Flexible assembly tray compatible with various types of axles and mixed-line production method

Abstract

The invention discloses a flexible assembly tray compatible with various types of axles and a mixed line production method, and relates to the technical field of automobile manufacturing equipment. The tray comprises a base assembly, an adjusting module and a supporting assembly. The supporting assembly is installed on the base assembly through the adjusting module and can move in the horizontal direction. The supporting assembly comprises a rigid supporting seat, and a composite supporting groove is formed in the top of the rigid supporting seat. The composite supporting groove is provided with an upper opening structure, the groove bottom face is constructed to be an arc-shaped supporting face matched with the axle with the circular section, and the two sides located above the arc-shaped supporting face are constructed to be plane supporting parts matched with the axle with the rectangular section. Shared supporting of the circular shaft and the square shaft is achieved through the composite supporting groove structure, transverse adjustment of the supporting position is achieved through the adjusting module, the interference problem of axles with different shaft pipe sections, different braking forms and suspension layouts in mixed line production is effectively solved, the flexibility and the automation level of a production line are remarkably improved, and the production efficiency is improved. And the equipment investment cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of automotive manufacturing equipment technology, and in particular to a flexible assembly tray compatible with multiple types of axles and a mixed-line production method. Background Technology

[0002] Semi-trailer axles, as important chassis components, come in a wide variety of types. For example... Figure 1 As shown, axles can be classified into square axles (e.g., 150x150mm) and round axles (e.g., φ146mm) according to their axle tube form; into drum brakes and disc brakes according to their braking form; into leaf spring suspensions and guide arm (air suspension) according to their suspension form; and into single-tire and dual-tire axles according to their tire mounting form and leaf spring center distance.

[0003] In automated or semi-automated axle assembly lines, pallets are the standard tooling for supporting and transporting axles. In existing technologies, specialized pallets are commonly used for assembly of different types of axles. For example, ... Figure 2 The square-shaft drum brake leaf spring dual-tire axle shown, and as... Figure 3 The single-tire axle with a circular disc brake guide arm shown has a significantly different structure, requiring the use of two completely different dedicated trays. The design of these dedicated trays is fixed and incompatible with other types of axles.

[0004] In existing semi-trailer axle assembly lines, specialized pallets are commonly used. This means:

[0005] 1. Incompatible with different cross sections: The shapes of square shafts and round shafts are very different, and the V-shaped blocks or flat bottom blocks of traditional pallets are difficult to stably support both types of shaft tubes at the same time.

[0006] 2. Frequent interference problems: The positions of brakes (drum / disc) and suspension supports vary between different axles. Fixed-space tray supports are prone to spatial interference with axle components (such as brake chamber brackets, welds, and suspension mounts), making loading impossible.

[0007] 3. Poor flexibility and high cost: Due to the above reasons, companies usually need to build different sub-assembly lines for different types of axles, or frequently change heavy pallets on the same line. This not only increases the cost of equipment investment, but also seriously limits the level of automated flexible production.

[0008] Therefore, there is an urgent need for a universal pallet that can adapt to different axle tube forms, different braking and suspension layouts, in order to realize mixed-line production of semi-trailer axles. Summary of the Invention

[0009] To address the shortcomings in the prior art, this invention provides a flexible assembly pallet compatible with multiple types of axles and a mixed-line production method, aiming to solve the technical problems in the prior art where pallets cannot be universally used and mixed-line automated production is difficult to achieve due to differences in axle cross-sectional shapes and component layouts.

[0010] To solve the above-mentioned technical problems, in a first aspect, the present invention provides the following technical solution:

[0011] A flexible assembly pallet compatible with multiple types of axles includes a base assembly, and further includes: an adjustment module disposed on the base assembly; and a support assembly mounted on the base assembly via the adjustment module and capable of moving horizontally relative to the base assembly; the support assembly includes a rigid support seat, the top of which is provided with a composite support groove for supporting the axle; the composite support groove has an open upper structure, the bottom surface of the composite support groove is configured as an arc-shaped support surface adapted to a circular cross-section axle, and the two sides of the composite support groove above the arc-shaped support surface are configured as planar support surfaces adapted to a rectangular cross-section axle.

[0012] This invention utilizes a composite support groove structure, enabling the pallet to achieve adaptive support by leveraging the axle's own geometry: when a round shaft is placed, its weight causes it to fall onto the lower arc-shaped support surface for centering and support; when a square shaft is placed, its bottom surface rests directly on the upper planar support surface. Simultaneously, by adjusting the module to allow lateral movement of the support assembly, the position of the support points can be flexibly adjusted, thus avoiding interference zones with components such as brakes and suspensions on different axles. This design allows a single pallet to accommodate mixed-line production of multiple axles.

[0013] In a preferred embodiment of the present invention, the support assembly further includes a buffer adapter disposed within the composite support groove. The inner surface of the buffer adapter is an arc-shaped surface that conforms to the outer wall of the circular cross-section axle. The buffer adapter is made of an elastic material and is fixedly connected to the side wall or bottom surface of the rigid support seat. By further employing a buffer adapter made of an elastic material (such as polyurethane), not only can the axle surface be protected from scratches by the rigid support seat, but the friction between the round shaft and the support surface can also be significantly increased, preventing the round shaft from rotating or wobbling during transportation and improving stability.

[0014] In a preferred embodiment of the present invention, the adjustment module includes: a linear guide rail extending laterally perpendicular to the pallet conveying direction and fixed to the base assembly; a slider slidably engaged with the linear guide rail, the bottom of the rigid support base being fixedly connected to the slider; and a locking mechanism for locking the support assembly at a preset position on the base assembly. By employing the linear guide rail and slider mechanism, the smoothness and accuracy of the support assembly's movement are ensured, while the locking mechanism ensures that the pallet's position is maintained during operation after adjustment.

[0015] In a preferred embodiment of the present invention, the locking mechanism includes an adjustable locking bolt, which passes through a mounting hole on the rigid support and is threadedly connected to a fixing structure below. Tightening the adjustable locking bolt restricts the movement of the slider on the linear guide rail. The bolt locking method is simple in structure, highly reliable, and easy for workers to operate.

[0016] In a preferred embodiment of the present invention, the adjustment module further includes a dust cover that covers the exposed area of ​​the linear guide rail to prevent welding spatter from falling into the linear guide rail. The dust cover design effectively solves the problem of guide rail jamming caused by welding slag falling from the welding station on the axle assembly line, thus extending the service life of the equipment.

[0017] As a preferred embodiment of the present invention, the base assembly includes: a base plate, serving as the main load-bearing structure; a walking support assembly, installed below the base plate, for supporting the pallet to move on the production line track; and a guide assembly, installed below the base plate, for limiting the left and right deviation of the pallet during movement.

[0018] In a preferred embodiment of the present invention, the traveling support assembly is a cam bearing, which has an eccentric adjustment structure for adjusting the levelness of the base plate; the guiding assembly is a guide bearing, which is arranged on the side of the production line track to achieve centering guidance. The eccentricity adjustment function of the cam bearing makes the overall levelness of the pallet adjustable to adapt to track errors; the guide bearing ensures that the pallet runs centered in the C-shaped track.

[0019] To solve the above-mentioned technical problems, in a second aspect, the present invention provides the following technical solution:

[0020] A method for mixed-line production of semi-trailer axles based on the aforementioned flexible assembly pallet, the method comprising the following steps:

[0021] S1: Identify the type of axle to be assembled, the type including the cross-sectional shape parameters and component layout parameters of the axle;

[0022] S2: Based on the component layout parameters, adjust the support assembly to move laterally to a position that avoids interference, and maintain the support assembly in the adjusted position;

[0023] S3: Hoist the axle to be assembled onto the pallet; if the axle has a circular cross-section, place the axle into the arc-shaped support surface of the support assembly and use the arc-shaped surface for positioning; if the axle has a rectangular cross-section, place the axle on the planar support surface of the support assembly and use the planar contact for support.

[0024] This method allows production line operators or automated systems to quickly adjust pallet status based on the type of products currently being produced, enabling "one-piece flow" or mixed-line production of small batches and multiple varieties, which greatly improves production efficiency and flexibility.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] 1. Multi-purpose and cost-reducing: The composite groove shape consisting of "rigid support + polyurethane support" enables the shared support of square and round shafts, eliminating the need to develop special pallets for axles with different cross-sections, and significantly reducing the equipment investment costs for enterprises.

[0027] 2. Eliminate interference and enhance flexibility: Through the Y-axis adjustable adjustment module, the support position can be flexibly adjusted according to the different positions of the axle brake (drum / disc) and suspension (leaf spring / air suspension), which effectively solves the interference problem caused by different leaf spring center distances and different component layouts, filling the gap in the field of mixed production of semi-trailer axles.

[0028] 3. Stable operation and easy maintainability: The base assembly integrates walking, guiding, and positioning functions. In particular, the dust cover design adapts to the harsh environment of the welding workshop, ensuring the long-term reliable operation of the linear guide. The polyurethane support increases the stability of the round shaft and prevents the workpiece from rotating. Attached Figure Description

[0029] To more clearly illustrate the technical solutions of the embodiments disclosed in this invention, the accompanying drawings of the embodiments will be briefly described below. These drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention.

[0030] Figure 1 This is a classification diagram of the types of semi-trailer axles in the existing technology;

[0031] Figure 2 This is a schematic diagram of a dual-trail tray with a square shaft drum brake and leaf spring, based on existing technology.

[0032] Figure 3 This is a schematic diagram of a single-tire pallet with a circular shaft disc brake guide arm in the existing technology;

[0033] Figure 4 This is a cross-sectional schematic diagram of the square shaft placement state in an embodiment of the present invention;

[0034] Figure 5 This is a cross-sectional schematic diagram of the circular shaft in its placement state in an embodiment of the present invention;

[0035] Figure 6 This is a schematic diagram of the structure of the circular shaft after adding polyurethane support in an embodiment of the present invention;

[0036] Figure 7 This is a schematic diagram of the interference between the pallet bracket and the axle brake in an embodiment of the present invention;

[0037] Figure 8 This is a schematic diagram illustrating how interference is avoided by moving the support in an embodiment of the present invention;

[0038] Figure 9 This is a schematic diagram of the dimensions for adjusting the support spacing in an embodiment of the present invention;

[0039] Figure 10 This is a schematic diagram of the overall structure of the flexible assembly pallet provided in an embodiment of the present invention;

[0040] Figure 11 This is a schematic diagram of the base assembly in an embodiment of the present invention;

[0041] Figure 12 This is a schematic diagram of the adjustment module in an embodiment of the present invention;

[0042] Figure 13 This is a schematic diagram of the support assembly in an embodiment of the present invention.

[0043] In the picture:

[0044] 1. Base assembly; 11. Base plate; 12. Travel support assembly; 13. Guide assembly; 14. Positioning pin; 15. Stop plate;

[0045] 2. Adjustment module; 21. Linear guide rail; 22. Slider; 23. Dust cover;

[0046] 3. Support assembly; 31. Rigid support seat; 32. Buffer adapter; 33. Adjustable distance locking bolt. Detailed Implementation

[0047] The technical solutions (including preferred technical solutions) of the present invention will be further described in detail below with reference to the accompanying drawings and by way of listing some optional embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0048] Example 1

[0049] This embodiment provides a flexible assembly pallet compatible with various types of axles, such as Figure 10 As shown, the pallet mainly consists of three parts: a base assembly 1, an adjustment module 2, and a support assembly 3. The support assembly 3 is used to support different types of axles and is mounted on the base assembly 1 via the adjustment module 2. It can slide freely in the Y direction (i.e., the transverse direction perpendicular to the production line conveying direction) to accommodate axles of different specifications.

[0050] like Figure 11 As shown, the base assembly 1 is the basic frame of the pallet, including a base plate 11. A walking support assembly 12 is mounted on the base plate 11; in this embodiment, a cam bearing is specifically used to allow the pallet to move on the plane of the C-shaped track (not shown) of the assembly line. This cam bearing has an eccentric adjustment function; by rotating the shaft, the height or level of the pallet can be finely adjusted to ensure the overall levelness of the pallet. A guide assembly 13, specifically a guide bearing, is also provided below the base plate 11. It rolls on the left and right guide surfaces of the C-shaped track, providing guidance and keeping the pallet centered during operation. Furthermore, a positioning pin 14 is provided on the base plate 11 for precisely positioning and fixing the pallet at manual or automated workstations; a stop plate 15 is provided below the base plate to block the pallet at the return section of the lower differential chain, allowing for pallet accumulation.

[0051] like Figure 12 As shown, the adjustment module 2, typically a slide rail assembly, is mounted on the base assembly 1. Its main function is to enhance the strength of the base and provide sliding functionality. It includes a linear guide rail 21, a standard slider 22, and a dust cover 23. The linear guide rail 21 is fixed to the base plate 11. The dust cover 23 is mounted on the base assembly and covers the exposed portion of the linear guide rail 21. Since axle assembly lines often involve welding processes, the dust cover effectively prevents welding slag from falling onto the linear guide rail, which could cause the slider to jam or be damaged.

[0052] like Figure 13 As shown, the support assembly 3 is the core load-bearing component, including a rigid support base 31 and a buffer adapter 32. Generally, the buffer adapter uses polyurethane support. The bottom of the rigid support base 31 is connected to the standard slider 22 of the adjustment module 2, thereby realizing sliding along the linear guide rail 21.

[0053] The top of the rigid support seat 31 is designed with a special composite geometry: the bottom has an arc groove, and the upper two sides of the arc groove are planar steps - that is, planar support surfaces.

[0054] like Figure 4As shown, when a square shaft (such as a 150x150mm square tube) is placed, the bottom plane of the square shaft rests directly on the plane support surface above the rigid support seat 31. Since the bottom surface of the square shaft is flat, it rests on the steel plane support without shaking, thus achieving stable support.

[0055] like Figure 5 and Figure 6 As shown, when a round shaft (such as a φ146mm round tube) is placed, because the diameter of the round shaft is smaller than the spacing of the upper plane steps, the round shaft will naturally fall into the lower arc groove. To solve the problem of low friction and instability when the round shaft falls on the steel arc surface, this embodiment installs a buffer adapter 32, specifically a polyurethane arc surface block, on the arc sidewall of the rigid support 31. Figure 3 and Figure 6 As shown, adding polyurethane arc surface support increases friction and ensures the stability of the round shaft during transportation.

[0056] The support assembly 3 is also equipped with a locking mechanism, which in this embodiment is specifically an adjustable locking bolt 33. By rotating the hexagonal bolt head with a wrench, the rigid support seat 31 can be fixed relative to the base assembly 1 to prevent accidental sliding of the support position during production.

[0057] Example 2

[0058] This embodiment provides a method for mixed production of semi-trailer axles based on the pallet described in Embodiment 1.

[0059] In the prior art, for different axles (such as...) Figure 1 As shown, a dedicated pallet needs to be replaced. However, using the pallet of this invention allows for mixed-line production.

[0060] The steps are as follows:

[0061] S1: First, confirm the type of axle that will be launched.

[0062] S2: Adjust the pallet support spacing according to the axle type.

[0063] like Figure 7 As shown, if the pallet support position is fixed, the brake drum or suspension bracket of some axles may interfere with the support seat.

[0064] At this time, the operator or the automatic adjustment device loosens the adjustment locking bolt 33 and pushes the support assembly 3 to slide along the linear guide rail 21.

[0065] like Figure 8 and Figure 9As shown, move the support assembly 3 to avoid interference areas with the axle brakes or suspension. For example, for a square-axle drum brake leaf spring dual-tire axle, the support spacing may need to be adjusted to 648mm (maximum support spacing); for other types of axles, it may be adjusted to 268mm (minimum support spacing) or any intermediate non-interference position. After adjustment, tighten the adjustment locking bolt 33.

[0066] S3: Lifting vehicle axle.

[0067] If it is a square axle, such as Figure 4 As shown, it is placed directly on the top plane support of support assembly 3.

[0068] If it is a round axle, such as Figure 5 and Figure 6 As shown, when placed in support assembly 3, the round shaft will automatically fall into the polyurethane arc surface support and be held tightly.

[0069] Example 3

[0070] This embodiment is a further extension of the above embodiments.

[0071] In the above embodiment, the buffer adapter 32 is made of polyurethane. In other alternative embodiments, the buffer adapter 32 may also be made of industrial rubber, nylon, or other high-wear-resistant, high-friction coefficient elastomer materials, as long as they can provide anti-slip and protection for the workpiece surface.

[0072] In the above embodiment, the adjustment module 2 is manually locked. In a more automated variant, the linear guide 21 can work with a lead screw and nut mechanism and be driven by a servo motor to automatically adjust the spacing of the support assembly 3, thereby linking with the production management system (MES) to achieve fully automated switching between mixed-line production.

[0073] Furthermore, the pallet of the present invention is not only applicable to semi-trailer axles, but also, by adjusting the size of the composite support groove, is fully applicable to the flexible transport of other long strip workpieces with similar cross-sectional changes (square / round) such as truck rear axles and construction machinery axles.

[0074] It should be noted that although the embodiments describe in detail the function of the locking mechanism through adjustable locking bolts, those skilled in the art should understand that the locking mechanism is not limited to bolt connections. In other embodiments, the locking mechanism may also employ quick-release clamps, cam locking mechanisms, pneumatic or hydraulic locking cylinders, or the self-locking torque of a servo motor to fix the position of the support assembly on the base assembly. Similarly, the connection method of the buffer adapter is not limited to a fixed connection; it may employ detachable methods such as snap-fit ​​connections, dovetail groove embedding, or Velcro fastening for quick replacement after wear.

[0075] It will be readily understood by those skilled in the art that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, combinations, substitutions, improvements, etc., made under the spirit and principles of the present invention are included within the protection scope of the present invention.

Claims

1. A flexible assembly pallet compatible with multiple types of axles, comprising a base assembly, characterized in that, Also includes: An adjustment module is mounted on the base assembly; as well as The support assembly is mounted on the base assembly via the adjustment module and is movable in the horizontal direction relative to the base assembly. The support assembly includes a rigid support base, the top of which is provided with a composite support groove for supporting the axle; The composite support groove has an open upper structure, and the bottom surface of the composite support groove is constructed into an arc-shaped support surface adapted to the circular cross-section axle. The two sides of the composite support groove above the arc-shaped support surface are constructed into planar support surfaces adapted to the rectangular cross-section axle.

2. The flexible assembly pallet according to claim 1, characterized in that, The support assembly also includes a buffer adapter disposed in the composite support groove, the inner surface of which is an arc-shaped surface that fits against the outer wall of the circular cross-section axle. The buffer adapter is made of elastic material and is disposed on the side wall or bottom surface of the rigid support. The radius of curvature of the arcuate surface of the buffer adapter is matched with the radius of the axle to be assembled, so as to provide frictional damping when the axle is loaded.

3. The flexible assembly pallet according to claim 1, characterized in that, The adjustment module includes: A linear guide rail extends laterally perpendicular to the pallet conveying direction and is fixed to the base assembly; A slider is slidably fitted onto the linear guide rail, and the bottom of the rigid support base is fixedly connected to the slider; and A locking mechanism is provided to lock the support assembly in a preset position on the base assembly. The locking mechanism includes an adjustable locking bolt that passes through a mounting hole on the rigid support and is threaded to a fixing structure below. Tightening the adjustable locking bolt restricts the movement of the slider on the linear guide.

4. The flexible assembly pallet according to claim 3, characterized in that, The adjustment module also includes a dust cover that covers the exposed area of ​​the linear guide rail to prevent welding spatter from falling into the linear guide rail.

5. The flexible assembly pallet according to claim 1, characterized in that, The base assembly includes: The base plate serves as the main load-bearing structure. A walking support assembly, installed below the base plate, is used to support the pallet as it moves on the production line track; A guide assembly, installed below the base plate, is used to limit the left and right deviation of the pallet during movement.

6. The flexible assembly pallet according to claim 5, characterized in that, The walking support assembly is a cam bearing, which has an eccentric adjustment structure for adjusting the levelness of the base plate; The guiding component is a guide bearing, which is arranged on the side of the production line track to achieve centering guidance.

7. The flexible assembly pallet according to claim 5, characterized in that, The base assembly also includes: A positioning pin is provided on the base plate and is used to cooperate with an external positioning mechanism at the assembly station to fix the position of the pallet. A stop plate is located at the bottom of the base plate and is used to cooperate with the blocking mechanism of the conveyor line.

8. The flexible assembly pallet according to any one of claims 1 to 7, characterized in that, The support assembly is symmetrically arranged in two sets, and the distance between the two sets of support assemblies is independently adjustable by the adjustment module to avoid the brake drums, brake discs or suspension components of different types of axles.

9. A method for mixed-line production of semi-trailer axles based on the flexible assembly pallet according to any one of claims 1-8, characterized in that, The method includes the following steps: S1: Identify the type of axle to be assembled, the type including the cross-sectional shape parameters and component layout parameters of the axle; S2: Based on the component layout parameters, adjust the support assembly to move laterally to a position that avoids interference, and maintain the support assembly in the adjusted position; S3: Hoist the axle to be assembled onto the pallet; If the axle has a circular cross-section, the axle is positioned within the arc-shaped support surface of the support assembly, using the arc-shaped surface for positioning. If the axle has a rectangular cross-section, the axle is mounted on the planar support surface of the support assembly, and the support is achieved through planar contact.

10. The method according to claim 9, characterized in that, In step S2, for the axle with square shaft drum brake leaf spring dual tire structure and the axle with round shaft disc brake guide arm single tire structure, the distance between the two sets of support assemblies is adjusted to different preset values ​​to avoid their respective braking and suspension components.

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