Mechanism for detecting neglected assembly of vehicle-mounted cup holder

Abstract

The invention provides a neglected assembly detection mechanism for vehicle-mounted cup holders. The neglected assembly detection mechanism comprises a frame assembly; the positioning assembly is fixedly mounted on the upper surface of the frame assembly, and the contour of the contact surface of the positioning assembly is complementary with the outer edge of a vehicle-mounted cup holder; the detection assembly comprises a bearing platform capable of vertically moving and a sensing unit arranged on the platform; the execution assembly comprises a screw locking device and a parameter acquisition unit integrated in the screw locking device; the control assembly is electrically connected with the detection assembly and the execution assembly; wherein the bearing platform is vertically connected with the frame assembly through the linear driving mechanism, and an output signal of the sensing unit controls the power-on state of the execution assembly. A vertical moving bearing platform of the detection assembly carries a sensing unit and lifts to a detection position under the action of a linear driving mechanism. When the sensing unit verifies that the foam exists, the screw locking device is allowed to be started. And process interlocking is realized through design, so that neglected loading is prevented from entering a subsequent process.

Description

Technical Field

[0001] This invention relates to the field of automotive cup holder manufacturing equipment technology, and in particular to an assembly and defect detection mechanism for automotive cup holders. Background Technology

[0002] As a key component of automotive interiors, the production of car cup holders involves two processes: foam installation and screw tightening. Currently, the industry commonly employs a manual, step-by-step operation: operators first pre-install the foam into the designated slots of the cup holder, then move it to the next station for screw tightening. Because the foam needs to be embedded in the internal grooves of the cup holder, it is completely covered by the cup holder's structure after installation, making it impossible to visually inspect the installation status in subsequent processes. Furthermore, the screw tightening process relies on manual operation, lacking a real-time counting and feedback mechanism, making it difficult to promptly identify missed screws.

[0003] In existing technologies, some production lines have attempted to introduce independent detection equipment. For example, optical sensors are installed at the foam installation station, or counters are added at the screw tightening station. However, such solutions have significant limitations: First, independent detection equipment requires additional production line space, increasing equipment costs and maintenance complexity; second, the split design results in no linkage mechanism between foam detection results and the screw tightening process, meaning operators may still tighten screws on products without foam installed; third, the separation of the detection unit and the execution unit cannot prevent missing products from flowing into subsequent stages. More importantly, when foam is missing, traditional sensors struggle to achieve accurate non-contact detection because the foam installation position is obstructed by the cup holder structure.

[0004] For example, Chinese Patent No. CN221649570U discloses an auxiliary triggering device for a photoelectric sensor; it includes a photoelectric sensor, a mounting bracket, a first conveyor belt, and a second conveyor belt. The discharge end of the first conveyor belt is connected to the feed end of the second conveyor belt, and the conveying speed of the second conveyor belt is greater than that of the first conveyor belt. The mounting bracket, the photoelectric sensor, and the frame of the second conveyor belt are detachably and fixedly connected, and the mounting bracket is located between the first conveyor belt and the photoelectric sensor. Two flexible light-shielding members are detachably and fixedly connected to the mounting bracket. The two flexible light-shielding members are mounted above the second conveyor belt, and a feeding channel for the workpiece to pass through is formed between the two flexible light-shielding members. The width of the feeding channel is smaller than the width of the workpiece.

[0005] The above-mentioned solution, if applied in this field, still presents several technical problems: First, foam omissions cannot be intercepted in time during the process; they can only be traced back through functional failures during the final testing stage, leading to a surge in rework costs. Second, the screw tightening quantity relies on manual memory, and there is no immediate alarm mechanism for omissions. Finally, the lack of interlocking logic between the two processes poses a risk that products with missing foam will be incorrectly processed. These problems lead to an increased product defect rate, and defective parts flowing into the OEM assembly line may cause larger-scale quality incidents. Therefore, there is an urgent need to develop an integrated testing mechanism that can simultaneously complete foam in-situ verification and screw tightening monitoring at a single workstation, and establish a mandatory correlation mechanism between test results and equipment start / stop. Summary of the Invention

[0006] To address the issues of missing foam installation and missing screws during vehicle cup holder assembly that cannot be intercepted, this solution integrates detection and execution functions into a single workstation: the foam detection module on the platform controls the power supply to the screw tightening device, while the screw parameter acquisition module monitors the tightening quantity in real time, forming a mandatory interlocking mechanism of "prohibiting operation if foam is missing and triggering an alarm if screws are missing".

[0007] The second objective of this invention is to solve the blind spot in foam detection caused by the cup holder structure. By utilizing the coordinated positioning of horizontal optical fiber beams and annular grooves, the optical path can accurately penetrate the foam installation area.

[0008] The third objective of this invention is to eliminate the error in manually tightening screws by using a torque sensor for coaxial acquisition and pulse conversion to achieve a millisecond-level audible and visual alarm for missed screws.

[0009] To achieve the above objectives, the present invention adopts the following technical solution: An assembly defect detection mechanism for a car cup holder, comprising: Framework components; A positioning component is fixedly installed on the upper surface of the frame component, and its contact surface contour is complementary to the outer edge of the vehicle cup holder. The detection component includes a vertically movable support platform and a sensing unit disposed on the platform; The execution component includes a screw tightening device and a parameter acquisition unit integrated into the device; The control component is electrically connected to the detection component and the execution component; The carrier platform is vertically connected to the frame assembly via a linear drive mechanism, and the output signal of the sensing unit controls the power-on state of the execution assembly.

[0010] This solution provides basic support through a frame component, while a positioning component uses complementary contours to ensure precise cup holder placement. The vertically moving platform of the detection component carries a sensing unit and is raised and lowered to the detection position by a linear drive mechanism. The screw-locking device of the execution component works in conjunction with the parameter acquisition unit, and the control component establishes a logical association between the sensing signal and the execution power-on: the screw-locking device is only allowed to activate when the sensing unit verifies the presence of foam. This design achieves process interlocking, effectively preventing missing products from entering subsequent processes. Compared to traditional split-type equipment, it solves the problem of missing products causing confusion due to dispersed processes.

[0011] Preferably, the positioning component includes a contoured base, which comprises: a central positioning boss, the outer contour of which fits with the inner wall of the cup holder with a clearance; and an annular limiting groove, surrounding the positioning boss and with a depth greater than the thickness of the foam. The clearance fit between the outer wall of the boss and the inner wall of the cup holder ensures positioning accuracy, and the groove depth design fully considers the concealed characteristics of the foam after installation, creating an unobstructed optical path for fiber optic detection. This structure directly addresses the defect of the foam installation position being concealed and undetectable by visual inspection, enabling the accuracy of the detection position to meet production line requirements.

[0012] Preferably, the linear drive mechanism includes a lifting cylinder, which is fixed to the bottom of the frame assembly by a mounting bracket; The piston rod, with its top end connected to the lower surface of the support platform via a floating joint, is used to lift the cylinder, which is fixed to the bottom of the frame via a mounting bracket. The floating joint compensates for mechanical assembly tolerances and eliminates the risk of off-center loading and jamming during lifting. This solution ensures the vertical stability of the detection unit's movement trajectory, meeting the reliability requirements for continuous operation.

[0013] Preferably, the detection component includes: An optical fiber transmitter is mounted on the first side of the support platform; an optical fiber receiver is mounted on the second side of the support platform. The optical axes of the transmitter and receiver are horizontally aligned, and the optical path passes through the cup holder foam mounting area. The transmitter and receiver are arranged in a horizontal, opposite-facing configuration. The optical path precisely passes through the center of the cup holder foam mounting area, utilizing the differences in the optical properties of the foam material to achieve non-contact detection. The horizontal optical path design overcomes the detection blind spot caused by the cup holder structure and is more suitable for compact spaces compared to oblique detection schemes.

[0014] Preferably, the detection assembly is externally mounted on a mounting frame, with the floating joint of the lifting cylinder abutting the bottom of the mounting frame. The mounting frame provides an independent load-bearing structure for the detection assembly. The lifting cylinder directly abutting the bottom of the mounting frame forms a force transmission path, preventing frame deformation from affecting the alignment accuracy of the optical fiber. This modular design ensures that the detection unit maintains positional consistency during repeated lifting and lowering.

[0015] Preferably, the parameter acquisition unit includes: a torque sensor, coaxially mounted on the output shaft of the screw tightening device; and a pulse counting circuit connected to the output end of the torque sensor. The torque sensor is coaxially mounted on the screwdriver output shaft to acquire the mechanical signals of the tightening process in real time. The pulse counting circuit converts the effective tightening action into a recognizable electrical signal, replacing the manual counting step and establishing a digital monitoring mechanism to address the deficiency of no immediate warning for missed screws.

[0016] Preferably, the control component includes: PLC controller; time relay, mounted on a rail below the PLC controller; The PLC controller is equipped with: a first input port connected to a sensing unit, a second input port connected to a parameter acquisition unit, and an output port connected to an audible and visual indicator device.

[0017] The PLC controller manages the output timing via time relays. The first input port receives the foam detection status, the second input port receives the screw tightening count signal, and the output port drives the audio-visual device according to preset logic. The time relays provide a status holding function to avoid malfunctions caused by transient signal interference.

[0018] Preferably, the audible and visual indicator includes: a dual-color LED light group disposed on the top of the frame assembly; and a buzzer integrated into the base of the LED light group; wherein the LED light group and the buzzer are connected in parallel to the output circuit of a time relay. The audible and visual device is an integrated design of dual-color LEDs and a buzzer. A green light indicates the completion of the process, and a red light simultaneously triggers a buzzer alarm. The parallel circuit design ensures functional redundancy and provides multiple status indications in the noisy environment of an automotive parts production line.

[0019] Further including: a push-button switch, located on the top operating surface of the frame assembly; and a boat-shaped emergency stop switch, located adjacent to the push-button switch; wherein the push-button switch is connected in series in the control circuit of the linear drive mechanism. The push-button trigger detection process, and the emergency stop switch provides an emergency power-off function. The operating surface conforms to the ergonomic requirements of single-handed operation, simplifying traditional two-person operation to single-person, single-station completion.

[0020] Preferably, the frame assembly includes: a bakelite body; a power interface located at the rear of the body; and a transport structure located at the bottom of the body. The bakelite frame combines electrical insulation and mechanical stability. The rear-mounted power interface avoids cable interference with the operating area, and the transport structures on both sides enable rapid equipment relocation. The overall structure is optimized for production line space constraints, meeting the stringent requirements for equipment mobility in the production of vehicle-mounted cup holders.

[0021] The present invention has the following beneficial effects: Through the electrical interlock between the sensing unit and the screw tightening device, the power is automatically cut off when foam is missing, prohibiting the screw tightening operation and forcibly blocking the flow of defective products, thus solving the problem of missed inspection and loss of control caused by the dispersion of processes.

[0022] The horizontally directed optical fiber and the annular groove work together for positioning, and the optical path penetrates the cup holder's obstruction area to directly verify the foam's position, eliminating misjudgments caused by blind spots in manual visual inspection.

[0023] A torque sensor coaxially acquires locking signals, and a pulse counting circuit triggers an audible and visual alarm to intercept products with missing screw counts in real time, replacing the manual memory monitoring mode.

[0024] The bakelite frame integrates detection and execution modules, allowing a single person to complete two processes in a single operation, reducing equipment footprint and personnel requirements, and adapting to the space constraints of automotive production lines. Attached Figure Description

[0025] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0026] Figure 2 This is a top view of the present invention.

[0027] Figure 3 for Figure 2 Side section view at point AA.

[0028] In the diagram: 1. Frame assembly; 11. Power interface; 2. Contouring base; 21. Center positioning boss; 22. Annular limiting groove; 3. Lifting cylinder; 31. Piston rod; 32. Floating joint; 4. Detection assembly; 41. Sensing unit; 42. Mounting bracket; 5. Screw tightening device; 51. Parameter acquisition unit; 6. Time relay; 7. Audible and visual indicator; 8. Push button switch. Detailed Implementation

[0029] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. Examples of the embodiments are shown in the drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout.

[0030] Example 1 like Figure 1As shown, this embodiment discloses an assembly omission detection mechanism for a car cup holder, comprising: a frame assembly 1; a positioning component, fixedly installed on the upper surface of the frame assembly 1, the contour of which is complementary to the outer edge of the car cup holder; a detection component 4, including a vertically movable support platform and a sensing unit 41 disposed on the platform; an execution component, including a screw locking device 5 and a parameter acquisition unit 51 integrated into the device; and a control component, electrically connected to the detection component 4 and the execution component; wherein the support platform is vertically connected to the frame assembly 1 via a linear drive mechanism, and the output signal of the sensing unit 41 controls the energization state of the execution component. The positioning component includes a contoured base 2, the contoured base 2 including: a central positioning boss 21, the outer contour of which is clearance-fitted with the inner wall of the cup holder; and an annular limiting groove 22, surrounding the positioning boss and having a depth greater than the foam thickness. The frame assembly 1 includes: a bakelite body; a power interface 11 disposed on the rear side of the body; and a transport structure disposed at the bottom of the body.

[0031] This solution provides basic support through frame component 1, while the positioning component ensures precise positioning of the cup holder using complementary contours. The vertical moving platform of the detection component 4 carries the sensing unit 41, which is raised and lowered to the detection position under the action of a linear drive mechanism. The screw locking device 5 of the execution component works in conjunction with the parameter acquisition unit 51, and the control component establishes a logical association between the sensing signal and the execution power-on: the screw locking device 5 is only allowed to activate when the sensing unit 41 verifies the presence of foam. Through this design, process interlocking is achieved, effectively preventing missing products from entering subsequent processes. Compared to traditional split-type equipment, this solves the problem of missing products caused by dispersed processes. The outer wall of the boss and the inner wall of the cup holder form a gap fit to ensure positioning accuracy, and the groove depth design fully considers the concealed characteristics of the foam after installation, creating an unobstructed optical path for fiber optic detection. This structure directly addresses the defect of the foam installation position being concealed and undetectable by visual inspection, ensuring that the detection position accuracy meets production line requirements. The bakelite frame combines electrical insulation and mechanical stability. The rear power interface 11 avoids cable interference in the operating area, and the side transport structures enable rapid equipment relocation. The overall structure is optimized for production line space constraints, meeting the stringent requirements for equipment mobility in the production of in-vehicle cup holders.

[0032] The linear drive mechanism in this embodiment includes: a lifting cylinder 3, fixed to the bottom of the frame assembly 1 by a mounting bracket; and a piston rod 31, the top of which is connected to the lower surface of the support platform via a floating joint 32. The detection assembly 4 includes: an optical fiber transmitter, embedded in the first side of the support platform; and an optical fiber receiver, embedded in the second side of the support platform; wherein the optical axes of the optical fiber transmitter and the optical fiber receiver are horizontally aligned and the optical path passes through the cup holder foam mounting area. A mounting frame 42 is provided on the outside of the detection assembly 4, and the floating joint 32 of the lifting cylinder 3 abuts against the bottom of the mounting frame 42. The mounting frame 42 provides an independent support structure for the detection assembly 4. The parameter acquisition unit 51 includes: a torque sensor, coaxially sleeved on the output shaft of the screw locking device 5; and a pulse counting circuit connected to the output end of the torque sensor.

[0033] The lifting cylinder 3 is fixed to the bottom of the frame via a mounting bracket, and the piston rod 31 is connected to the bearing platform via a floating joint 32. The floating joint 32 compensates for mechanical assembly tolerances and eliminates the risk of off-center loading and jamming during lifting. This solution ensures the vertical stability of the detection unit's movement trajectory and meets the reliability requirements of continuous operation. The fiber optic transmitter and receiver are arranged in a horizontally opposite layout. The optical path precisely passes through the center of the cup holder foam installation area, utilizing the difference in optical properties of the foam material to achieve non-contact detection. The horizontal optical path design overcomes the detection blind spot caused by the cup holder structure and is more suitable for compact spaces compared to the oblique detection solution. The lifting cylinder 3 directly abuts against the bottom of the mounting bracket 42 to form a force transmission path, avoiding frame deformation from affecting the fiber optic alignment accuracy. This modular design ensures that the detection unit maintains positional consistency during repeated lifting. A torque sensor is coaxially mounted on the screwdriver output shaft to collect mechanical signals during the tightening process in real time. The pulse counting circuit converts the effective tightening action into a recognizable electrical signal, replacing the manual counting step and establishing a digital monitoring mechanism to address the defect of no immediate warning for missed screws.

[0034] The control components include: a PLC controller; a time relay 6, mounted below the PLC controller via a guide rail; the PLC controller has: a first input port connected to a sensing unit 41, a second input port connected to a parameter acquisition unit 51, and an output port connected to an audible and visual indicator 7. The audible and visual indicator 7 includes: a dual-color LED light group, located on the top of the frame component 1; and a buzzer integrated into the base of the LED light group; wherein the LED light group and the buzzer are connected in parallel to the output circuit of the time relay 6.

[0035] The PLC controller manages the output timing via a time relay 6. The first input port receives the foam detection status, the second input port receives the screw tightening count signal, and the output port drives the audible and visual device according to preset logic. The time relay 6 provides a status holding function to avoid malfunctions caused by momentary signal interference. The audible and visual device is an integrated design of a dual-color LED and a buzzer. A green light indicates process completion, and a red light simultaneously triggers the buzzer alarm. Parallel circuit design ensures functional redundancy and provides multiple status indications in the noisy environment of an automotive parts production line.

[0036] The in-vehicle cup holder assembly omission detection mechanism also includes: a push-button switch 8, located on the top operating surface of the frame assembly 1; and a boat-shaped emergency stop switch, located adjacent to the push-button switch 8; wherein the push-button switch 8 is connected in series in the control circuit of the linear drive mechanism. The button triggers the detection process, and the emergency stop switch provides an emergency power-off function. The operating surface meets the ergonomic requirements of single-handed operation, simplifying the traditional two-person operation to a single-person, single-station operation.

[0037] Specifically, in this solution, frame component 1 constitutes the basic support structure of the entire mechanism. Its main body is made of bakelite, a material with excellent electrical insulation and mechanical strength, effectively isolating the risk of current conduction during operation. A power interface 11 is located on the rear side of the frame for connecting to an external 220V AC power supply. The bottom is designed with a specific groove structure for the handling components, facilitating operator grip and movement. The positioning component is fixedly installed on the upper surface of the frame, and its contact surface contour forms a complementary match with the outer edge of the vehicle cup holder. When the cup holder is placed, automatic centering and positioning are achieved through geometric constraints. The detection component 4 includes a vertically movable support platform, which is connected to the end of the piston rod 31 of the lifting cylinder 3 via a floating joint 32. The cylinder body is fixed to the bottom area of ​​the frame via a mounting bracket, forming a complete force transmission path. The screw locking device 5 of the actuator has a torque sensor coaxially mounted on its output shaft. The output end of this sensor is directly connected to a pulse counting circuit, converting the mechanical torque of the rotating component into a recognizable electrical signal change. The control components include a PLC controller and a time relay 6, both physically mounted and positioned via a guide rail. The PLC controller has a first input port connected to the signal line of the detection unit, a second input port connected to the output of the pulse counting circuit, and an output port connected to a status indicator. Push-button switches 8 in the operating area are connected in series to the cylinder control circuit, and an adjacent boat-shaped emergency stop switch is directly connected to the power supply line of the actuator, allowing for power cut-off in emergency situations.

[0038] After all components are physically assembled, frame assembly 1 serves as the basic platform supporting all functional modules. The positioning component is located on the top layer of the frame; its contour-matching characteristics ensure that the cup holders do not require manual adjustment during placement. The support platform of the detection component 4 is movably connected to the cylinder piston rod 31 via a floating joint 32. The internal spherical structure of the floating joint 32 compensates for axial assembly deviations, preventing jamming during lifting. The cylinder body is rigidly fixed to the bottom of the frame via a mounting bracket, forming a stable motion support structure. The torque sensor of the actuator is coaxially connected to the output shaft of the screw locking device 5 via a flange structure, ensuring no angular deviation in torque measurement. The pulse counting circuit board is installed inside the control cabinet and connected to the sensor via a shielded cable. The PLC controller and time relay 6 of the control component are mounted side-by-side on a guide rail, with the output contacts of the time relay 6 connected in series in the indicating device circuit. The push-button switch 8 and the emergency stop switch are positioned side-by-side on the top operating surface of the frame, with their circuits connected to the control circuit and power circuit, respectively.

[0039] In this embodiment, the insulation properties of the bakelite frame fundamentally eliminate the risk of leakage from 220V electrical equipment. The bottom handling groove conforms to the human hand's grip curve, allowing for safe transfer of the equipment by a single person. Secondly, the combination design of the floating joint 32 and the cylinder eliminates the influence of machining tolerances, ensuring the accuracy of the vertical lifting trajectory of the support platform and avoiding displacement deviation of the fiber optic detection module due to off-center loading. Finally, the physical isolation wiring between the push-button switch 8 and the emergency stop switch achieves layered operation logic, ensuring that normal start / stop and emergency power-off do not interfere with each other. The pulse counting circuit uses the Schmitt trigger principle to filter interference signals, only determining a valid screw tightening action when the torque value continuously reaches the threshold. This design avoids false counting caused by tool vibration. The time relay 6's contact delay disconnection characteristic maintains the stability of the status indication and prevents the light from flickering due to signal jitter. It is also worth noting that those skilled in the art can use an electric push rod instead of a cylinder; the pulse counting circuit can also be replaced with an AD conversion module.

[0040] Specifically, the operator switches the boat-shaped switch on the rear of the equipment to the ON position, supplying power to the control components via 220V AC. The operator manually places the car cup holder onto the upper surface of the positioning component; the outer edge of the cup holder complements the positioning contour, achieving self-positioning. After the foam is installed, the operator presses the button switch 8 on the front of the frame with one hand. This action activates the control circuit of the lifting cylinder 3. Compressed air drives the cylinder piston rod 31 to extend, pushing the support platform vertically upwards to the inspection station via the floating joint 32. The sensing unit 41 moves with the platform to the bottom area of ​​the cup holder; if the foam is present, a detection signal is generated and transmitted to the first input port of the PLC controller.

[0041] After receiving a valid signal, the PLC outputs a power command to the screw tightening device 5 of the actuator. The operator holds the screw tightening device 5 to perform the operation, and the torque sensor mounted coaxially monitors the rotational torque of the output shaft in real time. When the tightening torque of a single screw reaches a set threshold, the pulse counting circuit generates a square wave signal and transmits it to the second input port of the PLC. After receiving four pulse signals, the PLC drives the output port to conduct, causing the audible and visual indicator 7 to display a green light. If the number of screws does not meet the standard, the device maintains a red warning state. After the operation is completed, the cup holder product is manually removed, the exhaust valve of the lifting cylinder 3 opens, and the piston rod 31, under the action of the return spring, drives the support platform back to the initial position.

[0042] In the abnormal handling process, when foam is missing, sensor unit 41 has no signal output, and the PLC continuously blocks the power supply circuit of screw tightening device 5, physically interrupting the operation. If an equipment malfunction occurs during screw tightening, the boat-shaped emergency stop switch is struck to directly cut off the power supply to the actuator, achieving emergency braking. The contour matching characteristics of the positioning component ensure the stability of the cup holder in place and avoid detection displacement deviation. The floating joint 32 absorbs the axial assembly tolerance between the cylinder and the platform, ensuring no mechanical interference during the lifting process. The time relay 6 maintains contact closure for 0.5 seconds after the PLC outputs a signal to prevent signal fluctuations from causing the light to flicker.

[0043] In actual production line applications, this process integrates two steps. The original foam installer and screw operator are combined into a single position, where the operator completes foam installation and screw tightening sequentially at the same workstation. The bottom transport structure of frame component 1 supports rapid equipment relocation, meeting the flexibility requirements of automotive parts production lines. The pulse counting circuit's monitoring logic for the four screws replaces traditional manual counting, eliminating the risk of memory bias.

[0044] Example 2 In this embodiment, the frame assembly 1 continues the basic structure of the bakelite body. This engineering plastic has stable electrical insulation and mechanical strength. The power interface 11 located on the rear side is used to connect to a 220V AC power supply. The bottom carrying structure has a groove that conforms to the palm curve, making it easy for a single person to move the equipment. The positioning assembly adds a contour-following base 2 to the basic contour matching. The base has a cylindrical positioning boss at its center, and an annular limiting groove 22 is machined around the boss. The outer wall of the boss and the inner wall of the cup holder form a small assembly gap to achieve radial constraint positioning. The depth of the annular groove is greater than the thickness of the foam in its free state, providing a pressure-free space for the foam. The bearing platform of the detection assembly 4 is connected to the end of the piston rod 31 of the lifting cylinder 3 through a floating joint 32. The fiber optic transmitter module is installed on the left side of the platform, and the fiber optic receiver module is fixed symmetrically on the right side. The optical lens centers of both are on the same horizontal axis, forming a straight detection optical path that runs through the bottom area of ​​the cup holder. The mounting bracket 42 adopts a rectangular frame structure to completely wrap the detection unit. Its bottom plane directly and rigidly abuts against the top surface of the cylinder floating joint 32. The torque sensor of the actuator is coaxially mounted on the output shaft of the screw-locking device 5 via a flange structure. The pulse counting circuit board is connected to the sensor signal output terminal via a four-core shielded wire. The PLC controller of the control component is mounted via a DIN rail, with a time relay 6 module fixed at an adjacent rail position. The PLC output port is connected to the control circuit of the audible and visual indicator 7 via a terminal block. This device integrates a dual-color LED light group and an electromagnetic buzzer. The red and green lights are independently encapsulated in a waterproof housing, with the buzzer diaphragm facing the operating position. The power supply lines for both are connected in parallel to the output contacts of the time relay 6. The push-button switch 8 and the boat-shaped emergency stop switch in the operating area are arranged side by side on a 30-degree forward-leaning slope. The push-button switch 8 is connected in series in the cylinder air circuit solenoid valve control circuit, and the emergency stop switch is directly connected to the power relay coil circuit of the actuator.

[0045] After all functional modules are physically integrated, frame component 1 serves as the basic load-bearing platform supporting the entire system. The central boss of the positioning component extends into the inner cavity of the cup holder to achieve axial positioning constraint, and the annular groove forms a free-accommodating area for the foam, eliminating the interference of foam compression rebound force on detection accuracy. The mounting bracket 42 of the detection unit directly transmits the cylinder thrust to the load-bearing platform, effectively isolating the bakelite frame from the influence of micro-deformation caused by temperature and humidity changes. The parallel beam emitted by the fiber optic transmitter passes horizontally through the thinnest wall area at the bottom of the cup holder, reaching the sensing window of the receiver on the opposite side, with the light path direction strictly parallel to the cup holder mounting plane. The torque sensor measuring flange is fixed to the end of the output shaft of the screw locking device 5 by a set screw, ensuring that there is no angular deviation in torque measurement. The electromagnetic coil of the time relay 6 in the control cabinet is connected in series with the PLC output port, and the mechanical delay mechanism driven by the internal clock gear set maintains the contact pressure through a spring device. In the dual-color LED light group, the red and green LED beads are connected to independent drive circuits, and the buzzer piezoelectric ceramic sheet is encapsulated in a metal cavity with epoxy resin. The power supply lines for the two are wired separately but share a common grounding terminal.

[0046] This embodiment achieves multiple technical objectives through the aforementioned structural configuration. The gap between the central boss and the inner wall of the cup holder compensates for the dimensional tolerances of the injection molded parts. The depth design of the annular groove provides physical clearance for the foam, fundamentally solving the industry problem of "foam installation being relatively concealed, making visual inspection impossible after installation." The force transmission closed loop formed by the mounting bracket 42 ensures that the movement trajectory of the detection module is unaffected by frame deformation, guaranteeing that the optical fiber axis maintains the preset alignment accuracy during continuous operation. The horizontal straight optical path accurately penetrates the thick area of ​​the cup holder wall, reducing light signal attenuation caused by structural obstruction compared to the oblique detection scheme. The parallel circuit topology of the sound and light device ensures that the light warning still works normally when the buzzer coil is broken. The state switching of the dual-color LED is achieved by switching the current direction via a relay. The pulse counting circuit is equipped with a hysteresis voltage comparator, effectively filtering interference signals below 50 millivolts generated when the electric screwdriver is idle. After the armature of the time relay 6 is attracted, the contact is maintained in a closed state for 0.5 seconds through the escapement mechanism, solving the problem of light flickering caused by ±10% voltage fluctuations in the workshop power grid.

[0047] In this embodiment, the operator turns on the boat-shaped switch on the back of the equipment, and the 220V power supply powers the control system. The operator manually places the in-vehicle cup holder onto the contoured base 2 of the positioning component. The inner wall of the cup holder naturally fits against the central positioning boss 21, forming a radial constraint. The annular limiting groove 22 completely accommodates the foam, preventing compression deformation. After installing the foam, the operator presses the button switch 8 on the inclined operating area with one hand, triggering the solenoid valve of the lifting cylinder 3 to open. Compressed air pushes the piston rod 31 upwards through the floating joint 32, causing the mounting bracket 42 to vertically lift the supporting platform. The fiber optic transmitter and receiver simultaneously reach the detection station. The horizontal beam penetrates the thinnest wall area at the bottom of the cup holder. If foam is present, the change in light flux is captured by the receiver, converted into an electrical signal, and transmitted to the first input port of the PLC.

[0048] Upon receiving a valid signal, the PLC unlocks the power supply to the screw tightening device 5. An employee uses tools to tighten the screws, while a coaxial torque sensor monitors the output shaft torque in real time. When the tightening torque of a single screw reaches a threshold, the pulse counting circuit generates a square wave signal and inputs it to the PLC's second input port. After accumulating four valid pulses, the PLC drives the output port to activate the coil circuit of the time relay 6. Once the contacts of the time relay 6 are engaged, the dual-color LED group switches to a solid green light, and a buzzer sounds a warning tone. If the number of screws is insufficient, the red light remains lit. After the operation is completed, the cup holder is removed, the cylinder exhaust valve opens, and the piston rod 31, under the action of the return spring, drives the detection unit back to its original position via the mounting bracket 42.

[0049] In handling abnormal operating conditions, when foam is missing and the light flux remains unchanged, the lack of sensor signals causes the PLC to continuously block the power supply circuit of the screw tightening device 5, physically blocking subsequent processes. If an equipment malfunction occurs during screw tightening, the boat-shaped emergency stop switch is activated to directly cut off the power relay of the actuator, achieving millisecond-level power-off protection. The boss gap of the positioning component is designed to compensate for product injection molding tolerances, and the groove structure eliminates foam rebound interference. Mounting bracket 42 ensures the stability of the vertical lifting trajectory of the fiber optic module, preventing frame deformation from causing optical axis misalignment. The mechanical delay mechanism of time relay 6 maintains the contact closed state to prevent power grid fluctuations from causing light flickering. The parallel circuit of the buzzer and LED light group can still provide a basic warning by illuminating the green light when the buzzer coil is open.

[0050] In actual production line applications, the original dual-station operation of foam installation and screw tightening is combined into a single-person, single-process operation. Employees continuously complete all tasks on the positioning components, eliminating the risk of missed inspections caused by product flow. The horizontal optical path detection solution is suitable for the bottom area of ​​the cup holder, solving the problem of misjudgment caused by structural obstruction in traditional oblique detection.

Claims

1. A mechanism for detecting missing parts in the assembly of a car cup holder, characterized in that, include: Framework components; A positioning component is fixedly installed on the upper surface of the frame component, and its contact surface contour is complementary to the outer edge of the vehicle cup holder. The detection component includes a vertically movable support platform and a sensing unit disposed on the platform; The execution component includes a screw tightening device and a parameter acquisition unit integrated into the device; The control component is electrically connected to the detection component and the execution component; The carrier platform is vertically connected to the frame assembly via a linear drive mechanism, and the output signal of the sensing unit controls the power-on state of the execution assembly.

2. The in-vehicle cup holder assembly defect detection mechanism according to claim 1, characterized in that, The positioning component includes a contoured base, which includes a central positioning boss whose outer contour is fitted with the inner wall of the cup holder. An annular limiting groove is provided around the positioning boss and its depth is greater than the thickness of the foam.

3. The in-vehicle cup holder assembly defect detection mechanism according to claim 1, characterized in that, The linear drive mechanism includes: The lifting cylinder is fixed to the bottom of the frame assembly via a mounting bracket. The piston rod has a floating joint at its top that abuts against the lower surface of the bearing platform.

4. The in-vehicle cup holder assembly defect detection mechanism according to claim 3, characterized in that, The detection component further includes: The fiber optic transmitter is embedded on the first side of the support platform; The fiber optic receiver is embedded on the second side of the support platform; The optical axes of the fiber optic transmitter and the fiber optic receiver are horizontally aligned, and the optical path passes through the cup holder foam mounting area on the positioning assembly.

5. The in-vehicle cup holder assembly defect detection mechanism according to claim 4, characterized in that, The detection component is externally mounted on a mounting bracket, and the floating joint of the lifting cylinder abuts against the bottom of the mounting bracket.

6. The in-vehicle cup holder assembly defect detection mechanism according to any one of claims 1-5, characterized in that, The parameter acquisition unit includes: A torque sensor is coaxially mounted on the output shaft of the screw locking device. The pulse counting circuit is connected to the output of the torque sensor.

7. The in-vehicle cup holder assembly defect detection mechanism according to claim 6, characterized in that, The control component includes: PLC controller; Time relay, installed on the outside of the PLC controller; The PLC controller is equipped with: a first input port connected to a sensing unit, a second input port connected to a parameter acquisition unit, and an output port connected to an audible and visual indicator device.

8. The in-vehicle cup holder assembly omission detection mechanism according to claim 7, characterized in that, The audio-visual indication device includes: Dual-color LED light clusters are installed at the top of the frame assembly; Buzzer, integrated into the LED light assembly base; The LED light group and the buzzer are connected in parallel to the output circuit of the time relay.

9. The in-vehicle cup holder assembly defect detection mechanism according to claim 1, characterized in that, Further includes: A button switch is located at the top of the frame component; The push-button switch is connected in series in the control circuit of the linear drive mechanism.

10. The in-vehicle cup holder assembly defect detection mechanism according to claim 1, characterized in that, The framework components include: Bakelite body; The power interface is located on the rear of the main body; The transport structure is located at the bottom of the main body.

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