Multi-station automatic assembly system and multi-station automatic assembly method of communication controller

Abstract

The invention discloses a multi-station automatic assembly system of a communication controller, which is characterized in that a shell is provided with a plurality of mounting holes, plugs are placed in a plug tray, a visual module shoots the positions of the plugs and the positions of the mounting holes, a plug assembly device grabs the plugs and then assembles the plugs into the corresponding mounting holes, and the plugs are assembled into the mounting holes. The nut feeding device directionally conveys different nuts to a grabbing position; the nut assembling device comprises a nut grabbing and assembling assembly, the nut grabbing and assembling assembly comprises a plurality of grabbing parts, the multiple grabbing parts grab the nuts at the grabbing positions in sequence, and the grabbing parts assemble the nuts and the corresponding plugs on the mounting holes. According to the multi-station automatic assembly method of the communication controller, the plug multi-station automatic assembly system is adopted, and assembly is carried out through visual guidance feeding, visual guidance positioning, nut feeding and nut tightening. According to the shell plug and nut assembling device, assembling of a plug and a nut of a shell can be completed in a narrow space, the assembling precision is high, the quality controllability is good, the operation efficiency is high, and the product compatibility can be improved.

Description

Technical Field

[0001] This invention relates to the field of technology, and in particular to a multi-station automatic assembly system and method for a communication controller. Background Technology

[0002] In the field of precision instrument manufacturing, communication controllers are key components in industrial control. After internal assembly, they require a hydrostatic test to verify their sealing performance. Before testing, plugs must be installed at the interface and tightened with nuts to ensure a seal. The internal tightening of nuts is a crucial step in ensuring the structural integrity and long-term reliability of the product.

[0003] Currently, there are several main technical solutions for assembling nuts: (1) Manual assembly method: The operator uses a simple wrench or socket to tighten the communication controller plug inside the housing. This method lacks precision control, relies entirely on the operator's experience, and cannot accurately control the pre-tightening torque, which can easily lead to over-tightening or under-tightening. Manual operation makes it difficult to ensure the consistency of the tightening torque of each nut, which directly affects the overall quality stability of the product and results in poor quality consistency. Blind operation in a narrow space is extremely inconvenient for the operator, the assembly cycle is slow, the work efficiency is low, and the skill requirements for the operator are high.

[0004] (2) Dedicated Automated Locking Equipment: Dedicated locking mechanisms designed for specific product models can achieve a certain degree of automation, but they have fundamental limitations. Dedicated automated locking equipment has poor flexibility and adaptability; the equipment structure and control program are fixed and cannot adapt to changes in product models or minor structural adjustments. Dedicated fixtures are prone to motion interference inside a small housing and have limited adaptability to different locking positions. Furthermore, dedicated equipment needs to be designed and manufactured separately for each product model, resulting in high initial investment costs and no economies of scale.

[0005] (3) Direct assembly with general industrial robots: While using standard industrial robots equipped with conventional tightening shafts offers some flexibility, it still faces key technological bottlenecks. The end effector's posture adjustment is difficult, and within the confined space inside the casing, the robot's end effector struggles to achieve the optimal locking posture. Traditional tightening shafts lack the ability to compensate for torque transmission characteristics under complex working conditions, resulting in insufficient torque control accuracy. Furthermore, the lack of effective collision protection mechanisms during operation in confined spaces leads to weak collision resistance.

[0006] In summary, existing technologies are insufficient to simultaneously meet the requirements of adaptability to confined spaces, compatibility with multiple product models, and efficient production while ensuring assembly accuracy and quality consistency. Summary of the Invention

[0007] The technical problem to be solved by this invention is: in order to solve the technical problems of low assembly accuracy and poor quality consistency in the prior art, this invention provides a multi-station automatic assembly system and method for communication controllers, which can complete the assembly of plugs and nuts of the housing in a confined space, with high assembly accuracy, good quality controllability, high work efficiency, and improved product compatibility.

[0008] The technical solution adopted by this invention to solve its technical problem is: a multi-station automatic assembly system with a communication controller, comprising: The housing of the communication controller to be assembled, the housing having multiple mounting holes; A plug tray, wherein plugs are placed inside the plug tray; The vision module captures images of the position of the plug and the position of the mounting hole; A plug assembly device, which picks up the plug and assembles it into the corresponding mounting hole; A nut feeding device that directionally feeds different nuts to the gripping position; A nut assembly device includes a nut gripping and assembly assembly component, which includes multiple gripping parts. The multiple gripping parts sequentially grip nuts at gripping positions. The multiple gripping parts switch according to the mounting hole, and the gripping parts assemble the nuts with corresponding plugs on the mounting hole.

[0009] The multi-station automatic assembly system of the communication controller of this invention uses a vision module to accurately position the mounting holes and plugs of the housing, ensuring that the plug assembly device accurately assembles the plugs into the mounting holes. The nut assembly device completes the assembly of multiple nuts at one time, improving assembly efficiency and enabling the nuts to be tightened in a confined space. It can quickly adapt to the production needs of multiple varieties and small batches.

[0010] Furthermore, to ensure that the nut gripping and assembly assembly can accurately grip and assemble the nut, the nut assembly device further includes: A nut-tightening robot is connected to a nut-grabbing assembly via a quick-change mechanism. The nut-tightening robot drives the nut-grabbing assembly to move between the gripping position and the mounting hole. The nut-tightening robot also drives the nut-grabbing assembly to revolve, so that the nut in the gripping part faces the plug on the corresponding mounting hole.

[0011] Furthermore, in order to control the different gripping parts to grip and assemble the nut, the nut gripping and assembling assembly also includes; A drive unit is connected to the gripping part by a power source. The drive unit drives the gripping part to rotate and assembles the nut and plug located on the mounting hole. The gripping unit includes: Gearbox; A drive gear, which is connected to the output end of the drive unit; A transmission gear set is rotatably connected inside the housing. The input end of the transmission gear set meshes with the driving gear, and the output end of the transmission gear set has a nut positioning port, which cooperates with the nut to grip the nut.

[0012] Furthermore, in order to achieve the gripping and tightening of the nut, the transmission gear set includes: A primary gear, which meshes with a drive gear; The second-stage gear meshes with the first-stage gear; The third-stage gear meshes with the second-stage gear, and the nut positioning port is located on the third-stage gear.

[0013] Furthermore, to ensure the assembly quality of the nut, the drive unit includes: Tighten the gun; A torque sensor is installed on the output end of the tightening gun, and the torque sensor collects real-time data on the tightening of the nut by the gripping part; A connecting rod is mounted on a torque sensor; An adaptive floating head is mounted on a connecting square rod. An adapter rod, one end of which is mounted on the adaptive floating head, and the other end of which is connected to the drive gear to drive the drive gear to rotate.

[0014] Furthermore, in order to quickly assemble the nut gripping assembly, the nut gripping assembly also includes: A fixed flange, the upper end of which is connected to a quick-change mechanism, and a tightening gun installed on the side of the fixed flange; The connecting frame, the torque sensor, the connecting rod, the adaptive floating head and the adapter rod are located inside the connecting frame, the gearbox is mounted on the outer end face of the connecting frame, and the outer end face of the connecting frame is equipped with an end plate for pressing the gearbox.

[0015] Furthermore, in order to complete the assembly of the housing, the plug assembly device inserts the plug into the mounting hole from the outside of the housing, and the gripping part assembles the nut with the plug from the inside of the housing.

[0016] Furthermore, in order to assemble the plug onto the housing, the plug assembly device includes: A plug-grabbing fixture, the plug-loading robot including multiple gripper assemblies, the gripper assemblies closing or opening to grip or release the plug; The plug-loading robot is connected to the plug-grabbing fixture via a quick-change mechanism. The plug-loading robot drives multiple gripper assemblies to move sequentially to the plug material tray to clamp the plugs. The plug-loading robot also drives multiple gripper assemblies to move sequentially to the mounting holes to assemble the plugs.

[0017] Furthermore, in order to enable the quick replacement of the plug gripping fixture, the plug gripping fixture includes a base, the gripper assembly is mounted on the lower end face of the base, and the quick-change mechanism is mounted on the upper end face of the base.

[0018] Furthermore, in order to accurately locate the plug and mounting hole, the vision module includes: A rotating camera rotates between the plug tray and the housing, and the rotating camera captures the position of the plug and the position of a mounting hole. Multiple fixed cameras are used, each corresponding to a mounting hole, to capture the position of the mounting hole.

[0019] Another technical solution adopted by the present invention to solve its technical problem is: a multi-station automatic assembly method for a communication controller, using the above-mentioned multi-station automatic assembly system for plugs, comprising the following steps: S1. Vision-guided feeding: The rotating camera of the vision module rotates to the plug material tray and takes pictures, and sets the coordinates and angles of the plugs in the plug material tray. The plug feeding robot drives multiple gripper components to grab the plugs to be assembled in sequence. S2. Visual guidance positioning: The rotating camera and the fixed camera of the vision module respectively photograph the mounting holes on the side of the housing to obtain the position of the mounting holes. The plug feeding robot drives multiple gripper components to install the plugs into the corresponding mounting holes in sequence. S3. Nut feeding: The locking nut robot moves the nut gripping assembly to the nut feeding device and controls the gripping part to grip the nuts to be assembled in sequence; S4. Tighten the nuts: The locking nut robot controls one gripper to face the plug on the mounting hole. The drive unit drives the gripper to rotate in a preset speed and torque mode, connecting the nut to the plug threadedly. After the nut assembly is completed, the locking nut robot drives the nut gripping assembly assembly to rotate, so that another gripper faces the plug on another mounting hole. The assembly process is repeated until all nuts on the nut gripping assembly assembly are assembled. S5. Repeat steps S3 to S4 until all plugs and nuts on the housing are assembled.

[0020] Furthermore, in order to detect whether the assembled housing is qualified during the assembly process, in step S4, the torque sensor detects the nut assembly process in real time, and compares the torque-angle curve of the nut assembly with the preset qualified range. Based on the data comparison, it is determined whether the housing assembly is qualified. If it is qualified, the housing is placed into the qualified conveyor line; if it is not qualified, the housing is placed into the unqualified conveyor line.

[0021] Compared with the prior art, the beneficial effects of the present invention are: 1. The multi-station automatic assembly system and method of the communication controller of the present invention utilize a vision module to position the plug and mounting hole, ensuring that the plug assembly device can accurately assemble the plug, and the nut assembly device can accurately assemble multiple nuts of different specifications in a confined space. The assembly is accurate, greatly shortens the assembly time, and has a high pass rate.

[0022] 2. The multi-station automatic assembly system and method of the communication controller of the present invention can realize the rapid replacement of the plug gripping fixture and nut gripping assembly component by using the quick change mechanism. It can adapt to the flexible production needs of multiple varieties and small batches, and avoid the expensive cost of developing special equipment for each product model.

[0023] 3. The multi-station automatic assembly system and method of the communication controller of the present invention utilize torque sensors to detect the real-time torque-angle curve during nut assembly, and promptly provide feedback on unqualified nuts to ensure a high qualification rate of the assembled housing. Attached Figure Description

[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0025] Figure 1 This is a three-dimensional structural diagram of the multi-station automatic assembly system of the communication controller of the present invention. Figure 2 for Figure 1 A partial structural diagram; Figure 3 A schematic diagram of the assembly for gripping the plug, housing, and nut; Figure 4 Exploded view of the assembly for gripping the nut; Figure 5 for Figure 4 A schematic diagram of a partial structure; Figure 6 This is a schematic diagram of the assembled housing.

[0026] In the diagram: 1. Housing; 11. Mounting hole; 2. Plug tray; 3. Nut feeding device; 4. Integrated control cabinet; 5. Plug; 6. Nut; 7. Rotating camera; 8. Fixed camera; 9. Plug gripper; 91. Base; 92. Gripper assembly; 10. Plug feeding robot; 11. Quick change mechanism; 12. Nut locking robot; 13. Nut gripping assembly assembly; 131. Gearbox; 132. Drive gear; 133. First stage gear; 134. Second stage gear; 135. Third stage gear; 136. Tightening gun; 137. Torque sensor; 138. Connecting square rod; 139. Adaptive floating head; 140. Adapter rod; 141. Fixed flange; 142. Connecting frame; 143. End plate. Detailed Implementation

[0027] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0028] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, features defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0029] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0030] like Figures 1 to 6 As shown, a multi-station automatic assembly system for a communication controller includes: a housing 1 of the communication controller to be assembled, a plug tray 2, a vision module, a plug assembly device, a nut feeding device 3, a nut assembly device, and an integrated control cabinet 4.

[0031] The system is centrally controlled by a PLC and industrial computer within integrated control cabinet 4. This unit includes: a communication architecture employing a high-speed EtherCAT bus to ensure real-time communication between devices with a response time of less than 1ms, and an integrated Safety Torque Off (STO) function, complying with IEC 61800-5-2 safety standards. A torque monitoring and quality assessment module pre-stores qualified torque-angle curve models. During tightening, it receives data from torque sensor 137 and encoder in real time and performs online analysis and comparison. If the real-time curve rises smoothly and stabilizes within a preset threshold range, it is judged as OK; if abnormalities such as sudden torque changes, insufficient torque, or overload occur, it is immediately judged as NG and operation is stopped. A data management and traceability module binds and stores the OK / NG judgment results and complete torque-angle process curves for each assembly with the unique identifier of the current product read via RFID, forming a complete digital assembly file and achieving full lifecycle quality traceability. The feeding and auxiliary units include a plug tray that provides orderly feeding for the plug 5, and a nut feeding vibratory feeder that provides directional sorting and conveying for the nuts 6, ensuring the continuity of the automated process.

[0032] Specifically, the housing 1 has multiple mounting holes 11. In this embodiment, the housing 1 is a rectangular housing with a central mounting space, allowing the nut assembly device to move to the upper area of ​​the mounting space for nut 6 assembly. Mounting holes 11 are located on three sides of the housing 1, and these holes have different sizes and numbers (the specific number of mounting holes 11 is determined by the type of communication controller), requiring the corresponding assembly of different plugs 5 and nuts 6. The plugs 5 are made of high-quality copper and are connected to the nuts 6 via threads.

[0033] Specifically, a plug 5 is placed inside the plug tray 2. The type of plug 5 is the same as that of the mounting hole 11 to ensure the continuity of the automated process.

[0034] Specifically, the nut feeding device 3 directionally conveys different nuts 6 to the gripping position. In this embodiment, the nut feeding device 3 adopts a nut feeding vibratory plate, and different numbers of nut feeding vibratory plates can be set as needed to provide matching nuts 6 for subsequent assembly operations.

[0035] Specifically, the vision module captures the position of the plug 5 and the position of the mounting hole 11. In this embodiment, the vision module uses one rotating camera 7 and two fixed cameras 8. The rotating camera 7 is located between the plug tray 2 and one side of the housing 1. The rotating camera 7 rotates towards the plug tray 2 to capture the position of the plug 5, and rotates towards the side of the housing 1 to capture the mounting hole 11 on that side. The other two fixed cameras 8 are each positioned facing one side of the housing 1 to capture the mounting hole 11 on that side. Thus, the vision module can accurately provide the coordinates and positions of the plug 5 and the mounting hole 11, providing visual guidance for the subsequent assembly of the plug 5 and the nut 6.

[0036] The rotating camera 7 is a rotating 2D camera mounted on a rotating platform, and the fixed camera 8 is a 2D / 3D camera. They are used to accurately identify the plug mounting holes 11 at different positions (such as the side and end faces) on the communication controller housing 1. The vision processing module can guide the robot to achieve a positioning accuracy of ±0.1mm for the end effector through feature matching and coordinate calculation, and dynamically compensate for the robot's motion trajectory.

[0037] Specifically, after the plug assembly device picks up the plug 5, it assembles the plug into the corresponding mounting hole 11. After determining the position of the plug and the mounting hole 11, the plug assembly device moves above the plug material tray 2, picks up the plug 5 from the plug material tray 2, and then assembles the plug 5 into the corresponding mounting hole 11.

[0038] Preferably, the plug assembly device includes a plug gripping fixture 9 and a plug loading robot 10. The plug loading robot 10 is connected to the plug gripping fixture 9 via a quick-change mechanism 11. The quick-change mechanism 11 allows for rapid replacement of the plug gripping fixture 9, enabling quick adaptation to different housing 1 and plug 5 models. The plug loading robot 10 includes multiple gripper assemblies 92, which close or open to grip or release the plug 5. The number of gripper assemblies 92 can be set according to assembly requirements. Typically, each gripper assembly 92 corresponds to a plug 5. In this embodiment, three gripper assemblies 92 are used to grip different models of plugs 5, ensuring operational accuracy. The plug loading robot 10 drives the multiple gripper assemblies 92 to move sequentially to the plug tray 2 to grip the plug 5, and then drives the multiple gripper assemblies 92 to move sequentially to the mounting hole 11 to assemble the plug 5. Because the plug-loading robot 10 is a six-axis industrial robot, it can accurately control the position of the gripper assembly 92 in space, ensuring that the gripper assembly 92 can accurately hold the plug 5 and accurately assemble the plug 5 into the mounting hole 11. After assembling one plug 5, the gripper assembly 92 can be quickly switched to complete the assembly of the next plug 5. Three plugs 5 are assembled in a single plug assembly operation. Then the above process is repeated until all plugs 5 are assembled.

[0039] Specifically, the nut assembly device includes a nut gripping and assembly assembly 13, which includes multiple gripping parts. These gripping parts sequentially grip the nuts 6 at gripping positions. The gripping parts switch according to the mounting holes 11, and each gripping part assembles the nut 6 with its corresponding plug 5 through the mounting holes 11. In this embodiment, the number of gripping parts is also three, and these three gripping parts are used to grip and assemble different nuts 6.

[0040] Preferably, the nut assembly device further includes a nut-locking robot 12. In this embodiment, the nut-locking robot 12 is also a six-axis industrial robot. The nut-locking robot 12 is connected to the nut gripping assembly assembly 13 via a quick-change mechanism 11, facilitating the replacement of different nut gripping assembly assemblies 13 to adapt to different housings 1. The nut-locking robot 12 drives the nut gripping assembly assembly 13 to move between the gripping position and the mounting hole 11. The nut-locking robot 12 also drives the nut gripping assembly assembly 13 to revolve, so that the nut 6 of the gripping part faces the plug 5 on the corresponding mounting hole 11. The nut-locking robot 12 controls one gripping part to face the nut 6 and grip the nut 6, and then switches the gripping part to repeat the gripping process. After all three gripping parts have gripped the nut 6, the nut-locking robot 12 drives the nut gripping assembly assembly 13 to move to the inside of the housing 1. The locking nut robot 12 controls one gripper to face the mounting hole 11 and screw the nut 6 into the plug 5. After assembling one nut 6, the locking nut robot 12 switches grippers and aligns another gripper with another mounting hole 11, thus assembling three nuts 6 in a single nut assembly operation. Then, the above process is repeated for the next nut 6 assembly.

[0041] In Embodiment Two, based on Embodiment One, the nut gripping assembly 13 further includes a drive unit. The drive unit is poweredly connected to the gripping part, driving the gripping part to rotate and assembling the nut 6 located on the mounting hole 11 with the plug 5. The gripping part includes a gearbox 131, a drive gear 132, and a transmission gear set. The transmission gear set is rotatably connected within the housing 1. The drive gear 132 is connected to the output end of the drive unit. The input end of the transmission gear set meshes with the drive gear 132, and the output end of the transmission gear set has a nut positioning port, which engages with the nut 6 to grip the nut 6 (usually magnetically). The drive unit drives the drive gear 132 to rotate, and the drive gear 132 synchronously drives all transmission gear sets to rotate. Since the nut 6 is gripped and positioned by the nut positioning port, when the transmission gear set rotates, the nut 6 moves synchronously, thereby assembling the nut 6 with the plug 5.

[0042] Preferably, in this embodiment, there are three transmission gear sets, which are evenly spaced along the circumference of the main gear. These three transmission gear sets are used to grip three different nuts 6, allowing all three nuts 6 to be tightened in a single operation. The transmission gear sets include: a primary gear 133, a secondary gear 134, and a tertiary gear 135. The primary gear 133, secondary gear 134, and tertiary gear 135 mesh sequentially in a radial direction.

[0043] The first-stage gear 133 meshes with the drive gear 132, the second-stage gear 134 meshes with the first-stage gear 133, and the third-stage gear 135 meshes with the second-stage gear 134. The nut positioning port is located on the third-stage gear 135. The main gear transmits power to the third-stage gear 135 through the first-stage gear 133 and the second-stage gear 134. When the third-stage gear 135 rotates, it synchronously drives the nut 6 on the nut positioning port to rotate, thus achieving the assembly of the nut 6. With the drive gear 132 as the center, the three transmission gear sets are distributed in a star shape and form an independent transmission arm. From the perspective of power transmission path, the input torque is simultaneously and equally transmitted from the drive gear 132 to the first-stage gears 133 of the three transmission arms. Due to geometric symmetry and component consistency, theoretically, the input torque is automatically and evenly divided into three parts, with each transmission arm bearing approximately one-third of the total load. Through the centrally driven, star-shaped symmetrical mechanical structure, the internal mechanical load generated during the tightening of a single nut 6 can be naturally and evenly distributed to other parallel transmission paths. The star-shaped distribution realizes multi-station integration and uniform load distribution, enabling parallel assembly operations in a compact space, greatly improving efficiency and ensuring the consistency of tightening quality of multiple nuts 6.

[0044] The three-stage gear 135 utilizes an open nut positioning port to grip and tighten the nut 6. This open design avoids the long axial alignment stroke required by traditional sleeves, making it particularly suitable for the deep and narrow interior space of the housing 1. The "star-shaped" layout achieves a high degree of integration of the three workstations, allowing all nut 6 assembly points to be covered in a single operation, transforming traditional serial operations into parallel operations. Combined with the "open" locking head, it solves the alignment problem of insufficient axial space for the nut 6 and difficulty in inserting the sleeve deep within the housing. This, combined with the system's visually guided positioning and adaptive floating head 139, forms a complete high-precision assembly solution from "global positioning" to "local micro-compensation" to "final open-type rapid docking." The main gear, as the central drive, evenly distributes the input torque to the three transmission arms. The two-stage gear reduction in each transmission arm not only provides the required torque amplification, but its symmetrical distribution structure also disperses the load, avoiding single-point stress concentration. This ensures that the transmission system remains stable and reliable, without the risk of breakage, during the process of amplifying the motor output torque (10 N·m) to the required working torque (e.g., 8 N·m). By transforming traditional serial operations into parallel operations, the complete assembly cycle of a single product can be shortened from 30-45 seconds manually to less than 8 seconds, improving efficiency by more than 70%.

[0045] Preferably, the drive unit includes: a tightening gun 136, a torque sensor 137, a connecting rod 138, an adaptive floating head 139, and an adapter rod 140. The tightening gun 136 is mounted on a fixed flange 141. The torque sensor 137 is mounted on the output end of the tightening gun 136, and collects real-time data on the tightening of the nut 6 by the gripping part. The connecting rod 138 is mounted on the torque sensor 137. The adaptive floating head 139 is mounted on the connecting rod 138. One end of the adapter rod 140 is mounted on the adaptive floating head 139, and the other end is connected to the drive gear 132 to drive the drive gear 132 to rotate. The power of the tightening gun 136 is transmitted sequentially to the drive gear 132 through the torque sensor 137, the connecting rod 138, the adaptive floating head 139, and the adapter rod 140, thereby driving the drive gear 132 to rotate.

[0046] In this embodiment, the tightening gun 136 preferably uses a high-performance brushless servo motor with a maximum output torque of 10 N·m and a repeatability accuracy of ±1%. The motor integrates a high-resolution absolute encoder, enabling precise control of the output rotation angle at the ±0.1° level, laying the foundation for accurate tightening angle control. The tightening gun 136 is securely mounted via a rigid frame formed by a fixed flange 141 and a connecting bracket 142. This frame is made of 45# steel and has undergone heat treatment to ensure sufficient structural rigidity and stability, preventing deformation during stress that could affect accuracy. A torque sensor 137 is connected in series to the output end of the tightening gun 136. This high-sensitivity resistance strain gauge torque sensor 137 collects torque signals in real-time and accurately during the tightening process, forming the data source for torque closed-loop control. The adaptive floating head 139 employs a precision bearing guiding mechanism internally, allowing the end to adaptively float within ±2mm in the XY plane. When there is a slight deviation in the initial alignment between the nut gripping assembly 13 and the nut 6, the floating head can automatically fine-tune at the moment of contact, guiding the adapter rod 140 and its end, the nut gripping assembly 13, to accurately "fit" into the nut 6, achieving automatic "alignment". Furthermore, the floating head integrates a shock absorption mechanism and utilizes the magnetic hysteresis damping effect of special materials to effectively absorb the impact energy at the moment of contact, reducing the peak impact load by more than 60%. This protects the nut 6 and the controller housing threads, and also extends the equipment's lifespan. This module can automatically compensate for residual deviations or workpiece tolerances after visual positioning, and absorbs the impact at the moment of contact through the built-in magnetic hysteresis damping material, ensuring a smooth, "soft landing" docking with the nut, effectively protecting the workpiece and equipment (the adaptive floating head 139 is existing technology, and its structure will not be described in detail here).

[0047] Preferably, the upper end of the fixed flange 141 is connected to the quick-change mechanism 11, and the tightening gun 136 is installed on the side of the fixed flange 141. The torque sensor 137, the connecting square rod 138, the adaptive floating head 139, and the adapter rod 140 are located inside the connecting frame 142, and the gearbox 131 is installed on the outer end face of the connecting frame 142. An end plate 143 for pressing the gearbox 131 is installed on the outer end face of the connecting frame 142. The quick-change mechanism 11 can be used to replace the entire nut gripping assembly 13, thereby meeting the assembly requirements of different housings 1 and nuts 6. Through the quick-change mechanism 11, different end actuators (such as the plug gripping fixture 9 or the nut gripping assembly 13) can be quickly replaced, thereby adapting to multiple process tasks such as gripping, handling, positioning, and tightening, laying the foundation for the flexibility of the system.

[0048] The gearbox 131 is constructed by locking the gearbox with a threaded connecting rod via a gear shift wrench clamp and a gear shift wrench cover. The gearbox 131 is rigidly connected to the connecting frame 142 via the threaded connecting rod, ensuring that the entire transmission chain does not shift or deform when subjected to torque. The internal key bearings (such as angular contact ball bearings, model 7002C) are precisely preloaded to ensure transmission smoothness and rigidity.

[0049] In Example 3, based on Example 2, the plug gripping fixture 9 includes a base 91, and a gripper assembly 92 is mounted on the lower end face of the base 91. A quick-change mechanism 11 is mounted on the upper end face of the base 91. The quick-change mechanism 11 allows for quick replacement of the plug gripping fixture 9. The gripper assembly 92 uses conventional grippers to hold circular plugs 5. The number and distribution of the gripper assemblies 92 are not limited to the form shown in the figure.

[0050] A multi-station automatic assembly method for a communication controller, employing the aforementioned multi-station automatic assembly system for plugs, includes the following steps: S1. Visual guidance feeding: The rotating camera 7 of the vision module rotates to the plug material tray 2 and takes a picture, and sets the coordinates and angles of the plug 5 in the plug material tray 2. The plug feeding robot 10 drives multiple gripper components 92 to grab the plug 5 to be assembled in sequence.

[0051] Rotate the camera 7 to the plug material tray 2, and then photograph the position of the plug 5. Drive the plug feeding robot 10 to grab the material tray, move the gripper assembly 92 to the plug position and then grab the plug 5, until all gripper assemblies 92 have grabbed the plug 5.

[0052] S2. Visual guidance positioning: The rotating camera 7 and the fixed camera 8 of the vision module respectively photograph the mounting holes 11 on the side of the housing 1 to obtain the position of the mounting holes 11. The plug feeding robot 10 drives multiple gripper assemblies 92 to sequentially insert the plugs 5 into the corresponding mounting holes 11.

[0053] The rotating camera 7 rotates towards the housing 1. The rotating camera 7 and the fixed camera 8 respectively capture the positions of the mounting holes 11 on the three sides of the housing 1. The vision processing module calculates the precise pose of the holes and dynamically compensates for the standard motion trajectory of the robot. It guides the plug loading robot 10 to accurately move the plug to the mounting hole 11. The gripper assembly 92 sequentially inserts the plug 5 into the corresponding mounting hole 11. Then, the plug loading robot 10 controls the plug gripping fixture 9 to grab the plug 5 from the plug material tray 2, preparing for the next assembly.

[0054] S3. Nut loading: The locking nut robot 12 moves the nut gripping assembly 13 to the nut feeding device 3 and controls the gripping parts to sequentially grip the nuts 6 to be assembled. The locking nut robot 12 drives the nut gripping assembly 13 to move to the nut feeding device 3, and the three gripping parts sequentially grip the nuts 6.

[0055] S4. Nut Tightening: The nut tightening robot 12 controls one gripping part to face the plug 5 on the mounting hole 11. The drive unit drives the gripping part to rotate in a preset speed and torque mode, threading the nut 6 onto the plug. After assembling the nut 6, the nut tightening robot 12 drives the nut gripping assembly assembly 13 to rotate, so that another gripping part faces the plug 5 on another mounting hole 11. The assembly process is repeated until all nuts 6 on the nut gripping assembly assembly 13 are assembled. The nut tightening robot 12 drives the nut gripping assembly assembly 13 to move to the inside of the housing 1, and then adjusts the gripping part to face the plug 5 according to the assembly requirements, screwing the nut 6 into the plug 5. Then the gripping part is switched to complete the assembly of the plug 5 three times. The nut gripping assembly assembly 13 returns to the nut feeding device 3 to grip the nut 6 again, preparing for the next assembly.

[0056] Preferably, during each tightening of nut 6, a torque sensor 137 collects data. In a qualified tightening process, the torque-angle curve will smoothly rise and stabilize within the preset qualified range [T_min, T_max]. If the curve is abnormal (e.g., peak torque is too low or too high), it is immediately judged as unqualified. The judgment result and the complete torque-angle curve are recorded by the data management and traceability module and bound to the current communication controller ID obtained through an RFID reader. Subsequently, the robot places the assembled communication controller onto the qualified product conveyor line or the unqualified product return line based on the judgment result. Through the high-precision torque sensor 137 and encoder, the system can not only control the final output torque with an accuracy of ±0.5% FS, but also monitor and record the process parameter of the "torque-angle" curve throughout the entire process. Through intelligent comparison with a preset standard model, the system can automatically identify abnormalities in the tightening process (such as stripped threads, crossed threads, etc.) and achieve real-time quality judgment. All data is bound to the product ID and stored, enabling full-process digital traceability. This fundamentally eliminates the quality fluctuations and lack of traceability associated with manual assembly, and keeps the defective product rate stably controlled at an extremely low level (e.g., below 0.1%).

[0057] S5. Repeat steps S3 to S4 until all plugs 5 and nuts 6 of housing 1 are assembled.

[0058] In order to detect whether the assembled housing is qualified during the assembly process, in step S4, the torque sensor 137 detects the nut assembly process in real time, compares the torque-angle curve of the nut assembly with the preset qualified range, and judges whether the housing assembly is qualified based on the data comparison. If it is qualified, the housing is put into the qualified conveyor line; if it is not qualified, the housing is put into the unqualified conveyor line.

[0059] In summary, the multi-station automatic assembly system and method for the communication controller of the present invention can complete the assembly of plugs and nuts of the housing in a confined space, with high assembly accuracy, good quality control, high work efficiency, and improved product compatibility.

[0060] The above description is based on the preferred embodiments of the present invention. Through the above description, those skilled in the art can make various changes and modifications without departing from the technical concept of the present invention. The technical scope of the present invention is not limited to the contents of the specification, but must be determined by the scope of the claims.

Claims

1. A multi-station automatic assembly system with a communication controller, characterized in that, include: The housing (1) of the communication controller to be assembled has a plurality of mounting holes (11). A plug tray (2) is provided with a plug (5). The vision module captures the position of the plug (5) and the position of the mounting hole (11); A plug assembly device, which grabs the plug (5) and assembles the plug (5) into the corresponding mounting hole (11); Nut feeding device (3), which directionally feeds different nuts (6) to the gripping position; The nut assembly device includes a nut gripping assembly assembly (13), which includes multiple gripping parts. The multiple gripping parts sequentially grip the nut (6) at the gripping position. The multiple gripping parts switch according to the mounting hole (11). The gripping parts assemble the nut (6) with the corresponding plug (5) on the mounting hole (11).

2. The multi-station automatic assembly system with a communication controller according to claim 1, characterized in that, The nut assembly device further includes: A nut-tightening robot (12) is connected to a nut-grabbing assembly (13) via a quick-change mechanism. The nut-tightening robot (12) drives the nut-grabbing assembly (13) to move between the gripping position and the mounting hole (11). The nut-tightening robot (12) also drives the nut-grabbing assembly (13) to revolve, so that the nut (6) of the gripping part faces the plug (5) on the corresponding mounting hole (11).

3. The multi-station automatic assembly system with a communication controller according to claim 2, characterized in that, The nut gripping assembly (13) also includes; A drive unit is connected to the gripping part by a power source. The drive unit drives the gripping part to rotate and assembles the nut (6) located on the mounting hole (11) with the plug (5). The gripping unit includes: Gearbox (131); A drive gear (132) is connected to the output end of the drive unit; The transmission gear set is rotatably connected in the housing (1). The input end of the transmission gear set meshes with the drive gear (132). The output end of the transmission gear set has a nut positioning port. The nut positioning port cooperates with the nut to grip the nut (6).

4. The multi-station automatic assembly system with a communication controller according to claim 3, characterized in that, The transmission gear set includes: A primary gear (133) meshes with a drive gear (132); A secondary gear (134) meshes with a primary gear (133); The third gear (135) meshes with the second gear (134), and the nut positioning port is located on the third gear (135).

5. The multi-station automatic assembly system with a communication controller according to claim 4, characterized in that, The driving unit includes: Tighten the gun (136); Torque sensor (137) is installed on the output end of tightening gun (136) and the torque sensor (137) collects real-time data of tightening nut (6) of gripping part; A connecting rod (138) is mounted on a torque sensor (137); An adaptive floating head (139) is mounted on a connecting square rod (138); A converter rod (140) is mounted at one end on an adaptive floating head (139) and at the other end is connected to a drive gear (132) to drive the drive gear (132) to rotate.

6. The multi-station automatic assembly system with a communication controller according to claim 5, characterized in that, The nut gripping assembly (13) also includes: A fixed flange (141) is provided, the upper end of which is connected to a quick-change mechanism, and a tightening gun (136) is installed on the side of the fixed flange (141). The connecting frame (142) has the torque sensor (137), connecting square rod (138), adaptive floating head (139) and adapter rod (140) located inside the connecting frame (142). The gearbox (131) is mounted on the outer end face of the connecting frame (142). The outer end face of the connecting frame (142) is equipped with an end plate (143) for pressing the gearbox (131).

7. The multi-station automatic assembly system with a communication controller according to any one of claims 1-6, characterized in that, The plug assembly device inserts the plug into the mounting hole (11) from the outside of the housing (1), and the gripping part assembles the nut (6) and the plug (5) from the inside of the housing (1).

8. The multi-station automatic assembly system with a communication controller according to claim 1, characterized in that, The plug assembly device includes: The plug gripper (9) and the plug loading robot include multiple gripper assemblies that close or open to grip or release the plug (5). The plug feeding robot is connected to the plug gripper (9) through a quick-change mechanism. The plug feeding robot drives multiple gripper assemblies to move sequentially to the plug material tray (2) to grip the plug (5). The plug feeding robot drives multiple gripper assemblies to move sequentially to the mounting hole (11) to assemble the plug (5).

9. The multi-station automatic assembly system with a communication controller according to claim 8, characterized in that, The plug gripper (9) includes a base, the gripper assembly is mounted on the lower end face of the base, and the quick-change mechanism is mounted on the upper end face of the base.

10. The multi-station automatic assembly system with a communication controller according to claim 1, characterized in that, The vision module includes: A rotating camera (7) rotates between the plug tray (2) and the housing (1) to capture the position of the plug (5) and the position of a mounting hole (11); Multiple fixed cameras (8) are used, each corresponding to a mounting hole (11), to capture the position of the mounting hole (11).

11. A multi-station automatic assembly method for a communication controller, characterized in that, The multi-station automatic assembly system for plugs according to any one of claims 1-9 includes the following steps: S1. Visual guidance feeding: The rotating camera (7) of the vision module rotates to the plug material tray (2) and takes pictures, and sets the coordinates and angles of the plug (5) in the plug material tray (2). The plug feeding robot drives multiple gripper components to grab the plug (5) to be assembled in sequence. S2. Visual guidance positioning: The rotating camera (7) and the fixed camera (8) of the vision module respectively photograph the mounting hole (11) on the side of the housing (1) to obtain the position of the mounting hole (11). The plug feeding robot drives multiple gripper components to install the plug (5) into the corresponding mounting hole (11) in sequence. S3. Nut feeding: The locking nut robot (12) moves the nut gripping assembly component (13) to the nut feeding device (3) and controls the gripping part to grip the nuts to be assembled in sequence (6). S4. Tighten the nuts: The locking nut robot (12) controls one gripper to face the plug (5) on the mounting hole (11). The drive unit drives the gripper to rotate in a preset speed and torque mode, threading the nut (6) to the plug (5). After the nut (6) is assembled, the locking nut robot (12) drives the nut gripping assembly assembly (13) to rotate, so that another gripper faces the plug (5) on another mounting hole (11). The assembly process is repeated until all nuts (6) on the nut gripping assembly assembly are assembled. S5. Repeat steps S3 to S4 until all plugs (5) and nuts (6) of the housing (1) are assembled.

12. The multi-station automatic assembly method for the communication controller according to claim 11, characterized in that, In step S4, the torque sensor (137) detects the assembly process of the nut (6) in real time. The torque-angle curve of the nut (6) during assembly is compared with the preset qualified range. The assembly of the housing (1) is judged based on the data comparison. If it is qualified, the housing (1) is put into the qualified conveyor line. If it is not qualified, the housing (1) is put into the unqualified conveyor line.

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