An automated assembly equipment for small hooks on guide rails

Abstract

This invention relates to the field of automated mechanical equipment technology, and discloses an automated assembly equipment for guide rail small hooks. The equipment includes a main frame, within which are arranged a clamping assembly for gripping and transferring workpieces, a clamping assembly for positioning and locking the workpieces, an adjusting assembly for fine-tuning the position of the clamping assembly, and a bending mechanism for bending and forming. The equipment also includes a controller integrating a collaborative control system, which comprises a monitoring module, a control module, and a function execution module. During operation, the clamping assembly places the workpiece on the clamping assembly and initially abuts it against the support platform; the monitoring module collects real-time data on the fit between the workpiece and the support platform; subsequently, the clamping assembly locks the workpiece, and the bending mechanism completes the processing. This invention solves the accuracy problem caused by inaccurate positioning in traditional assembly by introducing a closed-loop feedback precision positioning and calibration mechanism, and has the advantages of high automation, high positioning and processing accuracy, and significant production efficiency.

Description

Technical Field

[0001] This invention relates to the field of automated mechanical equipment technology, specifically to an automated assembly equipment for guide rail small hooks. Background Technology

[0002] In the fields of rail transit, automated warehousing, and precision machinery manufacturing, guide rail hooks are a common type of connecting or supporting metal components, and their assembly accuracy directly affects the operational stability and reliability of the entire equipment or system.

[0003] Currently, the assembly process of these small, high-precision metal components still largely relies on manual or semi-automated operations. In these production modes, operators typically place the workpieces to be processed into the fixtures of bending machines or presses manually, align them visually or with the aid of simple positioning blocks, and then start the equipment to complete the bending or forming. This method is not only inefficient and labor-intensive, but the stability and consistency of assembly quality also heavily depends on the operator's skill level and work condition. Due to unavoidable random errors in manual positioning, there is often a slight deviation between the actual position of the workpiece in the fixture and its ideal position. This directly leads to poor consistency in the dimensions and angles of the final product, making it difficult to consistently guarantee the product qualification rate.

[0004] To overcome these problems, the industry has gradually introduced automated production equipment, using robotic arms and other automated devices to replace manual labor for loading and positioning. However, most existing automation solutions adopt an open-loop control mode, that is, after the robotic arm places the workpiece in the designated position according to the preset program path, it directly enters the next pressing and processing step.

[0005] In actual operation, due to factors such as the dimensional tolerances of the workpiece itself, the cumulative error of repeated positioning by the robotic arm, and the wear of tooling fixtures, the final placement position of the workpiece still deviates from the ideal position. Because of the lack of a real-time position verification and correction mechanism, once the initial positioning deviates, all subsequent high-precision processing steps, such as clamping and bending, will be based on this erroneous initial state. This inevitably leads to a defective final product, resulting in material waste and reduced production efficiency. Therefore, how to ensure high-precision and reliable positioning of the workpiece before critical processing steps in automated assembly processes is a pressing technical problem that needs to be solved in this field. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides an automated assembly equipment for small hooks on guide rails, which solves the problems of low final positioning accuracy and poor product consistency caused by the lack of real-time position verification and correction after workpiece placement in existing automated assembly technologies for small hooks on guide rails.

[0007] To achieve the above objectives, the present invention provides the following technical solution: an automated assembly equipment for guide rail small hooks, comprising a main frame, with casters mounted at the bottom and a light fixture mounted at the top, and a controller mounted externally on the main frame. A base plate is fixedly connected inside the main frame, and a bending mechanism and a clamping assembly are also located inside the main frame. An adjustment assembly is mounted externally on the clamping assembly, and a clamping assembly is located at the top inner side of the main frame. The controller integrates a collaborative control system, which processes data collected by the monitoring module through a control module, generates collaborative control commands, and inputs these commands to the function execution module.

[0008] Preferably, the clamping assembly includes two motorized slides. The two motorized slides are fixedly connected to the top inner side of the main frame, and a robotic arm is fixedly connected to the bottom of each of the two motorized slides. Through the cooperation of the motorized slides and the robotic arms, the device achieves the gripping, transfer, and initial placement of the workpiece.

[0009] Preferably, the bending mechanism includes a drive assembly, a support assembly, and an execution assembly. The drive assembly includes a motor, which is fixedly connected inside the main frame. A bracket is fixedly connected to the output end of the motor, and a base is fixedly connected to the top of the base plate. The bracket is rotatably connected to the outside of the base.

[0010] Preferably, the support assembly includes a crossbeam. The crossbeam is fixedly connected to the outside of the bracket, and a stop block is slidably connected to the inside of the crossbeam. A vertical plate is fixedly connected to the middle of the bracket, and the vertical plate abuts against the stop block. The support assembly provides stable support for the workpiece during bending.

[0011] Preferably, the actuating component includes a second hydraulic rod. The second hydraulic rod is rotatably connected to the middle of the bracket, and a fixed plate is fixedly connected to the middle of the bracket. A first rotating plate is rotatably connected to the outside of the fixed plate. The output end of the second hydraulic rod is rotatably connected to one end of the first rotating plate, and a second rotating plate is rotatably connected to the outside of the first rotating plate. A slide rail is fixedly connected to the inner side of the bracket, and a bending plate is slidably connected to the outside of the slide rail. The top of the bending plate is rotatably connected to the second rotating plate. Through the coordinated movement of the hydraulic rod, the multi-stage rotating plates, and the slide rail / slider, precise bending of the workpiece is achieved.

[0012] Preferably, the clamping assembly includes a first clamp and a second clamp. The first clamp and the second clamp are slidably connected to the top of the base plate, and a hydraulic rod is mounted on the top of both the first clamp and the second clamp. The first clamp is higher than the second clamp. This design allows the clamp to adapt to workpieces of various geometries and to perform effective clamping operations.

[0013] Preferably, the adjusting assembly includes a slider. The slider is fixedly connected to the bottom of the first clamp and the second clamp, and a groove is formed on the top of the base plate. The slider is slidably connected to the inside of the groove. The adjusting assembly realizes synchronous adjustment of the clamp position by sliding the slider within the groove.

[0014] Preferably, two grippers are fixedly connected inside the main frame, and rubber pads are fixedly connected to the outside of the two grippers. The grippers are used to clamp or buffer the clamping force on the workpiece to be processed.

[0015] Preferably, the monitoring module includes a monitor. The monitor is fixedly connected to the inner side of the main frame and is used to collect real-time operating status data of the bending mechanism, clamping assembly, adjusting assembly, and clamping assembly, as well as the position and posture information of the workpiece. The control module receives the data collected by the monitor, analyzes and processes the data through preset logic, and generates coordinated control commands. The function execution module is electrically connected to the bending mechanism, clamping assembly, adjusting assembly, and clamping assembly respectively, and is used to accurately receive and execute the coordinated control commands, realizing the coordinated operation of each component. This coordinated control system achieves real-time perception, intelligent decision-making, and precise execution of equipment operating status and workpiece information.

[0016] In a preferred embodiment, a support platform is fixedly connected to the top of the base plate. The monitoring module uses a monitor to specifically monitor the placement of the workpiece on the support platform, collecting data on the fit between the workpiece and the support platform. The control module compares the fit data with a preset standard; when the data does not meet the preset requirements, it generates a position adjustment command and transmits it to the function execution module. The function execution module controls the slider of the adjustment component to slide along the groove, causing clamping seats one and two to adjust their positions synchronously, ensuring precise fit between the workpiece and the support platform. This embodiment achieves precise alignment of the workpiece before processing by real-time monitoring and feedback adjustment of the workpiece placement fit, improving assembly accuracy.

[0017] Preferably, the functional execution module includes a bending execution unit, a clamping execution unit, and a clamping execution unit. The bending execution unit controls the motor operation to complete the workpiece bending operation. The clamping execution unit is electrically connected to a hydraulic rod and is used to adjust the clamping force of clamping seats one and two according to the coordinated control commands. The clamping execution unit is electrically connected to an electric slide and grippers, and is used to control the robotic arm to grasp and transfer the workpiece, as well as control the grippers to clamp and release the workpiece to be processed. Rubber pads on the outside of the grippers are used to buffer the clamping force. The functional execution module provides modular control of each functional component to ensure the accurate execution of the coordinated control commands.

[0018] This invention provides an automated assembly device for small hooks on guide rails. It has the following advantages:

[0019] 1. This invention integrates all processes of workpiece loading, positioning, clamping, bending, and unloading into a single unit by setting up a clamping assembly, a pressing assembly, a bending mechanism, and a collaborative control system, thus achieving full automation of the guide rail small hook assembly process. This replaces the traditional manual or semi-automatic operation mode, eliminates the interference of human factors on product quality stability, and significantly improves overall production efficiency and operational stability while greatly reducing labor intensity.

[0020] 2. This invention significantly improves the positioning accuracy and reliability of workpieces by introducing a closed-loop feedback precision positioning and calibration mechanism consisting of a monitoring module, a control module, and an adjustment component. Addressing the technical shortcomings of existing automation solutions that employ open-loop control and cannot verify the actual placement position, the monitor in this invention can detect the actual positional deviation of the workpiece in real time, and the control module drives the adjustment component to perform dynamic compensation and correction, ensuring that the workpiece's position reaches the required accuracy before final locking and machining.

[0021] 3. This invention ensures high consistency and a high pass rate of the final product by guaranteeing that each workpiece is in a precise initial position before processing. Due to the high-precision positioning and calibration mechanism, it effectively overcomes the positioning inaccuracy caused by workpiece tolerances and cumulative equipment errors, avoiding the situation where subsequent high-precision bending processes are performed based on an incorrect initial state. This directly improves the dimensional and angular accuracy of the product, effectively reduces the scrap rate, and minimizes unnecessary material waste. Attached Figure Description

[0022] Figure 1 This is a perspective view of the present invention;

[0023] Figure 2 This is a schematic diagram of the motor mounting position according to the present invention;

[0024] Figure 3 This is a schematic diagram showing the installation location of the monitor of the present invention;

[0025] Figure 4 This is a schematic diagram of the internal structure of the main frame of the present invention;

[0026] Figure 5 This is a schematic diagram of the clamping mechanism of the present invention;

[0027] Figure 6 This is a schematic diagram of the clamping seat of the present invention in an explosion state;

[0028] Figure 7 This is a functional block diagram of the collaborative control system of the present invention;

[0029] Figure 8 This is a flowchart illustrating the automated workflow of the present invention.

[0030] The components are as follows: 1. Main frame; 2. Controller; 3. Casters; 4. Robotic arm; 5. Grip seat one; 6. Grip seat two; 7. Lighting; 8. Support platform; 9. Motor; 10. Horizontal frame; 11. Hydraulic rod one; 12. Electric slide table; 13. Monitor; 14. Bracket; 15. Base; 16. Gripper; 17. Rubber pad; 18. Base plate; 19. Support block; 20. Vertical plate; 21. Hydraulic rod two; 22. Rotating plate one; 23. Fixing plate; 24. Rotating plate two; 25. Bending plate; 26. Slide rail; 27. Slider; 28. Slide groove. Detailed Implementation

[0031] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] See attached document Figure 1 and attached Figure 7 This invention provides an automated assembly equipment for guide rail small hooks. The equipment includes a main frame 1, which serves as the load-bearing platform for the entire equipment, integrating and supporting all functional components.

[0033] The main frame 1 is equipped with casters 3 at its bottom for easy movement and flexible deployment of the equipment. A light 7 is installed at the top of the main frame 1 to provide necessary illumination for the work area inside the equipment.

[0034] A controller 2 is mounted externally on the main frame 1. The controller 2 integrates a collaborative control system for unified scheduling and management of all automated processes of the equipment. A base plate 18 is fixedly connected inside the main frame 1, serving as the reference mounting plane inside the main frame 1.

[0035] The main frame 1 integrates several core functional systems that work together. The main frame 1 contains a bending mechanism, which performs the final bending and shaping operation on the workpiece.

[0036] The main frame 1 is equipped with a clamping assembly, which is installed on the base plate 18 and is used to position and lock the workpiece before bending operations.

[0037] An adjustment component is installed on the outside of the clamping assembly. This adjustment component is mechanically connected to the clamping assembly and controlled by the controller 2, and is used to precisely adjust the planar position of the clamping assembly.

[0038] A clamping assembly is provided on the top inner side of the main frame 1. This clamping assembly is used to perform material handling actions such as gripping, transferring and placing workpieces.

[0039] The collaborative control system inside controller 2 may include the following functional architecture: monitoring module a, control module b, and function execution module c.

[0040] Monitoring module a (for example, corresponding to component monitor 13) is used to collect in real time the working status data of each mechanism (such as bending mechanism, clamping component, etc.) in the equipment, as well as the position and posture information of the workpiece in the processing area.

[0041] Control module b is used to receive all the data collected by monitoring module a, analyze and process the data according to the preset control logic and algorithm model, and generate a series of coordinated control commands accordingly.

[0042] Function execution module c establishes electrical or communication connections with the bending mechanism, clamping assembly, adjusting assembly, and clamping assembly, respectively. This module is used to accurately receive and execute coordinated control commands from control module b, driving each functional component to complete the specified linkage operation.

[0043] In one specific embodiment, when performing workpiece positioning calibration, the control module b generates collaborative control commands based on a closed-loop feedback control model. The control module b uses the workpiece fit data collected by the monitoring module a (…) ) and preset standards ( Deviation between ) ), to calculate the control output of the regulating component ( ).

[0044] deviation( This can be represented as:

[0045] ;

[0046] in, for The deviation in fit at any given moment; Preset standard fit data (e.g., standard gap value); for The actual fit data collected by module a is monitored at all times.

[0047] Control output generated by control module b A proportional-integral-derivative (PID) control algorithm can be used, and its expression is:

[0048] ;

[0049] in, for The control output at any given time (e.g., the voltage or pulse signal that drives the slider of the regulating component); This is the proportionality coefficient; The integral coefficient; is the differential coefficient. , , These are control parameters that are preset based on the system's response characteristics.

[0050] Function execution module C receives this The signal drives the adjustment component (e.g., slider 27) to move until... The absolute value is less than the preset tolerance threshold (i.e. ,in (for the allowable zero-position error), at this time satisfy The tolerance requirements were met, and the positioning calibration was completed.

[0051] See attached document Figure 1 -Appendix Figure 5 In this embodiment of the invention, the clamping component is located in the top inner area of ​​the main frame 1, constituting the material transfer and handling subsystem of the equipment.

[0052] The clamping assembly mainly consists of a drive displacement unit and an end effector unit. The drive displacement unit includes two parallel electric slides 12. The main body of each electric slide 12 is rigidly fixed to the inner top crossbeam of the main frame 1 by bolts.

[0053] In the specific implementation structure, the electric slide table 12 adopts a linear module structure, which internally includes a servo motor, a precision ball screw, and a linear guide. The output shaft of the servo motor is connected to the ball screw via a coupling, and the rotational motion of the screw is converted into the horizontal reciprocating motion of the slide along the linear guide. This structure provides a high-precision displacement basis for the transfer of the workpiece in the horizontal direction (denoted as the X-axis). The repeatability of the electric slide table 12 is set at the micrometer level to ensure that the workpiece can be accurately aligned to the subsequent clamping station.

[0054] Each electric slide table 12 has a robotic arm 4 vertically fixedly connected to the bottom of its sliding seat. The robotic arm 4 serves as an end effector and its structure includes a longitudinal telescopic cylinder and a pneumatic finger cylinder.

[0055] The longitudinal telescopic cylinder is responsible for driving the end gripper to move up and down in the vertical direction (set as the Z axis) to realize the extraction and placement of the workpiece.

[0056] The pneumatic finger cylinder is installed at the output end of the longitudinal telescopic cylinder. Its finger tip is designed as a non-standard irregular structure that adapts to the cross-sectional shape of the small hook workpiece on the guide rail in order to maximize the contact area.

[0057] Two grippers 16 are fixedly connected to the inner side wall or support of the main frame 1. The grippers 16 serve as workpiece loading buffer stations or initial positioning points, and are arranged symmetrically. Rubber pads 17 are fixedly connected to the jaw surfaces of the grippers 16 via bonding or vulcanization. The rubber pads 17 are made of high-wear-resistant nitrile rubber or polyurethane material. The functions of the rubber pads 17 are mainly reflected in two aspects:

[0058] Physical buffering and protection: When the robotic arm 4 places the workpiece on or picks it up from the gripper 16, it avoids direct hard collisions between metals and prevents scratches or deformation on the workpiece surface.

[0059] Increase static friction: Utilize the high coefficient of friction of rubber material to ensure the stability of the pre-positioned posture of the workpiece on the gripper 16) and prevent the workpiece from slipping due to equipment vibration.

[0060] Under the control of the collaborative control system, the clamping components follow explicit mechanical constraints when performing actions. To ensure that the workpiece does not fall off during the high-speed movement of the robotic arm 4, and that the workpiece is not deformed due to excessive clamping force, the clamping execution unit in the function execution module c controls the clamping force. The following security conditions must be met for the settings:

[0061] ;

[0062] in, Mass (kg) of a single guide rail small hook workpiece; The acceleration due to gravity ( ); The maximum acceleration of the electric slide 12 or the robotic arm 4 during operation ( ); The static friction coefficient between the end effector gripper of the robotic arm 4 and the workpiece surface; This refers to the effective contact surface area between the finger cylinder and the workpiece. This is a safety factor (usually between 1.5 and 2.0).

[0063] The clamping actuator adjusts the input air pressure of the pneumatic finger cylinder. To control the actual clamping force output Their relationship is ,in The piston area of ​​the cylinder. To improve mechanical transmission efficiency, the precision pressure regulating valve can be adjusted via commands from control module b to achieve adaptive flexible clamping of workpieces of different specifications.

[0064] See attached document Figure 1 Appendix Figure 2 and attached Figure 6The clamping component and the adjusting component of the present invention work together to form a workpiece positioning and locking system, which is installed on the top surface of the base plate 18.

[0065] The clamping assembly includes clamp 5 and clamp 6. The bases of clamp 5 and clamp 6 are jointly fixed to the slider 27 of the adjusting assembly, thereby achieving a sliding connection with the base plate 18. A hydraulic rod 11 is vertically mounted on the top plane of both clamp 5 and clamp 6. The hydraulic rod 11 is a single-acting hydraulic cylinder, and the extension of its piston rod is controlled by the controller 2 through a solenoid valve to apply a vertically downward clamping force.

[0066] A key structural feature is that the workpiece bearing plane of clamp 15 is higher than the workpiece bearing plane of clamp 26, with a predetermined vertical height difference between them. The height difference The design is to match the irregular three-dimensional geometry of the small hook workpiece on the guide rail. Specifically, a thinner portion of the workpiece is placed on the higher clamp 5, while a thicker portion is placed on the lower clamp 6, allowing the workpiece to be placed stably in a natural, stress-free state before being clamped. This structure ensures that the clamping force applied by the hydraulic rod 11 is evenly distributed on the key support points of the workpiece, avoiding inaccurate positioning or machining deformation caused by workpiece tilting or warping.

[0067] The adjustment assembly provides precise planar position adjustment for the clamping assembly. This assembly includes a slider 27 fixedly connected to the bottom of the bases of clamping seat 5 and clamping seat 6. A high-precision groove 28 is machined on the top surface of the base plate 18 along a preset direction (e.g., the Y-axis perpendicular to the workpiece length). The slider 27 is a linear guide slider adapted to the groove 28, slidingly connected inside the groove 28 with minimal movement clearance, thus ensuring the smoothness and directional accuracy of the adjustment movement.

[0068] To achieve automated adjustment, when the controller 2 issues a position adjustment command, the function execution module c drives the slider 27 to move linearly, which in turn drives the entire clamping assembly (clamping seat one and clamping seat two) to move synchronously, so as to achieve closed-loop feedback calibration of the workpiece.

[0069] When the workpiece is clamped, the total clamping force provided by hydraulic rod 11 is... It must be strong enough to withstand the maximum horizontal force generated during subsequent bending processes. This clamping force is used to prevent the workpiece from slipping during processing. The following static conditions must be met for the setting:

[0070] ;

[0071] in, It is the total vertical clamping force (N) applied by the two hydraulic rods 11. It is the maximum horizontal force component (N) applied to the workpiece by the bending mechanism during processing. It is the coefficient of static friction between the workpiece material and the bearing surfaces of clamp 5 and clamp 6. The clamping actuator precisely controls the working pressure of the hydraulic system by adjusting the control current input to the electromagnetic proportional valve of the hydraulic station. This controls the output force of the hydraulic rod 11, thereby achieving the desired effect. The precise settings are adapted to meet the processing requirements of workpieces with different material thicknesses and strengths.

[0072] See attached document Figure 1 -Appendix Figure 7 The bending mechanism of the present invention is the core processing system for performing the final forming operation of the small hook of the guide rail. Its internal structure integrates three functional components: driving, supporting and executing.

[0073] The bending mechanism's drive assembly uses a motor 9 installed inside the main frame 1 as its core power source. This motor 9 is preferably a high-torque servo motor, with its output shaft rigidly connected to the input end of the support bracket 14. The support bracket 14 is the main moving component of the entire bending mechanism. A base 15 is fixedly mounted on the top of the base plate 18 inside the main frame 1, and bearings are integrated into this base 15. The support bracket 14 is rotatably connected to the base 15 via this bearing structure, allowing it to rotate precisely around a vertical central axis under the drive of the motor 9.

[0074] The support assembly of the bending mechanism provides stable reaction force support for the workpiece during the bending process. A crossbeam 10 is fixedly connected to the outer wall of the support 14. The inner surface of the crossbeam 10 is machined with a guide groove, and a stop block 19 is slidably connected to the guide groove of the crossbeam 10 through its sliding fit structure. A vertical plate 20 is fixedly connected to the middle of the support 14, and the side of the vertical plate 20 abuts against one end face of the stop block 19. During operation, the workpiece is clamped between the stop block 19 and the bending plate 25. Under the action of the bending force, the stop block 19 transmits the reaction force to the vertical plate 20 and the support 14, forming a closed mechanical support structure.

[0075] The bending mechanism's actuating component is a precision compound linkage mechanism used to convert driving force into the final bending action. The cylinder of a second hydraulic rod 21 is connected to the middle of a bracket 14 via a rotating hinge. A fixed plate 23 is fixedly connected to the bracket 14, adjacent to the second hydraulic rod 21. A rotating plate 22 is rotatably connected to the fixed plate 23 via a pin. The piston rod output end of the second hydraulic rod 21 is rotatably connected to one end of the lever arm of the rotating plate 22 via a hinge.

[0076] The other end of the first rotating plate 22 is rotatably connected to the second rotating plate 24 via a pin. A linear slide rail 26 is fixedly installed on the inner side of the bracket 14, i.e., the area facing the workpiece processing. A bending plate 25 is slidably connected to the slide rail 26 via a slider. The front end of the bending plate 25 is a forming cutter head designed according to the inner bending angle of the workpiece. The top of the bending plate 25 is rotatably connected to one end of the second rotating plate 24 via a pin.

[0077] The motion chain of the actuator is as follows: When the piston rod of the hydraulic rod 21 is extended by the function actuator c, its thrust acts on the rotating plate 22, causing it to rotate around the fulcrum on the fixed plate 23. The rotation of the rotating plate 22 drives the movement of the rotating plate 24, which in turn pushes the bending plate 25. Since the bending plate 25 is constrained by the slide rail 26 and can only move linearly, the compound motion of the entire linkage mechanism is ultimately converted into the linear reciprocating motion of the bending plate 25 along the slide rail 26, thereby applying a precise horizontal bending force to the pressed workpiece.

[0078] When generating control commands, the bending actuator needs to calculate the minimum bending force required for bending. The working pressure of hydraulic rod 21 is set. This force can be estimated using the following formula:

[0079] ;

[0080] in, The required bending force (N); This is the bending process factor, which depends on the geometry of the mold. For V-bending, it is usually taken as 1.33. The bending line width of the workpiece (mm); The material thickness of the workpiece (mm); The tensile strength (MPa) of the workpiece material; This is the distance between the support points, i.e., the force span (mm) of the workpiece during bending.

[0081] Controller 2 based on the input workpiece parameters ( ) and process parameters ( ), calculate The output force of hydraulic rod 21 is set accordingly to ensure that the bending operation is completed with minimal and sufficient energy, while avoiding excessive damage to the workpiece.

[0082] See attached document Figure 7 and Figure 8 The collaborative control system of this invention and its working principle are explained below. This system, integrated within controller 2, is the core for achieving automated and precise equipment operation.

[0083] The hardware and software architecture of the collaborative control system is divided into three basic functional layers: monitoring module a, control module b, and function execution module c.

[0084] Monitoring module a primarily consists of a monitor 13 fixed inside the main frame 1. In this embodiment, the monitor 13 can be a combination of one or more high-resolution industrial cameras (e.g., using a CMOS image sensor) and a laser displacement sensor. The module's function is to acquire two types of data in real time:

[0085] The working status data of each mechanism, such as the encoder reading of motor 9, the pressure sensor readings of hydraulic rod 11 and hydraulic rod 21, and the limit switch signals of each cylinder;

[0086] The position and orientation information of the workpiece, especially at the machining station, is obtained by acquiring the three-dimensional coordinates of the workpiece and the data on its fit with the reference (such as the support platform 8) through image acquisition and laser scanning.

[0087] Control module b receives all real-time data streams from monitoring module a via a data bus. Internally, control module b contains preset operating procedures and control algorithm models. Its core functions are: real-time analysis and processing of the collected data, such as edge detection and feature extraction of image data to calculate workpiece position, and logical judgment of status data; and based on the analysis results and preset process flow, generating a series of coordinated control instructions with sequential logical relationships.

[0088] Function execution module c, composed of a series of hardware driver units, serves as the interface between control module b and the various physical actuators of the device. Function execution module c can be further subdivided into:

[0089] The bending actuator unit includes a servo motor driver and a hydraulic proportional valve / solenoid valve drive circuit. This unit receives commands from the control module b regarding rotation speed, angle, thrust, and speed, and converts them into corresponding current or voltage signals to precisely control the operation of the motor 9 and the extension and retraction of the hydraulic rod 21.

[0090] The clamping actuator includes a hydraulic proportional valve / solenoid valve drive circuit. This unit is electrically connected to the control valve of hydraulic rod 11, and precisely adjusts the hydraulic system pressure according to the coordinated control command, thereby controlling the clamping force of clamp 5 and clamp 6.

[0091] The clamping execution unit includes a servo motor driver and a pneumatic solenoid valve drive circuit. This unit is used to control the servo motor of the electric slide table 12 to achieve precise horizontal displacement of the robotic arm 4; at the same time, it controls the valves of the pneumatic system to perform the gripping / releasing actions of the end effector of the robotic arm 4 and the clamping / releasing actions of the fixed gripper 16.

[0092] Based on the above-mentioned collaborative control system, the specific steps of the automated workflow of this invention are as follows:

[0093] Step 1: Loading and gripping the workpiece.

[0094] After system initialization, the clamping execution unit of function execution module c controls the electric slide table 12 and the robotic arm 4 to move to the preset loading station, i.e., the position of the fixed gripper 16. The end effector of the robotic arm 4 descends and grabs a workpiece to be processed.

[0095] Step 2: Workpiece placement and initial monitoring.

[0096] The clamping execution unit controls the robotic arm 4 to transfer the gripped workpiece to the processing area and gently place it on the clamping assembly's first clamp 5 and second clamp 6, so that one side of the workpiece initially contacts the abutment 8 on the top of the bottom plate 18. At this time, the workpiece is in a coarse positioning state.

[0097] Step 3: Precise positioning calibration based on closed-loop feedback.

[0098] This is a key step in the present invention. After the workpiece is placed, the control module b immediately activates the monitoring module a. The monitor 13 (such as an industrial camera) acquires images of the contact area between the workpiece and the support platform 8. The image processing algorithm of the control module b calculates the actual gap or deviation data between the edge of the workpiece and the reference line of the support platform 8. .

[0099] Control module b will Compared with the preset standard value stored in memory (The ideal value is 0) is compared to calculate the positional deviation. .like Greater than the preset tolerance threshold (For example, (mm), control module b immediately executes the PID control algorithm:

[0100] ;

[0101] Generate a precise control output signal The signal is sent to function execution module c. Function execution module c drives the motor of the adjustment component, causing the slider 27 to make a small displacement, thereby synchronously adjusting the position of the entire clamping component. This is an iterative process: adjustment-monitoring-calculation-readjustment, until the data fed back by monitor 13 meets the requirements. The calibration process is now complete.

[0102] Step 4: Workpiece clamping and bending.

[0103] After positioning and calibration are completed, control module b issues a clamping command. The clamping actuator controls the hydraulic rod 11 to extend, applying the set pressure. Securely lock the workpiece onto clamp 5 and clamp 6.

[0104] Next, control module b issues a bending command. The bending execution unit controls motor 9 and / or hydraulic rod 21 to drive the bending mechanism according to the preset motion curve and force value, so that the bending plate 25 completes a precise bending operation on the workpiece.

[0105] Step 5: Finished product unloading and system reset.

[0106] After bending is completed, the actuators (hydraulic rod 1, bending plate, etc.) of the bending and clamping mechanisms reset under control commands. The clamping actuator then controls the robotic arm 4 to move to the processing area, picks up the formed guide rail hook, and transfers it to the designated finished product collection area. All components reset to their initial state, awaiting the start of the next work cycle.

[0107] Working principle: When the equipment is working, the casters 3 installed at the bottom of the main frame 1 allow the equipment to move, and the top lighting 7 provides illumination. The whole process is directed by the controller 2 outside the main frame 1 and its internal collaborative control system. The system first controls the movement of the two electric slides 12 of the clamping assembly through the clamping execution unit of the function execution module, which drives the mechanical arm 4 at the bottom to grab the workpiece from the gripper 16 (which is equipped with rubber pads 17) inside the main frame 1 and place it on the clamping assembly on the bottom plate 18 inside the main frame 1. The clamping assembly consists of clamping seat 1 5 and clamping seat 2 6 above it. The workpiece is placed and initially abuts against the abutment 8 on the top of the bottom plate 18.

[0108] Subsequently, the monitor 13 of the monitoring module immediately collects the fit data between the workpiece and the platform 8 in real time. The control module receives the data and compares it with the preset standard. If the fit data does not meet the preset requirements, the control module generates a position adjustment command and transmits it to the function execution module. The function execution module controls the slider 27 of the adjustment component to slide inside the groove 28 of the base plate 18. This sliding causes the clamp 1 5 and clamp 2 6 to adjust their positions synchronously until the monitor 13 detects that the workpiece and the platform 8 are precisely fitted. Then, the pressing execution unit of the function execution module starts the hydraulic rod 11 on the top of clamp 1 5 and clamp 2 6 to firmly press the workpiece.

[0109] Next, the bending execution unit starts the bending mechanism. The motor 9 of its drive component drives the fixedly connected bracket 14 to rotate on the base 15. At the same time, the horizontal frame 10, the abutment block 19 and the vertical plate 20 of the support component provide stable contact with the workpiece. The rotation of the bracket 14 starts the execution component, causing the hydraulic rod 21 to push the rotating plate 22 rotatably connected to the fixed plate 23. The rotating plate 22 then links with the rotating plate 24, finally driving the bending plate 25 to slide on the slide rail 26 to complete the precise bending of the workpiece. After the bending is completed, the hydraulic rod 11 is released, and the clamping execution unit controls the robotic arm 4 to grab the formed workpiece and remove it. The entire collaborative control system realizes fully automated assembly through the coordinated operation of the monitoring module, the control module and the functional execution module.

Claims

1. A rail small hook automated assembly apparatus comprising a main frame (1), characterized in that, The bottom of the main frame (1) is provided with universal wheels (3), the top of the main frame (1) is provided with illuminating lamps (7), the outside of the main frame (1) is provided with a controller (2), the inside of the main frame (1) is fixedly connected with a bottom plate (18), the inside of the main frame (1) is provided with a bending mechanism, the inside of the main frame (1) is provided with a pressing assembly, the outside of the pressing assembly is provided with an adjusting assembly, the top of the inside of the main frame (1) is provided with a clamping assembly, the inside of the controller (2) is integrated with a cooperative control system, the cooperative control system processes data collected by a monitoring module through a control module to generate a cooperative control instruction, and the cooperative control instruction is input to a function execution module. The clamping assembly comprises two electric sliding tables (12), both of which are fixedly connected to the top of the inside of the main frame (1), and both of which are fixedly connected with mechanical arms (4) at the bottom. The monitoring module comprises a monitor (13) fixedly connected to the inside of the main frame (1), which is used for collecting the working state data of the bending mechanism, the pressing assembly, the adjusting assembly and the clamping assembly in real time, and collecting the position and attitude information of the workpiece at the same time. The control module is used for receiving the collected data of the monitor (13), and generating a cooperative control instruction after analyzing and processing the data through a preset logic. The function execution module is electrically connected with the bending mechanism, the pressing assembly, the adjusting assembly and the clamping assembly respectively, and is used for accurately receiving and executing the cooperative control instruction to realize the linkage operation of each component. The top of the bottom plate (18) is fixedly connected with a supporting table (8), and the monitoring module monitors the placement state of the workpiece on the supporting table (8) through the monitor (13) to collect the adhesion data of the workpiece and the supporting table (8). The control module compares the adhesion data with a preset standard, generates a position adjustment instruction and transmits it to the function execution module when the data does not meet the preset requirement, the function execution module controls the sliding block (27) of the adjusting assembly to slide along the sliding groove (28), drives the clamping seat one (5) and the clamping seat two (6) of the pressing assembly to adjust the position synchronously, and ensures the accurate adhesion of the workpiece and the supporting table (8).

2. The rail small bend hook automated assembly apparatus according to claim 1, wherein The bending mechanism comprises a driving assembly, a supporting assembly and an execution assembly, the driving assembly comprises a motor (9) fixedly connected to the inside of the main frame (1), the output end of the motor (9) is fixedly connected with a support (14), the top of the bottom plate (18) is fixedly connected with a base (15), and the support (14) is rotatably connected to the outside of the base (15).

3. The rail small bend hook automated assembly apparatus according to claim 2, wherein The supporting assembly comprises a cross frame (10) fixedly connected to the outside of the support (14), the inside of the cross frame (10) is slidably connected with a resisting block (19), the middle of the support (14) is fixedly connected with a vertical plate (20), and the vertical plate (20) and the resisting block (19) abut each other.

4. The rail small bend hook automated assembly apparatus according to claim 2, wherein The executing assembly includes a hydraulic rod two (21), the hydraulic rod two (21) is rotatably connected in the middle of the support (14), the middle of the support (14) is fixedly connected with a fixed plate (23), the outer part of the fixed plate (23) is rotatably connected with a rotating plate one (22), the output end of the hydraulic rod two (21) is rotatably connected with one end of the rotating plate one (22), the outer part of the rotating plate one (22) is rotatably connected with a rotating plate two (24), the inner side of the support (14) is fixedly connected with a sliding rail (26), the outer part of the sliding rail (26) is slidably connected with a bending plate (25), the top of the bending plate (25) is rotatably connected with a rotating plate two (24).

5. The rail small bend hook automated assembly apparatus according to claim 1, wherein The pressing assembly includes a clamping seat one (5) and a clamping seat two (6), the clamping seat one (5) and the clamping seat two (6) are slidably connected on the top of the bottom plate (18), the clamping seat one (5) and the clamping seat two (6) are both provided with a hydraulic rod one (11) on the top, and the clamping seat one (5) is higher than the clamping seat two (6).

6. A rail small bend hook automated assembly apparatus according to claim 5, wherein The adjusting assembly includes a sliding block (27), the sliding block (27) is fixedly connected on the bottom of the clamping seat one (5) and the clamping seat two (6), and the top of the bottom plate (18) is provided with a sliding groove (28), and the sliding block (27) is slidably connected on the inner side of the sliding groove (28).

7. The rail small bend hook automated assembly apparatus according to claim 1, wherein The inner side of the main frame (1) is fixedly connected with two clamping jaws (16), and the outer part of the two clamping jaws (16) is fixedly connected with a rubber pad (17).

8. The rail small bend hook automated assembly apparatus according to claim 1, wherein The function executing module includes a bending executing unit, a pressing executing unit and a clamping executing unit; the bending executing unit is used for controlling the motor (9) to run and completing the workpiece bending operation; The pressing executing unit is electrically connected with the hydraulic rod one (11), and is used for adjusting the pressing force of the clamping seat one (5) and the clamping seat two (6) according to the cooperative control instruction; The clamping executing unit is electrically connected with the electric sliding table (12) and the clamping jaw (16), and is used for controlling the mechanical arm (4) to complete the workpiece grabbing and transferring and controlling the clamping jaw (16) to clamp and loosen the workpiece for preliminary processing, and the rubber pad (17) outside the clamping jaw (16) is used for buffering the clamping force.

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