Twin binding sequencing process method and system

Abstract

The invention discloses a twin rolloff sequencing process method and system, and the method comprises the steps: before the process is started, a double-station tire membrane and a gripper positioning device are moved to a corresponding precise positioning structure, and standard unification is completed; the transfer robot takes the binding gripper to a waiting area, the binding robot is adjusted to the initial position, and early-stage positioning and resetting are completed; 6ST station pre-edge-covering: conveying the inner and outer plates of the vehicle door to a tire film by a carrying robot, fixing the outer plate, and then moving an edge-rolling gripper for positioning and pressing, so as to fix the inner plate; the binding robot works and monitors according to the track and then retreats, the gripper is matched with the forming die to enable the outer plate to be separated, the robot conveys the plate to a 7ST station, and the forming die is reset; 7, final edge covering at the ST station is conducted, specifically, the robot conveys the pre-edge-covering plate to the tire film to be fixed, and the other robot moves an edge rolling gripper to be positioned; and finally, a finished product is conveyed to the next working procedure, the tire film and the gripper are reset, and the double stations enter circulation. And the continuity of the whole process is improved.

Description

Technical Field

[0001] This invention belongs to the field of welding production line technology, and more specifically, relates to a twin-ringing sequence process method and system. Background Technology

[0002] With the rapid development of the automotive market and the accelerating pace of new model iterations, the market is placing higher demands on the flexibility and rapid adaptability of automotive production. In the automotive welding production process, existing welding lines are often limited by fixed equipment layouts and process designs. When faced with the introduction of new models, a large number of equipment adjustments and process refactorings are required, making it difficult to quickly match production needs. This leads to extended production preparation cycles and an inability to respond promptly to market demands for new model capacity. This problem is particularly prominent in the field of new energy vehicle production.

[0003] Due to structural design and functional requirements, the hemming length of new energy vehicle doors has increased significantly, with some models reaching 4850mm. To complete this length of hemming, existing processes require two operations, extending the total hemming path to approximately 10 meters. Considering industry-standard production parameters, the hemming speed for car doors is typically maintained between 100-140mm / s, meaning the hemming process alone consumes a significant amount of time. Furthermore, auxiliary processes such as assembly, retrieval, and inter-station transfers are also included in the production process, with these auxiliary processes taking approximately 20 seconds. After comprehensive calculation, the total time for a single machine to complete a single car door hemming operation reaches as high as 97 seconds.

[0004] To shorten the processing cycle, some production scenarios have attempted to use three machines operating simultaneously. Theoretically, this could reduce the average time for hemming a single car door to 33 seconds. However, due to limitations in equipment coordination efficiency, workstation layout, and auxiliary process integration, the actual effective hemming processing time can only be reduced to 25 seconds, still failing to meet the customer's production requirement of a 45-second cycle time for welding lines. This substandard production cycle time directly leads to a decrease in overall production line capacity, increases production costs, and makes it difficult to adapt to the flexible demands of mixed production lines for multiple new energy vehicle models, thus hindering the company's competitive advantage in the market. Therefore, optimizing the car door hemming process to improve processing efficiency and meet cycle time requirements within limited production environments has become a critical issue that urgently needs to be addressed in the current automotive welding production field. This has significant practical implications for promoting flexible production in the automotive manufacturing industry and enhancing market responsiveness. Summary of the Invention

[0005] This invention aims to solve the problems of slow adaptation to new car models and low efficiency of door hemming in automotive welding lines. Through a dual-station sequential hemming design, the pre-hemming and final hemming processes are optimized, reducing auxiliary time, improving equipment synergy, and ensuring a 45-second production cycle time even with long hemming paths and numerous auxiliary processes. This adapts to flexible production needs and enhances capacity and market responsiveness.

[0006] To address the aforementioned deficiencies or improvement needs of the existing technology, as a first aspect of the present invention, the present invention provides a twin-ringing sequence process method, comprising:

[0007] S1. Before the process starts, the dual-station membrane clamp and gripper positioning device are moved to the corresponding bottom precision positioning structure. The multi-dimensional degrees of freedom are locked by the cooperation of the positioning sleeve and positioning pin, support and limiting surface to unify the benchmark. At the same time, the transfer robot grabs the rolling gripper of the corresponding station to the waiting area. The rolling robot is equipped with a special module and adjusted to the initial rolling position to complete the initial positioning and equipment reset.

[0008] When performing 45° pre-edge binding at the S2.6ST station, the transport robot first delivers the inner and outer door panel assemblies to the membrane and fixes the outer panel, then moves the edge-rolling gripper to position and press it against the membrane, while simultaneously fixing the inner panel with the gripper; subsequently, the edge-rolling robot completes the 45° edge rolling according to the preset trajectory, with real-time monitoring during the process; finally, the edge-rolling robot retracts, the gripper and the membrane suction cup work together to detach the outer panel, and the transport robot transfers the panel to the 7ST station, where the membrane is reset;

[0009] When performing 0° final edge binding at station S3.7ST, a transport robot first delivers the pre-bound panel to the mold, and after adaptation and adjustment, it is accurately positioned and the outer panel is fixed. Then, another transport robot moves the edge-rolling gripper to complete the positioning, pressing and fixing of the inner panel. Subsequently, the edge-rolling robot completes the 0° final edge binding according to the trajectory, with real-time monitoring during the process. Finally, the transport robot transfers the finished product to the next process, the mold and gripper are reset, and the dual stations enter the next cycle.

[0010] Furthermore, the dual workstations in S1 include: a 6ST workstation responsible for 45° pre-edge wrapping of the inner and outer panels of the car door and a 7ST workstation responsible for 0° final edge wrapping; both are equipped with positioning devices including a first positioning mechanism, a second positioning mechanism, and a third positioning mechanism for the outer panel, and a diaphragm clamp with a built-in suction cup and the first and second positioning devices; and both have a unified bottom precision positioning structure, which uses the positioning sleeve of the diaphragm clamp and the first and second positioning pins of the bottom positioning fixture to position the XYZ degrees of freedom, and uses the positioning support at the bottom of the diaphragm and the limiting surface of the bottom fixture to position the Z direction, thereby achieving a unified reference for the dual workstations.

[0011] Furthermore, in S1, the dual workstations are connected by a first transport robot, a second transport robot, and a third transport robot to form a rolling edge operation unit that combines pre-edge wrapping and final edge wrapping.

[0012] Furthermore, the 6ST station is equipped with a first edge-rolling robot, a second edge-rolling robot, a third edge-rolling robot, and a dedicated 45° edge-rolling module.

[0013] Furthermore, the 7ST station is equipped with a fourth, fifth, and sixth edge-rolling robot and a dedicated 0° edge-rolling module. The positioning hole diameter of the 7ST station's membrane gripper positioning mechanism is 1mm smaller than that of the 6ST station to accommodate the precise placement of the pre-edge-wrapped panels.

[0014] Furthermore, in S2, the outer plate is positioned and fixed by the positioning device and suction cup of the positioning mechanism on the fetal membrane.

[0015] Furthermore, the real-time monitoring process in S2 where the hemming robot completes the 45° hemming according to a preset trajectory is as follows:

[0016] Let θ be the real-time monitoring correlation parameter. act (t) represents the actual bending angle of the outer plate at time t, θ ref =45° is the preset reference angle, and the angle deviation Δθ(t) = θ act (t)-θ ref ;F act (t) represents the actual output pressure of the hemming module at time t; S con S represents the contact area between the rolled edge and the outer panel. con =w sup ×l roll w sup For the width of the film support, l roll The length of a single hemming pass; the actual contact stress σ act (t)=F act (t) / S con ;P act (t) represents the actual trajectory coordinates of the robot at time t, P ref (t) represents the preset trajectory coordinates;

[0017] The displacement deviation ΔP(t) is:

[0018]

[0019] Where, x act y act The x and y coordinates of the actual trajectory are: ref y ref The horizontal and vertical coordinates of the preset trajectory;

[0020] θ tol For the allowable angular deviation, r roll The radius of the hemming head is to match the specifications of the dedicated hemming module; σ allow σ is the allowable stress of the outer panel material. allow =F inner / S inner F inner To apply pressure to the inner plate with the gripper, S inner δ is the area of ​​the inner plate subjected to force.fit v is the clearance between the diaphragm positioning sleeve and the positioning pin. ref Preset rolling speed;

[0021] The angle closed-loop control logic is: when |Δθ(t)|≥θ tol At that time, the robot's end-effector compensation displacement ΔL(t) = Δθ(t) × r roll until |Δθ(t)| < θ tol ;

[0022] The pressure closed-loop control logic is as follows: when σ act (t)>σ allow At that time, the pressure output of the hemming module is adjusted to F. act =σ allow ×S con ;

[0023] The trajectory closed-loop control logic is as follows: when ΔP(t) ≥ δ fit At that time, the robot's motion speed is corrected to v(t) = v ref ×(δ fit -ΔP(t)) / δ fit until ΔP(t) < δ fit .

[0024] Furthermore, the real-time monitoring process in S3 where the hemming robot completes the 0° final hemming according to the trajectory is as follows:

[0025] Set up real-time monitoring of related parameters; Let t be the actual angle of the final edge of the outer panel. Preset final package reference angle, angle deviation The actual pressure of the final wrapping and hemming module at time t; This refers to the contact area of ​​the final roll edge.

[0026] w sup7 The width of the membrane support component at station 7ST. This refers to the length of a single hemming pass in the final package; actual contact stress. Let be the actual trajectory coordinates of the final delivery robot at time t. Preset final package trajectory coordinates;

[0027] Displacement deviation ΔP f (t) is:

[0028]

[0029] Where, x act_f y act_f x represents the actual trajectory coordinates of the final package. ref_f yref_f Preset trajectory coordinates for the final package;

[0030] The angle closed-loop control logic is: when |Δθ f (t)|≥θ tol_f θ tol_f The allowable deviation of the final wrapping angle is related to the pre-wrapping angle deviation Δθ(t) at station 6ST. tol_f =|Δθ(t) end When t = 1 / 2, end At the end of the pre-wrapping process, the end-effector compensation displacement ΔL of the final wrapping robot is calculated. f (t)=Δθ f (t)×r roll_f r roll_f The final wrapping edge radius is matched to the 7ST dedicated module specifications, up to |Δθ f (t)|<θ tol_f ;

[0031] The pressure closed-loop control logic is: the allowable stress σ of the outer plate at the end of the circumference. allow_f Related to the residual stress of the outer panel after pre-sealing, σ allow_f =σ res (t end ), σ res (t end ) represents the residual stress in the outer plate at the end of the pre-sealing process, when σ act_f (t)>σ allow_f At that time, the final package pressure was adjusted to F. act_f (t)=σ allow_f ×S con_f ;

[0032] The trajectory closed-loop control logic is as follows: the final package trajectory deviation must be less than the clearance δ between the positioning hole and the positioning pin at the 7ST station. fit_7 When ΔP f (t)≥δ fit_7 At that time, the final packet speed is corrected to v. f (t)=v ref_f ×(δ fit_7 -ΔP f (t)) / δ fit_7 , where v ref_f Preset the final packet speed until ΔP f (t)<δ fit_7 .

[0033] As a second aspect of the present invention, a twin-rolling separation process system is also provided, comprising:

[0034] The pre-positioning and reset unit is used to move the dual-station membrane clamp and gripper positioning device to the corresponding bottom precision positioning structure before the process starts. The multi-dimensional degrees of freedom are locked by the cooperation of the positioning sleeve and positioning pin, support and limiting surface to unify the benchmark. At the same time, the transfer robot grabs the rolling gripper of the corresponding station to the waiting area. The rolling robot is equipped with a special module and adjusted to the initial rolling position to complete the pre-positioning and equipment reset.

[0035] The 6ST 45° pre-edge binding unit is used for 45° pre-edge binding at the 6ST station. First, the transport robot delivers the inner and outer door panel assemblies to the membrane and fixes the outer panel. Then, the rolling gripper is moved to position and press against the membrane, while the gripper fixes the inner panel. Subsequently, the rolling robot completes the 45° rolling according to the preset trajectory, with real-time monitoring during the process. Finally, the rolling robot retracts, and the gripper and the membrane suction cup work together to detach the outer panel. The transport robot then transfers the panel to the 7ST station, where the membrane is reset.

[0036] The 7ST 0° final edge wrapping unit is used for 0° final edge wrapping at the 7ST station. First, a transport robot delivers the pre-wrapped panel to the mold, and after adaptation and adjustment, it is accurately positioned and the outer panel is fixed. Then, another transport robot moves the rolling gripper to complete the positioning, pressing and fixing of the inner panel. Subsequently, the rolling robot completes the 0° final edge wrapping according to the trajectory, with real-time monitoring during the process. Finally, the transport robot transfers the finished product to the next process, the mold and gripper are reset, and the dual stations enter the next cycle.

[0037] As a third aspect of the invention, a computer-readable storage medium is also provided, on which a computer program is stored, which is executed by a processor of any step of the twin-rolling separation process described above.

[0038] In summary, compared with the prior art, the above-described technical solutions conceived by this invention can achieve the following beneficial effects:

[0039] 1. This invention provides a twin-station hemming process with a unified benchmark. The process involves setting up two workstations (6ST and 7ST) and first transferring the membrane clamps and gripper positioning devices of both workstations to the corresponding bottom precision positioning structures. Multi-dimensional freedom is locked by the cooperation of positioning sleeves and pins, and support components and limiting surfaces. Simultaneously, a transfer robot picks up the hemming gripper and moves it to the waiting area. The hemming robot, equipped with a dedicated module, adjusts to its initial position and completes the reset. This technical feature ensures that both workstations have a consistent operating benchmark before the process starts, avoiding hemming accuracy problems caused by benchmark deviations. It effectively improves the synergy of the twin-station operations, lays the foundation for accurate sequential hemming, and reduces product quality fluctuations caused by differences between workstations.

[0040] 2. This invention provides a twin-panel rolling process, which involves a 45° pre-rolling edge binding operation at station 6ST. First, a transport robot transports the inner and outer door panels to a membrane-fixed outer panel. Then, a rolling gripper positions, presses, and fixes the inner panel. The rolling robot then completes the rolling along a preset trajectory, with real-time monitoring. Finally, the gripper and membrane suction cup work together to detach the outer panel and transfer it to station 7ST. This process clearly defines the core workflow of the pre-rolling edge binding stage. Real-time monitoring allows for timely correction of rolling deviations, and the outer panel detachment mechanism prevents damage to the panels. This ensures the processing accuracy of the 45° pre-rolling edge binding and provides qualified intermediate products for the subsequent final rolling edge binding process, improving the overall process continuity.

[0041] 3. This invention provides a twin-station hemming process, which involves performing a 0° final hemming sequence operation at the 7ST station. A transport robot delivers the pre-hemmed sheet to the mold for fitting and adjustment, then fixes it. Another transport robot moves the hemming gripper for positioning and clamping. The hemming robot completes the final hemming along a trajectory and monitors it in real time. Finally, the finished product is transferred to the next process, and the dual-station resets and enters a cycle. This sequence operation optimizes the fixing and hemming process based on the characteristics of the pre-hemmed sheet, ensures the 0° final hemming accuracy meets requirements through real-time monitoring, and enables continuous production through a dual-station reset cycle design. This effectively shortens the processing cycle of a single product, improves overall production efficiency, and ensures the stability and consistency of the final hemmed product quality. Attached Figure Description

[0042] Figure 1 This is a flowchart of a twin-ringing and separating process according to an embodiment of the present invention;

[0043] Figure 2 This is a schematic diagram of the layout of the inner membrane clamps 1 and 2 of the rolling edge in an embodiment of the present invention;

[0044] Figure 3 This is a schematic diagram of the fetal membrane clamp positioning and gripper assembly in a 1 / 2 sequence according to an embodiment of the present invention;

[0045] Figure 4 This is a schematic diagram of the fetal membrane bottom precision positioning device according to an embodiment of the present invention;

[0046] Figure 5 This is a schematic diagram of the bottom of the universal positioning system for the fetal membranes according to an embodiment of the present invention;

[0047] Figure 6 This is a schematic diagram of the tire membrane clamp positioning pattern for a car door panel according to an embodiment of the present invention;

[0048] Figure 7 This is a schematic diagram of the positioning pattern of the hemmed gripper according to an embodiment of the present invention;

[0049] Figure 8 This is a schematic diagram of the area of ​​the door hemming according to an embodiment of the present invention;

[0050] Figure 9 This is a schematic diagram of the roller head according to an embodiment of the present invention;

[0051] Figure 10 This is a system unit diagram of an embodiment of the present invention.

[0052] In all the accompanying drawings, the same reference numerals denote the same technical features, specifically: 11-limiting surface component, 12-first positioning pin, 13-second positioning pin, 14-positioning sleeve, 15-positioning support component, 21-first positioning device, 22-second positioning device, 23-outer plate first positioning mechanism, 24-outer plate second positioning mechanism, 25-outer plate third positioning mechanism, 31-first upper component, 32-second upper component, 41-dedicated 45° rolling edge module, 42-dedicated 0° rolling edge module, 51-first positioning component, 52-second positioning component, 61-plate detection module, 61B-first rolling edge robot, 62B-second rolling edge robot, 63B-third rolling edge robot, 71B-fourth rolling edge robot, 72B-fifth rolling edge robot, 73B-sixth rolling edge robot, MH54B-first handling robot, MH64B-second handling robot, MH74B-third handling robot. Detailed Implementation

[0053] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0054] Example 1

[0055] Please refer to Figure 1 This embodiment 1 proposes a twin-ringing sequence process method, including:

[0056] S1. Before the process starts, the dual-station membrane clamp and gripper positioning device are moved to the corresponding bottom precision positioning structure. The multi-dimensional degrees of freedom are locked by the cooperation of the positioning sleeve and positioning pin, support and limiting surface to unify the benchmark. At the same time, the transfer robot grabs the rolling gripper of the corresponding station to the waiting area. The rolling robot is equipped with a special module and adjusted to the initial rolling position to complete the initial positioning and equipment reset.

[0057] When performing 45° pre-edge binding at the S2.6ST station, the transport robot first delivers the inner and outer door panel assemblies to the membrane and fixes the outer panel, then moves the edge-rolling gripper to position and press it against the membrane, while simultaneously fixing the inner panel with the gripper; subsequently, the edge-rolling robot completes the 45° edge rolling according to the preset trajectory, with real-time monitoring during the process; finally, the edge-rolling robot retracts, the gripper and the membrane suction cup work together to detach the outer panel, and the transport robot transfers the panel to the 7ST station, where the membrane is reset;

[0058] When performing 0° final edge binding at station S3.7ST, a transport robot first delivers the pre-bound panel to the mold, and after adaptation and adjustment, it is accurately positioned and the outer panel is fixed. Then, another transport robot moves the edge-rolling gripper to complete the positioning, pressing and fixing of the inner panel. Subsequently, the edge-rolling robot completes the 0° final edge binding according to the trajectory, with real-time monitoring during the process. Finally, the transport robot transfers the finished product to the next process, the mold and gripper are reset, and the dual stations enter the next cycle.

[0059] In this embodiment 1, by analyzing and adjusting the process method of the hemming process, a production cycle of 45 seconds was achieved by using twin robots with two workstations simultaneously for hemming, thus improving the production cycle of the hemming process.

[0060] By designing the gripper membrane and equipment in a coordinated manner, unifying the benchmark, and synchronously positioning the hemming, hemming of the front, back, left, and right doors can be achieved on the same line within one island, saving production line space and floor space; debugging within the hemming line allows for better verification of the product's processability and continuous monitoring of the hemmed product quality.

[0061] In this embodiment 1, after the vehicle body door assembly enters the hemming station, the outer door panel is gripped onto the liner for initial positioning. When the inner panel is gripped to the hemming 6ST sequence, it falls onto the outer panel. The gripper and the bottom liner position the inner and outer panel assemblies, performing the hemming 6ST sequence. After completion, the gripper grips the assembly 6ST onto the hemming 7ST device, where the 7ST sequence gripper repositions the inner and outer panels. The 7ST sequence robot then completes the hemming, and the 7ST sequence gripper transports the assembly to the next station, completing the entire hemming process. For multiple vehicle models, the liner and gripper can be directly switched. The bottom positioning device and the positioning detection feedback system are shared. After the accuracy test is qualified, the equipment can be debugged and verified. Once the debugging is completed, it can be put into operation directly.

[0062] This embodiment 1 further elaborates on the above steps.

[0063] (1) Pre-positioning and repositioning

[0064] Please refer to Figure 2In this embodiment 1, the overall process layout for simultaneous edge rolling of two processes is realized; the 6ST station is responsible for the 45° pre-edge rolling operation of the inner and outer panels of the car door, which is performed by the first edge rolling robot 61B, the second edge rolling robot 62B, and the third edge rolling robot 63B, and is equipped with a dedicated 45° edge rolling module 41; the 7ST station is responsible for the 0° final edge rolling operation, which is performed by the fourth edge rolling robot 71B, the fifth edge rolling robot 72B, and the sixth edge rolling robot 73B, and is equipped with a dedicated 0° edge rolling module 42.

[0065] The first handling robot MH54B, the second handling robot MH64B, and the third handling robot MH74B are responsible for the transfer of sheet metal and hemming grippers, realizing the operation connection between the two workstations. Both the 6ST and 7ST workstations are equipped with positioning devices including an outer plate first positioning mechanism 23, an outer plate second positioning mechanism 24, and an outer plate third positioning mechanism 25, as well as a membrane clamp with a built-in suction cup and a first positioning device 21 and a second positioning device 22. Through the cooperation of the limiting surface part 11, the first positioning pin 12, the second positioning pin 13, the positioning sleeve 14, and the positioning support part 15, the benchmark is unified. The same benchmark and same precision collinear synchronous detection technology is adopted to make the product precision of the two workstations complementary and ensure the consistency of hemming.

[0066] Before the process starts, the preliminary preparation work for the dual workstations needs to be completed. The membrane clamps and gripper positioning devices of the 6ST and 7ST workstations are moved to the corresponding bottom precision positioning structures. Both lock the XYZ degrees of freedom by cooperating with the positioning sleeve 14 of the membrane clamp and the first positioning pin 12 and the second positioning pin 13 of the bottom positioning fixture. At the same time, the Z-direction is positioned by cooperating with the positioning support 15 at the bottom of the membrane and the limiting surface 11 of the bottom fixture, thereby achieving the unification of the reference of the dual workstations.

[0067] At the same time, the transfer robot picks up the edge-rolling gripper of the corresponding workstation and places it in the waiting area. The first edge-rolling robot 61B, the second edge-rolling robot 62B, and the third edge-rolling robot 63B equipped with the 6ST workstation are equipped with a dedicated 45° edge-rolling module 41, and the fourth edge-rolling robot 71B, the fifth edge-rolling robot 72B, and the sixth edge-rolling robot 73B equipped with the 7ST workstation are equipped with a dedicated 0° edge-rolling module 42. All of them are adjusted to the initial edge-rolling position to complete the initial positioning and equipment reset.

[0068] The two workstations are connected by a first handling robot MH54B, a second handling robot MH64B, and a third handling robot MH74B, forming a parallel pre-edge binding and final edge binding operation unit. Both workstations are equipped with positioning devices including a first positioning mechanism 23, a second positioning mechanism 24, and a third positioning mechanism 25 for the outer panel, as well as a membrane clamp with built-in suction cups and a first positioning device 21 and a second positioning device 22. The positioning hole diameter of the membrane gripper positioning mechanism in the 7ST workstation is 1mm smaller than that in the 6ST workstation to accommodate the precise placement of the pre-edge bound panels, ensuring complementary product precision in both locations and achieving consistent edge binding.

[0069] (2) 6ST 45° pre-wrapping

[0070] When starting the 45° pre-sealing process at station 6ST, first transport the membrane clamp and gripper positioning device to the bottom positioning device. Please refer to... Figure 3 , Figure 4 as well as Figure 5 The membrane clamp and gripper device, through the positioning sleeve 14, cooperate with the positioning pins 12 and 13 of the bottom positioning fixture to lock the XYZ degrees of freedom; at the same time, with the help of the positioning support 15 and the limiting surface 11, the Z-axis is positioned, completing the unification of the dual-station reference. After the positioning is completed, the second handling robot MH64B and the third handling robot MH74B respectively grab the grippers stored on the membrane clamps at the 6ST and 7ST stations and return to their original positions to wait.

[0071] Subsequently, the first handling robot, MH54B, grips the inner and outer door panels and delivers them to the membrane fixture at station 6ST before departing. The outer door panel is positioned and fixed using positioning devices and suction cups on the membrane, including the first positioning mechanism 23, the second positioning mechanism 24, and the third positioning mechanism 25. Please refer to [reference needed]. Figure 6 as well as Figure 7 Next, the second handling robot MH64B transfers the hemming gripper of the 6ST station, which, through the first positioning device 21 and the second positioning device 22 of the tire membrane clamp, cooperates with the first upper part 31 and the second upper part 32 on the gripper for positioning and clamping; at the same time, the positioning components 51 and 52 on the gripper position the inner panel to ensure the accurate relative position of the inner and outer panels of the door.

[0072] After positioning is complete and the board inspection module 61 confirms the product is correct by inspecting it in place, please refer to... Figure 8 as well as Figure 9The first, second, and third edging robots 61B, 62B, and 63B are equipped with a dedicated 45° edging module 41, which performs 45° edging operations according to a preset trajectory, with real-time monitoring during the operation. During monitoring, three core parameters are tracked in real time: the actual bending angle of the outer panel, the actual output pressure of the edging module, and the actual trajectory coordinates of the robot. If the deviation between the actual bending angle and the preset 45° reference angle exceeds the allowable range, the robot end effector will compensate for the displacement based on the deviation value and the edging head radius. If the edging contact stress exceeds the allowable stress of the outer panel material, the pressure of the edging module will be adjusted to the pressure value corresponding to the allowable stress. If the deviation between the actual trajectory and the preset trajectory reaches the positioning fit gap, the robot's movement speed will be reduced proportionally to the deviation until all parameter deviations are within the allowable range.

[0073] Specifically, the real-time monitoring process of the hemming robot completing a 45° hemming along a preset trajectory is as follows:

[0074] Let θ be the real-time monitoring correlation parameter. act (t) represents the actual bending angle of the outer plate at time t, θ ref =45° is the preset reference angle, and the angle deviation Δθ(t) = θ act (t)-θ ref ;F act (t) represents the actual output pressure of the hemming module at time t; S con S represents the contact area between the rolled edge and the outer panel. con =w sup ×l roll w sup For the width of the film support, l roll The length of a single hemming pass; the actual contact stress σ act (t)=F act (t) / S con ;P act (t) represents the actual trajectory coordinates of the robot at time t, P ref (t) represents the preset trajectory coordinates;

[0075] The displacement deviation ΔP(t) is:

[0076]

[0077] Where, x act y act The x and y coordinates of the actual trajectory are: ref y ref The horizontal and vertical coordinates of the preset trajectory;

[0078] θ tol For the allowable angular deviation, r roll The radius of the hemming head is to match the specifications of the dedicated hemming module; σ allowσ is the allowable stress of the outer panel material. allow =F inner / S inner F inner To apply pressure to the inner plate with the gripper, S inner δ is the area of ​​the inner plate subjected to force. fit v is the clearance between the diaphragm positioning sleeve and the positioning pin. ref Preset rolling speed;

[0079] The angle closed-loop control logic is: when |Δθ(t)|≥θ tol At that time, the robot's end-effector compensation displacement ΔL(t) = Δθ(t) × r roll until |Δθ(t)| < θ tol ;

[0080] The pressure closed-loop control logic is as follows: when σ act (t)>σ allow At that time, the pressure output of the hemming module is adjusted to F. act =σ allow ×S con ;

[0081] The trajectory closed-loop control logic is as follows: when ΔP(t) ≥ δ fit At that time, the robot's motion speed is corrected to v(t) = v ref ×(δ fit -ΔP(t)) / δ fit until ΔP(t) < δ fit .

[0082] After the hemming operation is completed, the hemming robot retracts. The first positioning device 21 and the second positioning device 22 on the membrane clamp are released from their clamping state. At the same time, the suction cup positioning device on the gripper at station 6ST firmly holds the outer panel. The suction cup device on the membrane clamp adopts a back-blowing air design to ensure that the outer panel is completely detached from the membrane. After the outer panel suction device is completely released, the second handling robot MH64B grabs the panel and transfers it to the membrane at station 7ST, ensuring that the gripper at station 6ST and the panel smoothly enter the positioning device of the membrane gripper at station 7ST. The positioning diameter of the membrane gripper positioning mechanism at station 7ST is 1mm smaller than that at station 6ST. After the 45° hemming part is placed in place, the gripper suction cup and positioning pin retract, the second handling robot MH64B drives the gripper back to the waiting area, and the membrane at station 6ST resets, completing the entire 45° pre-hemming process.

[0083] (3) 7ST 0° final edge wrapping unit

[0084] When the 0° final edge-wrapping process at station 7ST is initiated, the transport robot delivers the pre-wrapped panel to the membrane, where it is precisely positioned after adaptation and adjustment. The outer door panel at station 7ST is positioned and fixed by the positioning devices and suction cups of the first positioning mechanism 23, the second positioning mechanism 24, and the third positioning mechanism 25 on the membrane. Subsequently, the third transport robot MH74B transfers the edge-rolling gripper at station 7ST, which is positioned and pressed by the first positioning device 21 and the second positioning device 22 of the membrane clamp in conjunction with the first upper part 31 and the second upper part 32 on the gripper. At the same time, the positioning components 51 and 52 on the gripper position the inner panel, ensuring the accurate relative position of the inner and outer door panels.

[0085] After positioning is complete and the board inspection module 61 confirms the product is correct by inspecting it in place, please refer to... Figure 8 as well as Figure 9 The fourth, fifth, and sixth hemming robots 71B, 72B, and 73B are equipped with a dedicated 0° hemming module 42. They perform 0° final hemming operations according to a preset trajectory, with real-time monitoring during the process. The monitoring focuses on three core parameters: the actual angle of the final hemming of the outer panel, the actual pressure of the final hemming module, and the actual trajectory coordinates of the final hemming robot. The actual angle needs to be compared with the preset 0° reference angle. The allowable deviation is related to the angle deviation at the end of the pre-hemming at the 6ST station, which is half of it. If the deviation exceeds the allowable range, the robot end will perform displacement compensation based on the deviation value and the radius of the final hemming head. The hemming contact stress needs to be compared with the allowable stress of the final hemming of the outer panel. This allowable stress is consistent with the residual stress of the outer panel after pre-hemming. If the contact stress exceeds the allowable stress, the pressure of the hemming module will be adjusted to the pressure value corresponding to the allowable stress. The actual trajectory needs to be compared with the preset trajectory. The deviation needs to be less than the fit clearance between the positioning hole and the positioning pin at the 7ST station. If the deviation reaches this clearance, the robot's movement speed will be reduced proportionally to the deviation until all parameter deviations are within the allowable range.

[0086] Specifically, the real-time monitoring process of the hemming robot completing the 0° final hemming according to the trajectory is as follows:

[0087] Let θ be the real-time monitoring correlation parameter. actf (t) represents the actual final edge angle of the outer panel at time t. Preset final package reference angle, angle deviation The actual pressure of the final wrapping and hemming module at time t; This refers to the contact area of ​​the final roll edge.

[0088] w sup7 The width of the membrane support component at station 7ST. This refers to the length of a single hemming pass in the final package; actual contact stress. Let be the actual trajectory coordinates of the final delivery robot at time t. Preset final package trajectory coordinates;

[0089] Displacement deviation ΔP f (t) is:

[0090]

[0091] Where, x act_f y act_f x represents the actual trajectory coordinates of the final package. ref_f y ref_f Preset trajectory coordinates for the final package;

[0092] The angle closed-loop control logic is: when |Δθ f (t)|≥θ tol_f θ tol_f The allowable deviation of the final wrapping angle is related to the pre-wrapping angle deviation Δθ(t) at station 6ST. tol_f =|Δθ(t) end When t = 1 / 2, end At the end of the pre-wrapping process, the end-effector compensation displacement ΔL of the final wrapping robot is calculated. f (t)=Δθ f (t)×r roll_f r roll_f The final wrapping edge radius is matched to the 7ST dedicated module specifications, up to |Δθ f (t)|<θ tol_f ;

[0093] The pressure closed-loop control logic is: the allowable stress σ of the outer plate at the end of the circumference. allow_f Related to the residual stress of the outer panel after pre-sealing, σ allow_f =σ res (t end ), σ res (t end ) represents the residual stress in the outer plate at the end of the pre-sealing process, when σ act_f (t)>σ allow_f At that time, the final package pressure was adjusted to F. act_f (t)=σ allow_f ×S con_f ;

[0094] The trajectory closed-loop control logic is as follows: the final package trajectory deviation must be less than the clearance δ between the positioning hole and the positioning pin at the 7ST station. fit_7 When ΔP f (t)≥δ fit_7 At that time, the final packet speed is corrected to v. f (t)=v ref_f ×(δ fit_7 -ΔP f (t)) / δfit_7 , where v ref_f Preset the final packet speed until ΔP f (t)<δ fit_7 .

[0095] After the hemming operation is completed, the hemming robot retracts. The first positioning device 21 and the second positioning device 22 on the diaphragm clamp are released from their clamping state, while the suction cup positioning device on the gripper at station 7ST maintains a stable pressure state. Once the suction device of the diaphragm clamp is completely released, the third transport robot MH74B grabs the gripper and the sheet metal, transferring the finished product to the next process. Afterward, the diaphragm and gripper at station 7ST are reset, and the dual stations enter the next cycle. This sequential hemming method achieves the preset hemming cycle time and solves the problem of poor hemming quality caused by inconsistent hemming references.

[0096] The twin-station rolling process described in Example 1 effectively solves the cycle time bottleneck problem in the long rolling path of new energy vehicle doors through dual-station collaborative operation and sequential rolling design. Its unified benchmark and synchronous detection technology ensures complementary accuracy between the 45° pre-rolling and 0° final rolling, while also compressing the processing time of a single piece through parallel operation of multiple robots, meeting the 45-second cycle time requirement. This provides a flexible solution for automakers to cope with mixed production lines of multiple models and quickly adapt to new models. It can be widely applied to high-cycle, high-precision automotive welding lines, improving the market responsiveness and capacity stability of the production line.

[0097] This process reduces hemming quality issues caused by reference deviations by optimizing the adaptability of the positioning mechanism and implementing real-time monitoring and dynamic adjustment mechanisms. Simultaneously, the dual-station cyclic operation mode minimizes equipment downtime, achieving a balance between efficiency and precision within limited production environments. As the new energy vehicle market continues to demand higher precision in vehicle body structures and increased production efficiency, this process can be further extended to hemming other long-dimension, complex-contour automotive parts, providing technical support for the flexible production upgrade in the automotive manufacturing industry and helping companies maintain cost and quality advantages in fierce market competition.

[0098] Example 2

[0099] Please refer to Figure 10 This embodiment 2 provides a twin-ringing sequence process system, including:

[0100] The pre-positioning and reset unit is used to move the dual-station membrane clamp and gripper positioning device to the corresponding bottom precision positioning structure before the process starts. The multi-dimensional degrees of freedom are locked by the cooperation of the positioning sleeve and positioning pin, support and limiting surface to unify the benchmark. At the same time, the transfer robot grabs the rolling gripper of the corresponding station to the waiting area. The rolling robot is equipped with a special module and adjusted to the initial rolling position to complete the pre-positioning and equipment reset.

[0101] The 6ST 45° pre-edge binding unit is used for 45° pre-edge binding at the 6ST station. First, the transport robot delivers the inner and outer door panel assemblies to the membrane and fixes the outer panel. Then, the rolling gripper is moved to position and press against the membrane, while the gripper fixes the inner panel. Subsequently, the rolling robot completes the 45° rolling according to the preset trajectory, with real-time monitoring during the process. Finally, the rolling robot retracts, and the gripper and the membrane suction cup work together to detach the outer panel. The transport robot then transfers the panel to the 7ST station, where the membrane is reset.

[0102] The 7ST 0° final edge wrapping unit is used for 0° final edge wrapping at the 7ST station. First, a transport robot delivers the pre-wrapped panel to the mold, and after adaptation and adjustment, it is accurately positioned and the outer panel is fixed. Then, another transport robot moves the rolling gripper to complete the positioning, pressing and fixing of the inner panel. Subsequently, the rolling robot completes the 0° final edge wrapping according to the trajectory, with real-time monitoring during the process. Finally, the transport robot transfers the finished product to the next process, the mold and gripper are reset, and the dual stations enter the next cycle.

[0103] Example 3

[0104] This embodiment 3 also provides a computer-readable storage medium storing a computer program, which, when executed by a processor, can implement any step of a twin-edge rolling separation process.

[0105] The computer-readable storage medium may include various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0106] For a description of the computer-readable storage medium provided in this application, please refer to the above method embodiments; further details will not be repeated here.

[0107] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A twin serging process method characterized by, Comprise: S1. Before the process starts, the double-station tire membrane clamp and gripper positioning device is moved to the corresponding bottom precise positioning structure, the positioning sleeve is locked with the positioning pin, the support and the limiting surface, and the multi-dimensional freedom is unified to unify the reference, and the transfer robot grabs the corresponding station of the edge rolling gripper to the waiting area, the edge rolling robot is adjusted to the edge rolling initial position, the pre-positioning and equipment reset are completed; S2. When the 6ST station performs 45° pre-hemming, the handling robot first sends the door inner and outer plate assembly to the tire membrane and fixes the outer plate, then moves the edge rolling gripper and the tire membrane to position and press tightly, and fixes the inner plate at the same time; then the edge rolling robot completes 45° edge rolling according to the preset track, and the process is monitored in real time; finally, the edge rolling robot retreats, the outer plate is separated from the gripper and the tire membrane suction cup, the plate is transferred to the 7ST station by the handling robot, and the tire membrane is reset; S3. When the 7ST station performs 0° final hemming, the handling robot first sends the pre-hemming plate to the tire membrane, accurately positions and fixes the outer plate after adaptation and adjustment; then the other handling robot moves the edge rolling gripper, completes positioning and pressing tightly, and fixes the inner plate; then the edge rolling robot completes 0° final hemming according to the track, and the process is monitored in real time; finally, the handling robot transfers the finished product to the next process, the tire membrane and the gripper are reset, and the double-station enters the next cycle.

2. A twin serging process method according to claim 1 wherein, The double-station in S1 comprises: the 6ST station responsible for 45° pre-hemming of the door inner and outer plate and the 7ST station responsible for 0° final hemming; both are equipped with a positioning device comprising an outer plate first positioning mechanism (23), a second positioning mechanism (24), and a third positioning mechanism (25), and a tire membrane clamp with an inner suction cup and a first positioning device (21) and a second positioning device (22); and the bottom precise positioning structures of the two are unified, the positioning sleeve (14) of the tire membrane clamp of the two is matched with the first positioning pin (12) and the second positioning pin (13) of the bottom positioning tool to position the XYZ freedom, and the positioning support (15) at the bottom of the tire membrane is matched with the limiting surface (11) of the bottom tool to position Z, to unify the reference of the double-station.

3. A twin serging process method according to claim 1 wherein, The double-station in S1 also forms a work link through the first handling robot (MH54B), the second handling robot (MH64B), and the third handling robot (MH74B), and together constitutes a pre-hemming-final-hemming parallel edge rolling operation unit.

4. A twin serging process method according to claim 2 wherein, The 6ST station is matched with the first edge rolling robot (61B), the second edge rolling robot (62B), the third edge rolling robot (63B), and the special 45° edge rolling module (41).

5. A twin serging process method according to claim 2 wherein, The 7ST station is matched with the fourth edge rolling robot (71B), the fifth edge rolling robot (72B), the sixth edge rolling robot (73B), and the special 0° edge rolling module (42), and the positioning hole diameter of the 7ST station tire membrane gripper positioning mechanism is 1mm smaller than that of the 6ST station, to adapt to the accurate positioning of the pre-hemming plate.

6. A twin serging process method according to claim 1 wherein, In S2, the outer plate is positioned and fixed by the positioning device and suction cup of the positioning mechanism on the tire membrane.

7. A twin serging process method according to claim 1 wherein, In S2, the real-time monitoring process of the edge rolling robot completing 45° edge rolling according to the preset track is: θ act (t) is the actual bending angle of the outer plate at time t, θ ref = 45° is the preset reference angle, and the angle deviation Δθ(t) = θ act (t) - θ ref ; F act (t) is the actual output pressure of the rolling edge module at time t; S con is the contact area between the rolling head and the outer plate, S con = w sup × l roll , w sup is the width of the film support, and l roll is the single rolling length; the actual contact stress σ act (t) = F act (t) / S con ; P act (t) is the actual trajectory coordinate of the robot at time t, and P ref (t) is the preset trajectory coordinate; The displacement deviation ΔP(t) is: Wherein, x act , y act are actual trajectory horizontal and vertical axis coordinates, x ref , y ref are preset trajectory horizontal and vertical axis coordinates; θ tol is the angle of allowable deviation, r roll is the radius of the hem head, which matches the specifications of the special hemming die set; σ allow is the allowable stress of the outer plate material, σ allow = F inner / S inner , F inner is the pressure of the grip fixed inner plate, S inner is the force area of the inner plate; δ fit is the gap between the film positioning sleeve and the positioning pin, v ref is the preset hemming speed; The angle closed-loop control logic is: when |Δθ(t)|≥θ tol , the robot end compensates displacement ΔL(t)=Δθ(t)×r roll , until |Δθ(t)|<θ tol ; The pressure closed-loop control logic is: when σ act (t) > σ allow , the overlock module pressure output is adjusted to F act = σ allow × S con ; The trajectory closed-loop control logic is: when ΔP(t)≥δ fit , the robot motion speed correction is v(t) = v ref ×(δ fit -ΔP(t)) / δ fit , until ΔP(t)<δ fit .

8. A twin serging process method according to claim 1 wherein, The real-time monitoring process of the S3 edge rolling robot completing 0° end covering according to the trajectory is: Set real-time monitoring correlation parameters; For the actual angle of the outer plate final wrapping at time t, For the preset final wrapping reference angle, angle deviation For the actual pressure of the final wrapping rolling edge module at time t; For the final wrapping rolling edge head contact area, w sup7 For the 7ST station tire membrane support width, For the final wrapping single rolling edge length; actual contact stress For the actual trajectory coordinates of the final wrapping robot at time t, For the preset final wrapping trajectory coordinates; Displacement deviation ΔP f (t) is: wherein x act_f , y act_f are the actual trajectory coordinates of the end package, and x ref_f , y ref_f are the preset trajectory coordinates of the end package. The angle closed-loop control logic is: when |Δθ f (t)|≥θ tol_f , θ tol_f is the final wrapping angle allowable deviation, related to the 6ST station pre-wrapping angle deviation Δθ(t), θ tol_f =|Δθ(t end )| / 2, t end is the pre-wrapping end time, the final wrapping robot end compensation displacement ΔL f (t) = Δθ f (t) x r roll_f , r roll_f is the final wrapping edge head radius, matched with the 7ST special module specification, until |Δθ f (t)|<θ tol_f ; The pressure closed-loop control logic is: the final package allowable stress σ allow_f related to the residual stress of the pre-edged outer plate σ allow_f res (t end ), v res (t end ) is the residual stress of the outer plate at the end of pre-edges, when σ act_f (t)>σ allow_f , the final package pressure is adjusted to F act_f (t) = σ allow_f ×S con_f ;​ The trajectory closed-loop control logic is: the final package trajectory deviation needs to be less than 7ST work station positioning hole and positioning pin cooperation gap δ fit_7 When ΔP f (t)≥δ fit_7 , the final package speed correction is v f (t)=v ref_f ×(δ fit_7 -ΔP f (t)) / δ fit_7 , wherein v ref_f is the final package preset speed, until ΔP f (t)<δ fit_7 .

9. A twin serging sequencing process system characterized by, Comprise: The early positioning and resetting unit is used for positioning and moving the double-station tire membrane clamp and gripper positioning device to the corresponding bottom precise positioning structure before process starting, locking multiple dimensions of freedom through the cooperation of the positioning sleeve and positioning pin, the support and the limiting surface to unify the reference, and simultaneously transferring the robot to grab the edge rolling gripper of the corresponding station to the waiting area, the edge rolling robot is adjusted to the edge rolling initial position by carrying the special module, and the early positioning and equipment resetting are completed; The 6ST 45° pre-covering unit is used for 45° pre-covering at the 6ST station, the carrying robot is used to send the door inner and outer plate assembly to the tire membrane and fix the outer plate, the edge rolling gripper is moved and positioned and pressed with the tire membrane, and the inner plate is fixed through the gripper; then the edge rolling robot completes 45° edge rolling according to the preset trajectory, and the process is monitored in real time; finally, the edge rolling robot retreats, the outer plate is separated from the gripper and the tire membrane suction cup, the plate is transported to the 7ST station by the carrying robot, and the tire membrane is reset; The 7ST 0° end covering unit is used for 0° end covering at the 7ST station, the pre-covering plate is sent to the tire membrane by the carrying robot, the outer plate is fixed after accurate positioning and adjustment; the edge rolling gripper is moved by another carrying robot, the inner plate is fixed after positioning and pressing; then the edge rolling robot completes 0° end covering according to the trajectory, and the process is monitored in real time; finally, the carrying robot transports the finished product to the next process, the tire membrane and the gripper are reset, and the double-station enters the next cycle.

10. A computer-readable storage medium having stored thereon a computer program, characterized in that, The computer program is executed by the processor to perform the double-twin edge rolling process method according to any one of claims 1-8.

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