An automatic stamping system and method for production of a portal of a stacker

Abstract

This invention belongs to the field of forklift mast manufacturing technology, specifically relating to an automated stamping system and method for forklift mast production. The automated stamping system includes a load-bearing component, a crossbeam loading component, a stamping assembly component, a riveting robot, and a welding robot. The load-bearing component supports and clamps the horizontally placed vertical beam components. The crossbeam loading component clamps the crossbeam components at both ends of the vertical beam components and, in conjunction with the riveting robot, installs the riveted connectors, and, in conjunction with the welding robot, performs welding reinforcement operations between the vertical and horizontal beam components. The stamping assembly component pre-drills holes in the vertical beam components, fills them with lever-type anti-fall components, and, in conjunction with the riveting robot, installs the pin components. This invention can meet the automated stamping assembly requirements of an outer mast with anti-fall buffer function and an inner mast with rotation function, and is suitable for the production of forklift masts for loading explosive, fragile, or high-value items.

Description

Technical Field

[0001] This invention belongs to the field of forklift mast manufacturing technology, specifically relating to an automated stamping system and method for forklift mast manufacturing. Background Technology

[0002] The fixed outer mast and the movable inner mast in the forklift mast system together form the core framework of the equipment's lifting function. The fixed outer mast, as the main support structure, is rigidly connected to the vehicle body at the bottom, playing a crucial role in transferring loads and maintaining overall stability. Its vertical guide rails provide precise guidance for the movement of the inner mast. The movable inner mast is nested inside the outer mast and achieves vertical lifting via hydraulic cylinders, directly bearing the weight of the forks and cargo. Its lifting height determines the forklift's operating range. The coordinated operation of the two masts achieves a functional division of "fixed support from the outer mast and dynamic lifting from the inner mast": the outer mast acts like a static skeleton, ensuring the equipment's anti-tipping ability, while the inner mast acts like a flexible arm, accurately positioning the cargo. This layered design ensures the structural strength of the mast system under high loads and achieves efficient space utilization through the relative movement of the inner and outer masts, allowing the forklift to achieve a greater lifting height within a limited machine height. The precision of their coordination directly affects the smoothness of cargo lifting and positioning accuracy, making it a key design element in balancing equipment stability and operational flexibility.

[0003] The existing automated stamping system for forklift mast production has been found to have shortcomings during use. It cannot meet the automated stamping assembly requirements of the outer mast with anti-fall buffer function and the inner mast with rotation function. The forklift mast produced is not suitable for loading explosive, fragile or high-value items.

[0004] In view of this, the inventors hope to optimize and improve the existing automated stamping system for forklift mast production. Summary of the Invention

[0005] The purpose of this invention is to overcome the above-mentioned problems existing in the prior art and to provide an automated stamping system and method for forklift gantry production.

[0006] To achieve the above-mentioned technical objectives and effects, the present invention is implemented through the following technical solution:

[0007] This invention provides an automated stamping system for the production of forklift masts. The automated stamping system includes a load-bearing component, a crossbeam plate loading component, a stamping assembly component, a riveting robot, and a welding robot.

[0008] The forklift gantry includes an outer gantry and an inner gantry disposed therein. The outer gantry includes vertical beam plate components, horizontal beam plate components, press-fit connectors, lever-type anti-fall components, and pin components. The inner gantry slides between two parallel vertical beam plate components. Each end of the vertical beam plate component is equipped with a horizontal beam plate component via press-fit connectors. Each vertical beam plate component is equipped with two rows of staggered lever-type anti-fall components, and a pin component is installed at the fulcrum of the lever-type anti-fall component.

[0009] The load-bearing component is used to support and clamp the horizontally placed vertical beam plate component;

[0010] There are two crossbeam plate loading assemblies, which are symmetrically arranged on the front and rear sides of the bearing assembly. The crossbeam plate loading assemblies are used to clamp the crossbeam plate components at both ends of the vertical beam plate components and cooperate with the riveting robot to install the press-fit connectors, and cooperate with the welding robot to perform welding reinforcement operations between the vertical beam plate components and the crossbeam plate components.

[0011] There are two stamping assembly components, which are symmetrically arranged on the left and right sides of the load-bearing component. The stamping assembly components are used to pre-drill holes in the vertical beam plate component, fill the lever-type anti-fall component, and cooperate with the riveting robot to install the pin component.

[0012] Furthermore, in the aforementioned automated stamping system for forklift gantry production, the vertical beam plate component includes an H-beam body. After pre-drilling, the H-beam body has press-fit connection holes at both ends of the web, two rows of slide rails in the middle of the web, and several pin riveting holes on both side plates.

[0013] Furthermore, in the aforementioned automated stamping system for forklift gantry production, the crossbeam plate component includes a crossbeam plate body. Two sets of snap-fit ​​components are symmetrically installed on the inner side of the crossbeam plate body. Each set of snap-fit ​​components consists of an outer U-shaped snap-fit ​​protrusion and an inner U-shaped snap-fit ​​protrusion. The outer / inner U-shaped snap-fit ​​protrusion and the inner cavity shape of the H-beam body located on the outer / inner periphery of the web plate are mutually compatible. Each of the outer and inner U-shaped snap-fit ​​protrusions has a snap-fit ​​connection hole that matches the position of the snap-fit ​​connection hole. The snap-fit ​​connection component is obtained by a riveting robot through which rivets extending into the snap-fit ​​connection connection hole and the snap-fit ​​connection hole are snapped. The upper-layer crossbeam plate component has a rope through hole in the middle of its crossbeam plate body.

[0014] Furthermore, in the aforementioned automated stamping system for forklift gantry production, the lever-type anti-fall component includes a grooved lever. The grooved lever has a fulcrum seat in the middle for easy insertion of a pin. The two side plates of the grooved lever are connected to anti-fall blocks via connecting plates. The two ends of the connecting plates are rotatably connected to the outer ends of the side plates of the grooved lever and the rear end lugs of the anti-fall blocks, respectively. The outer end of the anti-fall block is provided with an arc-shaped stop. The anti-fall block slides and is restricted in the corresponding slide rail. The pin is displaced by a riveting robot and riveted into the pin riveting hole through the rotating hole of the fulcrum seat.

[0015] Furthermore, in the aforementioned automated stamping system for forklift mast production, the inner mast includes a carrier plate seat. The carrier plate seat has two sides with grooved sliding plates that slide and restrict the H-beam body within the inner region of the web. A hanger is installed on the upper side of the carrier plate seat. A drive mounting slot is provided in the carrier plate seat to facilitate the installation of a rotary drive. An annular rotating plate for mounting forks is installed at the movable end of the rotary drive. An anti-detachment groove for the annular rotating plate is provided on the front side of the carrier plate seat in front of the drive mounting slot. The length of the grooved sliding plate is less than the length of the grooved lever. When the upper / lower side plate of the grooved sliding plate presses against the upper / lower anti-fall block of the lever-type anti-fall component and causes it to displace inward, the lower / upper anti-fall block of the lever-type anti-fall component displaces outward under the action of the lever.

[0016] Furthermore, in the aforementioned automated stamping system for forklift gantry production, the load-bearing component includes a base. The upper side of the base has two symmetrically inwardly oriented vertical beam plate positioning slots for placing vertical beam plate components. The depth of the vertical beam plate positioning slots is matched with the thickness of the side plates in the H-beam body. Several tilting motors are installed on the base between the two vertical beam plate positioning slots. The output end of the tilting motors is equipped with a limiting rotating plate for restricting the vertical beam plate components from the top.

[0017] Furthermore, in the aforementioned automated stamping system for forklift gantry production, the crossbeam plate loading assembly includes a base plate, a drive push rod, a grooved loading plate, and a suction cup. The base plate is supported by the drive push rod on the grooved loading plate. The spacing between the two side plates of the grooved loading plate is matched with the length of the crossbeam plate body. The suction cup is embedded and fixed in the web of the grooved loading plate near the two side plates.

[0018] Furthermore, in the above-mentioned automated stamping system for forklift gantry production, the stamping assembly component includes a common slide rail, on which a slide rail stamping mechanism for forming slide rails, an opening mechanism for forming press-fit connection holes and pin riveting holes, and an assembly mechanism for filling lever-type anti-fall components into the corresponding installation positions are installed.

[0019] The slide block stamping mechanism includes a first slider that forms a first linear guide pair with a shared slide rail. A first horizontal push rod is installed on the upper side of the first slider via a first lifting push rod. A slide block forming punch is installed on the movable end of the first horizontal push rod.

[0020] The hole-opening mechanism includes a second slider that forms a second linear guide pair with a shared slide rail. A second horizontal push rod is supported on the upper side of the second slider by a support plate. A clamping frame is installed on the movable end of the second horizontal push rod. A steering motor is installed inside the clamping frame. A rotating block with a movement limit provided by the clamping frame is installed on the output end of the steering motor. A hole-opening laser head is embedded on the side end of the rotating block.

[0021] The assembly mechanism includes a third slider that forms a third linear guide pair with a shared slide rail. A third horizontal push rod is mounted on the upper side of the third slider via a second lifting push rod. A groove-like frame is mounted on the movable end of the third horizontal push rod. Positioning protrusions are symmetrically mounted on both sides of the web of the groove-like frame. The distance between the two positioning protrusions matches the length of the web of the groove-like lever. Mechanical grippers for clamping the connecting plate are symmetrically mounted on the two side plates of the groove-like frame. The inner side of the gripper's claw is provided with a clamping positioning groove that matches the width of the connecting plate.

[0022] Furthermore, the aforementioned automated stamping system for forklift gantry production also includes a controller, which is connected to the load-bearing component, the beam loading component, the stamping assembly component, the riveting robot, and the welding robot.

[0023] The present invention also provides an automated stamping method for forklift gantry assemblies, based on the aforementioned automated stamping system for forklift gantry production, comprising the following steps:

[0024] S1, Beam plate snap-fit ​​and press-fit connection

[0025] The suction cup of the crossbeam plate loading assembly adsorbs the crossbeam plate body, and the drive rod pushes the channel-shaped material plate to align the snap-fit ​​of the crossbeam plate component with the inner cavity of the H-beam of the vertical beam plate component; the riveting robot inserts the press-fit rivets into the press-fit connection mating hole and the press-fit connection hole, and press-fits to form a press-fit connection; the welding robot welds and reinforces the connection between the vertical beam plate component and the crossbeam plate component.

[0026] S2. Vertical beam positioning and pre-drilling treatment

[0027] The vertical beam plate component is placed horizontally in the vertical beam plate positioning groove of the bearing component, and the limit plate is pressed and fixed by the flipping motor; the controller starts the hole-opening mechanism in the stamping assembly component, and the hole-opening laser head of the hole-opening mechanism processes the riveting connection holes at both ends of the web plate of the vertical beam plate component and the pin riveting holes on both side plates; the slide stamping mechanism processes two rows of slides in the middle of the web plate of the vertical beam plate component.

[0028] S3, Lever-type fall arrestor component filling and pin installation

[0029] The assembly mechanism moves along the common slide rail to the top of the vertical beam plate component. The mechanical gripper holds the connecting plate of the lever-type fall arrestor component and aligns the web position of the slotted lever with the positioning convex plate. The fall arrestor block is embedded in the slide rail, and the riveting robot presses the pin into the rotating hole and pin riveting hole of the fulcrum seat to complete the installation of the lever-type fall arrestor component.

[0030] The beneficial effects of this invention are:

[0031] 1. It can meet the automated stamping and assembly requirements of the outer mast with anti-fall buffer function and the inner mast with rotation function. It is suitable for the production of forklift masts for loading explosive, fragile or high-value items, effectively avoiding cargo damage or safety accidents.

[0032] 2. The entire system includes multiple automated components, such as load-bearing components, crossbeam loading components, stamping and assembly components, riveting robots, and welding robots. These components work together to automate the gantry production process, improve production efficiency, and reduce labor costs.

[0033] 3. The stamping assembly components are reasonably designed. The slide stamping mechanism is used to stamp and form the slide. The hole-opening mechanism uses a steering motor to drive the rotating block and the hole-opening laser head on it to rotate, which can meet the opening requirements of functional holes in different directions and improve the flexibility and accuracy of hole opening. The assembly mechanism aligns the position of the web of the slotted lever with the positioning convex plate and the mechanical gripper holds the connecting plate, which can accurately fill the lever-type anti-fall component into the corresponding installation position and ensure the assembly quality.

[0034] 4. The vertical beam plate components and horizontal beam plate components are connected and reinforced by riveting connectors and welding robots, which enhances the stability of the gantry structure and ensures the structural strength of the gantry system under high load.

[0035] Of course, any product implementing this invention does not necessarily need to achieve all of the above advantages at the same time. Attached Figure Description

[0036] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0037] Figure 1 This is a schematic diagram showing the positions of some components in this invention;

[0038] Figure 2This is a connection block diagram of the main components in this invention;

[0039] Figure 3 This is a schematic diagram of the structure of the forklift gantry in this invention;

[0040] Figure 4 This is an exploded view of the outer gantry in this invention;

[0041] Figure 5 This is a structural schematic diagram of the vertical beam plate component in this invention;

[0042] Figure 6 This is a structural schematic diagram of the crossbeam plate component in this invention;

[0043] Figure 7 This is a structural schematic diagram of the lever-type fall arrestor and pin in this invention;

[0044] Figure 8 This is a schematic diagram of the inner gantry structure in this invention;

[0045] Figure 9 This is a schematic diagram of the structure of the inner gantry after omitting the annular rotating plate in this invention;

[0046] Figure 10 This is a schematic diagram of the structure of the load-bearing component in this invention;

[0047] Figure 11 This is a schematic diagram of the crossbeam plate loading assembly in this invention;

[0048] Figure 12 This is a schematic diagram of the stamping assembly component in this invention;

[0049] Figure 13 This is a schematic diagram of the slide rail stamping mechanism in this invention;

[0050] Figure 14 This is a schematic diagram of the opening mechanism in this invention;

[0051] Figure 15 This is a schematic diagram of the assembly mechanism in this invention;

[0052] In the attached diagram, the components represented by each number are as follows:

[0053] 1-Bearing component, 101-Base, 102-Vertical beam plate positioning groove, 103-Tilting motor, 104-Limiting rotating plate;

[0054] 2-Crossbeam plate loading assembly, 201-Base plate, 202-Drive push rod, 203-Slotted material carrier plate, 204-Suction cup;

[0055] 3-Stamping assembly component, 31-Common slide rail, 32-Slide stamping mechanism, 321-First slider, 322-First lifting push rod, 323-First horizontal push rod, 324-Slide forming punch, 33-Opening mechanism, 331-Second slider, 332-Support plate, 333-Second horizontal push rod, 334-Clamping frame, 335-Steering motor, 336-Rotating block, 337-Opening laser head, 34-Assembly mechanism, 341-Third slider, 342-Second lifting push rod, 343-Third horizontal push rod, 344-Slot-like frame, 345-Positioning convex plate, 346-Mechanical gripper;

[0056] 4-Riveting robot;

[0057] 5- Welding robot;

[0058] 6-Controller;

[0059] 7-Outer gantry, 71-Vertical beam plate component, 711-H-shaped steel body, 712-Pressure riveting connection hole, 713-Slide rail, 714-Pin shaft riveting hole, 72-Horizontal beam plate component, 721-Horizontal beam plate body, 722-Outer U-shaped snap-fit ​​protrusion, 723-Inner U-shaped snap-fit ​​protrusion, 724-Pressure riveting connection mating hole, 73-Pressure riveting connector, 74-Lever-type anti-fall component, 741-Slotted lever, 742-Fulcrum seat, 743-Connecting plate, 744-Anti-fall stop block, 75-Pin shaft component;

[0060] 8-Inner gantry, 801-Carrier plate seat, 802-Slotted slide plate, 803-Hanging seat, 804-Rotary drive, 805-Annular rotating plate, 806-Driver mounting slot, 807-Anti-detachment slot. Detailed Implementation

[0061] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0062] like Figures 1-2 As shown, this embodiment provides an automated stamping system for the production of forklift gantry. The automated stamping system includes a load-bearing component 1, a crossbeam plate loading component 2, a stamping assembly component 3, a riveting robot 4, and a welding robot 5.

[0063] like Figures 3-4As shown, the forklift gantry includes an outer gantry 7 and an inner gantry 8 disposed therein. The outer gantry 7 includes vertical beam plate components 71, horizontal beam plate components 72, press-fit connectors 73, lever-type anti-fall components 74, and pins 75. The inner gantry 8 is slidably restricted between two parallel vertical beam plate components 71. Horizontal beam plate components 72 are installed at both ends of each vertical beam plate component 71 through press-fit connectors 73. Two rows of staggered lever-type anti-fall components 74 are installed in each vertical beam plate component 71, and pins 75 are installed at the fulcrum of the lever-type anti-fall components 74.

[0064] like Figure 5 As shown, the vertical beam plate component 71 includes an H-beam body 711. After pre-drilling, the H-beam body 711 has press-fit connection holes 712 at both ends of the web, two rows of slide rails 713 in the middle of the web, and several pin riveting holes 714 on both side plates.

[0065] like Figure 6 As shown, the crossbeam plate component 72 includes a crossbeam plate body 721. Two sets of snap-fit ​​components are symmetrically installed on the inner side of the crossbeam plate body 721. Each set of snap-fit ​​components consists of an outer U-shaped snap-fit ​​protrusion 722 and an inner U-shaped snap-fit ​​protrusion 723. The outer U-shaped snap-fit ​​protrusion 722 / inner U-shaped snap-fit ​​protrusion 723 and the inner cavity shape of the H-beam body 711 located on the outer / inner periphery of the web plate are mutually matched. The outer U-shaped snap-fit ​​protrusion 722 and the inner U-shaped snap-fit ​​protrusion 723 are each provided with a press-fit connection hole 724 that matches the position of the press-fit connection hole 712. The press-fit connection component 73 is obtained by press-fitting rivets that extend into the press-fit connection hole 724 and the press-fit connection hole 712 through the riveting robot 4. The crossbeam plate component 72 located on the upper layer has a rope through hole in the middle of its crossbeam plate body 721.

[0066] like Figure 7 As shown, the lever-type fall arrestor 74 includes a grooved lever 741. The middle part of the grooved lever 741 is provided with a fulcrum seat 742 for easy insertion of the pin 75. The two side plates of the grooved lever 741 are connected to fall arrest blocks 744 via connecting plates 743. The two ends of the connecting plates 743 are rotatably connected to the outer ends of the side plates of the grooved lever 741 and the rear end lugs of the fall arrest blocks 744, respectively. The outer end of the fall arrest blocks 744 is provided with an arc-shaped stop. The fall arrest blocks 744 slide and are restricted in the corresponding slide rails 713. The pin 75 is driven to move by the riveting robot 4 and is riveted into the pin riveting hole 714 through the rotating hole of the fulcrum seat 742.

[0067] like Figures 8-9As shown, the inner mast 8 includes a carrier plate seat 801. The carrier plate seat 801 has grooved sliding plates 802 on both sides that slide and restrict the H-beam body 711 in the inner area of ​​the web. A hanger 803 is installed on the upper side of the carrier plate seat 801. The carrier plate seat 801 has a drive mounting groove 806 for easy installation of a rotary drive 804. The movable end of the rotary drive 804 is equipped with an annular rotating plate 805 for adding forks. The carrier plate seat 801 has an anti-detachment groove 807 on the front side of the drive mounting groove 806 to restrict the movement of the annular rotating plate 805.

[0068] The length of the grooved slide plate 802 is less than the length of the grooved lever 741. When the upper / lower side plate of the grooved slide plate 802 presses against the upper / lower anti-fall block 744 of the lever-type anti-fall component 74 and causes it to move inward, the lower / upper anti-fall block 744 of the lever-type anti-fall component 74 moves outward under the action of the lever.

[0069] When the inner gantry 8 is raised or lowered normally, the lever-type anti-fall component 74 can swing the lever to avoid the fall stop 744, without affecting the raising or lowering. When the inner gantry 8 falls accidentally, the fall stop 744 of the lever-type anti-fall component 74 does not have time to swing to avoid the fall, thus providing a fall protection buffer for the inner gantry 8 and preventing damage to the loaded explosive, fragile or high-value items or causing a safety accident.

[0070] like Figure 10 As shown, the supporting component 1 is used to support and clamp the horizontally placed vertical beam plate component 71. The supporting component 1 includes a base 101, on which two vertical beam plate positioning grooves 102 for placing the vertical beam plate component 71 are symmetrically opened inward on the upper side. The depth of the vertical beam plate positioning grooves 102 is matched with the thickness of the side plate in the H-beam body 711. Several tilting motors 103 are installed on the base 101 between the two vertical beam plate positioning grooves 102. The output end of the tilting motors 103 is equipped with a limiting rotating plate 104 for restricting the vertical beam plate component 71 from the top.

[0071] like Figure 11 As shown, there are two crossbeam plate loading assemblies 2, which are symmetrically arranged on the front and rear sides of the bearing assembly 1. The crossbeam plate loading assembly 2 is used to clamp the crossbeam plate component 72 at both ends of the vertical beam plate component 71 and to cooperate with the riveting robot 4 to install the press-fit connector 73. It also cooperates with the welding robot 5 to perform welding reinforcement operations between the vertical beam plate component 71 and the crossbeam plate component 72. The crossbeam plate loading assembly 2 includes a base plate 201, a drive push rod 202, a grooved material carrier plate 203 and a suction cup 204. The base plate 201 is supported by the drive push rod 202 and the grooved material carrier plate 203 is supported by the drive push rod 202. The spacing between the two side plates of the grooved material carrier plate 203 is matched with the length of the crossbeam plate body 721. The suction cup 204 is embedded and fixed in the web of the grooved material carrier plate 203 near the two side plates.

[0072] like Figure 12 As shown, there are two stamping assembly components 3, symmetrically arranged on the left and right sides of the bearing component 1. The stamping assembly components 3 are used to pre-drill holes in the vertical beam plate component 71, fill the lever-type anti-fall component 74, and cooperate with the riveting robot 4 to install the pin component 75. The stamping assembly component 3 includes a common slide rail 31, on which are installed a slide rail stamping mechanism 32 for forming the slide rail 713, a hole-opening mechanism 33 for forming the press-fit connection hole 712 and the pin riveting hole 714, and an assembly mechanism 34 for filling the lever-type anti-fall component 74 into the corresponding installation position.

[0073] like Figure 13 As shown, the slide block stamping mechanism 32 includes a first slider 321 that forms a first linear guide pair with the shared slide rail 31. A first horizontal push rod 323 is installed on the upper side of the first slider 321 via a first lifting push rod 322. A slide block forming punching cutter 324 is installed on the movable end of the first horizontal push rod 323.

[0074] like Figure 14 As shown, the hole-opening mechanism 33 includes a second slider 331 that forms a second linear guide pair with the shared slide rail 31. A second horizontal push rod 333 is supported on the upper side of the second slider 331 by a support plate 332. A clamping frame 334 is installed at the movable end of the second horizontal push rod 333. A steering motor 335 is installed inside the clamping frame 334. A rotating block 336, whose movement is limited by the clamping frame 334, is installed at the output end of the steering motor 335. A hole-opening laser head 337 is embedded in the side end of the rotating block 336. The steering motor 335 drives the rotating block 336 and the hole-opening laser head 337 to rotate, thereby meeting the requirements for opening functional holes in different directions.

[0075] like Figure 15 As shown, the assembly mechanism 34 includes a third slider 341 that forms a third linear guide pair with the shared slide rail. A third horizontal push rod 343 is mounted on the upper side of the third slider 341 via a second lifting push rod 342. A groove-like frame 344 is mounted on the movable end of the third horizontal push rod 343. Positioning protrusions 345 are symmetrically mounted on both sides of the web of the groove-like frame 344. The distance between the two positioning protrusions 345 is matched with the length of the web of the groove-like lever 741. Mechanical grippers 346 for clamping the connecting plate 743 are symmetrically mounted on the two side plates of the groove-like frame 344. The inner side of the gripper of the mechanical gripper 346 is provided with a clamping positioning groove that matches the width of the connecting plate 743.

[0076] The automated stamping system also includes a controller 6, which is connected to the load-bearing component 1, the crossbeam plate loading component 2, the stamping assembly component 3, the riveting robot 4, and the welding robot 5.

[0077] This embodiment also provides an automated stamping method for a forklift gantry assembly, comprising the following steps:

[0078] S1, Beam plate snap-fit ​​and press-fit connection

[0079] The suction cup 204 of the crossbeam plate loading assembly 2 adsorbs the crossbeam plate body 721, and the drive push rod 202 pushes the channel-shaped material carrier plate 203 to align the snap-fit ​​of the crossbeam plate component 72 with the inner cavity of the H-beam of the vertical beam plate component; the riveting robot 4 inserts the press-fit rivet into the press-fit connection mating hole 724 and the press-fit connection hole 712, and press-fits to form the press-fit connection component 73; the welding robot 5 welds and reinforces the connection between the vertical beam plate component 71 and the crossbeam plate component 72.

[0080] S2. Vertical beam positioning and pre-drilling treatment

[0081] The vertical beam plate component 71 is placed horizontally in the vertical beam plate positioning groove 102 of the bearing component 1, and the limiting rotating plate 104 is pressed and fixed by the flipping motor 103. In order to make the limiting rotating plate 104 rotate smoothly to the top of the vertical beam plate component 71, the controller 6 starts the hole-opening mechanism 33 in the stamping assembly component 3. The hole-opening laser head 337 of the hole-opening mechanism 33 processes the riveting connection holes 712 at both ends of the web plate of the vertical beam plate component 71 and the pin riveting holes 714 on both side plates. The slide stamping mechanism 32 processes two rows of slides 713 in the middle of the web plate of the vertical beam plate component 71.

[0082] S3, Lever-type fall arrestor component filling and pin installation

[0083] The assembly mechanism 34 moves along the common slide rail 31 to above the vertical beam plate component 71. The mechanical gripper 346 clamps the connecting plate 743 of the lever-type fall arrestor component 74 and aligns the web position of the slot-type lever 741 with the positioning protrusion 345. The fall arrestor block 744 is embedded into the slide rail 713, and the riveting robot 4 presses the pin 75 into the rotating hole and pin riveting hole 714 of the fulcrum seat 742 to complete the installation of the lever-type fall arrestor component 74.

[0084] A specific application of this embodiment is as follows:

[0085] Preparation

[0086] Ensure that all components of the automated stamping system (load-bearing component 1, crossbeam plate loading component 2, stamping assembly component 3, riveting robot 4, welding robot 5, and controller 6) are in normal working condition, and prepare the raw materials required for production, such as vertical beam plate component 71, crossbeam plate component 72, lever-type anti-fall component 74, pin shaft component 75, and press rivets.

[0087] The controller 6 initiates the operation of the crossbeam plate loading assembly 2. The suction cup 204 of the crossbeam plate loading assembly 2 adsorbs the crossbeam plate body 721, driving the push rod 202 to push the channel-shaped loading plate 203, aligning the outer U-shaped snap-fit ​​protrusion 722 and inner U-shaped snap-fit ​​protrusion 723 of the crossbeam plate component 72 with the H-shaped steel inner cavity of the vertical beam plate component 71, thus achieving snap-fit ​​positioning of the crossbeam plate component 72 at both ends of the vertical beam plate component 71. Under the control of the controller 6, the riveting robot 4 inserts the press-fit rivets into the press-fit connection mating hole 724 of the crossbeam plate component 72 and the press-fit connection hole 712 of the vertical beam plate component 71, performing press-fit processing to form the press-fit connection part 73, completing the initial connection between the crossbeam plate component 72 and the vertical beam plate component 71. Following the instructions of the controller 6, the welding robot 5 welds and reinforces the connection between the vertical beam plate component 71 and the crossbeam plate component 72, enhancing the connection strength and ensuring the stability of the outer gantry structure.

[0088] The operator places the vertical beam plate component 71 horizontally within the vertical beam plate positioning groove 102 of the bearing assembly 1, ensuring accurate placement. The controller 6 activates the tilting motor 103, which drives the limiting rotating plate 104 to rotate above the vertical beam plate component 71 and press it firmly to prevent movement during subsequent processing. The controller 6 then controls the hole-opening mechanism 33 in the stamping assembly 3 to begin operation. The second slider 331 of the hole-opening mechanism 33 moves along the common slide rail 31 to a suitable position, and the second horizontal push rod 333 pushes the clamping frame 334, aligning the hole-opening laser head 337 with the two ends of the web plate and the two side plates of the vertical beam plate component 71. Under the control of the controller 6, the steering motor 335 drives the rotating block 336 and the hole-opening laser head 337 to rotate, machining the riveting connection holes 712 at the two ends of the web plate of the vertical beam plate component 71 and the pin riveting holes 714 on the two side plates. The slide stamping mechanism 32 begins operation under the control of the controller 6. The first slider 321 moves along the common slide rail 31 to the middle of the web of the vertical beam plate component 71. The first lifting push rod 322 and the first horizontal push rod 323 adjust the position of the slide forming punch 324 and process two rows of slide rails 713 in the middle of the web of the vertical beam plate component 71 to provide space for the subsequent installation of the lever-type anti-fall component 74.

[0089] The controller 6 controls the third slider 341 of the assembly mechanism 34 to move along the common slide rail 31 to a suitable position above the vertical beam plate component 71. Under the control of the controller 6, the second lifting push rod 342 and the third horizontal push rod 343 adjust the position of the groove-shaped frame 344 so that the positioning protrusion 345 of the groove-shaped frame 344 aligns with the web position of the groove-shaped lever 741. The mechanical gripper 346 clamps the connecting plate 743 of the lever-type fall arrestor 74 to ensure the accurate placement of the lever-type fall arrestor 74. The fall arrestor block 744 is embedded into the slide rail 713. Under the control of the controller 6, the riveting robot 4 presses the pin 75 into the rotating hole and pin riveting hole 714 of the fulcrum seat 742 to complete the installation of the lever-type fall arrestor 74, so that the outer gantry has a fall arrest buffer function.

[0090] Slotted slide plates 802 are installed on both sides of the carrier plate seat 801 to ensure that the slotted slide plates 802 can slide and be restricted within the area of ​​the H-beam body 711 located in the web. A hanger 803 is installed on the upper side of the carrier plate seat 801. A drive mounting slot 806 is opened in the carrier plate seat 801 to install a rotary drive 804. An annular rotating plate 805 for adding forks is installed on the movable end of the rotary drive 804. An anti-detachment groove 807 for restricting the movement of the annular rotating plate 805 is opened on the front side of the carrier plate seat 801 located in front of the drive mounting slot 806, thus completing the assembly of the inner mast 8.

[0091] The prefabricated inner mast 8 is pre-installed between the two vertical beam plate components 71 of the outer mast, ensuring that the grooved slide plate 802 slides smoothly within the slide rail 713. After installation, the mast system is debugged, and the avoidance function of the lever-type fall arrestor 74 during normal lifting and lowering of the inner mast 8 is checked. A certain number of samples are also taken to test the fall arrest buffer effect of the lever-type fall arrestor 74 in the event of an accidental fall of the inner mast 8, ensuring that the mast system meets the design requirements. Through the above steps, a forklift mast with an outer mast having fall arrest buffer function and an inner mast having rotation function is produced using this automated stamping system and method.

[0092] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to specific implementations. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. An automated stamping system for forklift gantry production, characterized in that, The automated stamping system includes a load-bearing component, a crossbeam plate loading component, a stamping assembly component, a riveting robot, and a welding robot. The forklift gantry includes an outer gantry and an inner gantry disposed therein. The outer gantry includes vertical beam plate components, horizontal beam plate components, press-fit connectors, lever-type anti-fall components, and pin components. The inner gantry slides between two parallel vertical beam plate components. Each end of the vertical beam plate component is equipped with a horizontal beam plate component via press-fit connectors. Each vertical beam plate component is equipped with two rows of staggered lever-type anti-fall components, and a pin component is installed at the fulcrum of the lever-type anti-fall component. The load-bearing component is used to support and clamp the horizontally placed vertical beam plate component; There are two crossbeam plate loading assemblies, which are symmetrically arranged on the front and rear sides of the bearing assembly. The crossbeam plate loading assemblies are used to clamp the crossbeam plate components at both ends of the vertical beam plate components and cooperate with the riveting robot to install the press-fit connectors, and cooperate with the welding robot to perform welding reinforcement operations between the vertical beam plate components and the crossbeam plate components. There are two stamping assembly components, which are symmetrically arranged on the left and right sides of the bearing component. The stamping assembly components are used to pre-drill holes in the vertical beam plate component, fill the lever-type anti-fall component, and cooperate with the riveting robot to install the pin component. The stamping assembly includes a common slide rail, on which a slide rail stamping mechanism for forming slide rails, an opening mechanism for forming press-fit connection holes and pin riveting holes, and an assembly mechanism for filling lever-type anti-fall components into the corresponding installation positions are installed. The slide block stamping mechanism includes a first slider that forms a first linear guide pair with a shared slide rail. A first horizontal push rod is installed on the upper side of the first slider via a first lifting push rod. A slide block forming punch is installed on the movable end of the first horizontal push rod. The hole-opening mechanism includes a second slider that forms a second linear guide pair with a shared slide rail. A second horizontal push rod is supported on the upper side of the second slider by a support plate. A clamping frame is installed on the movable end of the second horizontal push rod. A steering motor is installed inside the clamping frame. A rotating block with a movement limit provided by the clamping frame is installed on the output end of the steering motor. A hole-opening laser head is embedded on the side end of the rotating block. The assembly mechanism includes a third slider that forms a third linear guide pair with a shared slide rail. A third horizontal push rod is mounted on the upper side of the third slider via a second lifting push rod. A groove-like frame is mounted on the movable end of the third horizontal push rod. Positioning protrusions are symmetrically mounted on both sides of the web of the groove-like frame. The distance between the two positioning protrusions matches the length of the web of the groove-like lever. Mechanical grippers for clamping the connecting plate are symmetrically mounted on the two side plates of the groove-like frame. The inner side of the gripper's claw is provided with a clamping positioning groove that matches the width of the connecting plate.

2. The automated stamping system for forklift gantry production according to claim 1, characterized in that, The vertical beam plate component includes an H-beam body. After pre-drilling, the H-beam body has press-fit connection holes at both ends of the web, two rows of slide rails in the middle of the web, and several pin riveting holes on both side plates.

3. The automated stamping system for forklift gantry production according to claim 2, characterized in that, The crossbeam plate component includes a crossbeam plate body. Two sets of snap-fit ​​components are symmetrically installed on the inner side of the crossbeam plate body. Each set of snap-fit ​​components consists of an outer U-shaped snap-fit ​​protrusion and an inner U-shaped snap-fit ​​protrusion. The outer U-shaped snap-fit ​​protrusion and the inner U-shaped snap-fit ​​protrusion are matched with the inner cavity shape of the H-beam body located on the outer / inner perimeter of the web. The outer U-shaped snap-fit ​​protrusion and the inner U-shaped snap-fit ​​protrusion are each provided with a press-fit connection hole that matches the position of the press-fit connection hole. The press-fit connection component is obtained by press-fitting rivets that extend into the press-fit connection connection hole and the press-fit connection hole through a riveting robot. The crossbeam plate component located on the upper layer has a suspension rope through hole in the middle of its crossbeam plate body.

4. The automated stamping system for forklift gantry production according to claim 3, characterized in that, The lever-type fall arrestor includes a grooved lever with a fulcrum seat in the middle for easy insertion of a pin. Fall arrest blocks are connected to the two side plates of the grooved lever via connecting plates. The two ends of the connecting plates are rotatably connected to the outer ends of the side plates of the grooved lever and the rear lugs of the fall arrest blocks, respectively. The outer end of the fall arrest blocks is provided with an arc-shaped stop. The fall arrest blocks slide and are restricted in the corresponding slide rails. The pin is displaced by a riveting robot and riveted into the pin riveting hole through the rotating hole of the fulcrum seat.

5. The automated stamping system for forklift gantry production according to claim 4, characterized in that, The inner mast includes a carrier plate seat. The carrier plate seat has grooved sliding plates on both sides that slide within the inner region of the web of the H-beam body. A hanger is mounted on the upper side of the carrier plate seat. A drive mounting slot is provided in the carrier plate seat to facilitate the installation of a rotary drive. An annular rotating plate for mounting forks is installed at the movable end of the rotary drive. An anti-detachment groove for the annular rotating plate is provided on the front side of the carrier plate seat, restricting its movement. The length of the grooved sliding plate is less than the length of the grooved lever. When the upper / lower side plate of the grooved sliding plate presses against the upper / lower anti-fall block of the lever-type anti-fall component and causes it to move inward, the lower / upper anti-fall block of the lever-type anti-fall component moves outward under the lever's action.

6. The automated stamping system for forklift gantry production according to claim 5, characterized in that, The supporting component includes a base, on the upper side of which two vertical beam plate positioning grooves are symmetrically opened inward for placing vertical beam plate components. The depth of the vertical beam plate positioning grooves is matched with the thickness of the side plate in the H-beam body. Several flipping motors are installed on the base between the two vertical beam plate positioning grooves. The output end of the flipping motors is equipped with a limiting rotating plate for restricting the vertical beam plate components from the top.

7. The automated stamping system for forklift gantry production according to claim 6, characterized in that, The crossbeam loading assembly includes a base plate, a drive push rod, a grooved material carrier plate, and a suction cup. The base plate is supported by the drive push rod and has a grooved material carrier plate. The spacing between the two side plates of the grooved material carrier plate is matched with the length of the crossbeam plate body. The suction cup is embedded and fixed in the web of the grooved material carrier plate near the two side plates.

8. An automated stamping system for forklift gantry production according to claim 7, characterized in that, It also includes a controller, which is connected to the load-bearing component, the beam loading component, the stamping assembly component, the riveting robot, and the welding robot.

9. An automated stamping method for a forklift gantry assembly, implemented based on the automated stamping system for forklift gantry production as described in claim 8, characterized in that, Includes the following steps: S1, Beam plate snap-fit ​​and press-fit connection The suction cup of the crossbeam plate loading assembly adsorbs the crossbeam plate body, and the drive rod pushes the channel-shaped material plate to align the snap-fit ​​of the crossbeam plate component with the inner cavity of the H-beam of the vertical beam plate component; the riveting robot inserts the press-fit rivets into the press-fit connection mating hole and the press-fit connection hole, and press-fits to form a press-fit connection; the welding robot welds and reinforces the connection between the vertical beam plate component and the crossbeam plate component. S2. Vertical beam positioning and pre-drilling treatment The vertical beam plate component is placed horizontally in the vertical beam plate positioning groove of the bearing component, and the limit plate is pressed and fixed by the flipping motor; the controller starts the hole-opening mechanism in the stamping assembly component, and the hole-opening laser head of the hole-opening mechanism processes the riveting connection holes at both ends of the web plate of the vertical beam plate component and the pin riveting holes on both side plates; the slide stamping mechanism processes two rows of slides in the middle of the web plate of the vertical beam plate component. S3, Lever-type fall arrestor component filling and pin installation The assembly mechanism moves along the common slide rail to the top of the vertical beam plate component. The mechanical gripper holds the connecting plate of the lever-type fall arrestor component and aligns the web position of the slotted lever with the positioning convex plate. The fall arrestor block is embedded in the slide rail, and the riveting robot presses the pin into the rotating hole and pin riveting hole of the fulcrum seat to complete the installation of the lever-type fall arrestor component.

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