determined by the vision system. Based on the identification result, the automatic bolt feeding module and the automatic gasket feeding module are controlled to automatically switch and match the material model for feeding. The clamps in the fixture are automatically matched and installed to pick up the corresponding bolts and gaskets and install them at the inner tank opening.

10. The self-adaptive installation method for the inner tank bolts and rubber gaskets of a water heater according to claim 9, characterized in that: The number of bolts at the inner liner is determined by taking a picture and identifying the 3D AI vision of the vision system.

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