Machine vision-based front fork bushing automatic press-in and positioning system

Abstract

The invention discloses an automatic press-in and positioning system for a front fork bushing based on machine vision, and relates to the technical field of bicycle front fork bushing assembly.The automatic press-in and positioning system comprises a base, a supporting seat is fixedly mounted at the top of the base, and a lower fork pipe is mounted at the top of the supporting seat through a pressing assembly; the lifting seat mechanism comprises a first electric cylinder and a lifting plate, the first electric cylinder is fixedly installed at the top of the base, the center of the bottom of the lifting plate is fixedly connected with the telescopic end of the first electric cylinder, and two first sliding grooves are longitudinally formed in the top of the lifting plate; and the adjusting seat mechanism comprises a base, a ball screw and a driving motor, the bottom of the base is in sliding connection with the first sliding groove through two T-shaped sliding connecting pieces, and the ball screw is rotationally installed at the top of the lifting plate through two bearing seats. The problems that in the prior art, when the front fork lining is pressed in and assembled, the positioning precision is low, the consistency is poor, and quality feedback is lacked are effectively solved, and the assembling precision, the percent of pass and the efficiency are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of bicycle fork bushing assembly technology, and in particular to a machine vision-based automatic pressing and positioning system for fork bushings. Background Technology

[0002] A bicycle, also known as a pedal bike or cyclist, is typically a small, two-wheeled land vehicle. Riders power it by pedaling, making it a green and environmentally friendly mode of transportation. More and more people are using bicycles for exercise and leisurely cycling trips; cycling itself is also a competitive sport, with events such as road cycling, mountain biking, track cycling, and stunt cycling.

[0003] A bicycle fork bushing is a ring-shaped sliding component installed inside a suspension fork, located between the inner tube (top tube) and the outer tube (bottom tube). It is typically made of self-lubricating composite materials (such as a PTFE blend with an aluminum alloy base plate) and is a key component in the fork's shock absorption system. The material and hardness of bicycle fork bushings can be broadly summarized as a harder outer layer and a softer inner layer, with the mainstream material being PTFE composite material + aluminum alloy base plate. In most cases, after the bushing is pressed in, its end face should be basically flush with the end of the outer tube (bottom tube), meaning neither protruding nor deeply recessed. This is the most common installation standard, ensuring smooth sliding of the inner tube and preventing interference with other components.

[0004] In most bicycle forks, whether suspension or rigid, the two lower fork tubes are rigidly connected by a fork bridge. The fork bridge is a crossbeam connecting the two lower fork tubes, ensuring synchronous movement and even stress distribution, preventing deformation or wobbling due to excessive stress on one side. During bicycle manufacturing, the two lower fork tubes are typically rigidly connected and fixed using the fork bridge before the bushings are pressed in. Currently, there are two main technical solutions for pressing in bicycle front fork bushings:

[0005] 1. Manual or semi-manual pressing: Operators use simple presses, or even hand hammers and bushings, relying on experience and feel to knock or press the bushings into the fork tube openings.

[0006] Disadvantages: extremely low precision, poor consistency, easy to cause scratches and deformation on the fork tube or bushing surface, difficult to control the pressing angle and depth, low product qualification rate, low production efficiency, and high requirements for worker skills.

[0007] 2. Automated pressing based on fixed tooling: The fork and bushing are fixed separately by mechanical positioning fixtures. The pressing head is driven by a cylinder or hydraulic cylinder to press the bushing into the fork. The pressing path is generally preset and fixed.

[0008] Disadvantages: The system cannot compensate for the dimensional tolerances of the incoming workpieces, which can easily lead to misalignment or damage due to inaccurate positioning. It also lacks process monitoring and quality feedback.

[0009] In summary, the current industry standard for bicycle bushing assembly commonly employs manual, semi-automatic, or automatic pressing methods based on fixed tooling. These methods have several drawbacks: First, positioning accuracy depends on the physical precision of the tooling and the consistency of the incoming materials, making it unsuitable for workpiece tolerance fluctuations, leading to problems such as misalignment, failure to press in, or bushing tilting after pressing. Second, the lack of real-time monitoring and feedback of the pressing process makes it impossible to guarantee that the assembly quality of each product meets standards, resulting in a high defect rate. Therefore, there is an urgent need for an automatic pressing and positioning system for fork bushings based on machine vision to solve these technical problems. Summary of the Invention

[0010] This invention discloses an automatic fork bushing pressing and positioning system based on machine vision. It is equipped with a vision-assisted mechanism. Its core function and purpose is to form a precise control link of detection-adjustment-alignment during the critical stage when the bushing approaches the lower fork tube through the pressing mechanism. Through the dynamic cooperation of vision detection and mechanism adjustment, it ensures that the bushing body and the lower fork tube opening achieve millimeter-level precise docking. This fundamentally avoids problems such as pressing failure, tube opening scratches, bushing deformation and other component damage caused by misalignment, and greatly improves assembly accuracy and product qualification rate.

[0011] Through the coordinated operation of the lifting seat mechanism, adjusting seat mechanism, pressing mechanism and vision-assisted mechanism, a highly automated assembly process is constructed. Except for the manual placement of the lower fork tube on the bearing seat and the initial fixing of the bushing body into the three-jaw chuck, the rest of the core assembly links do not require excessive manual intervention. This highly automated design not only eliminates tedious operations such as manual alignment and adjustment, but also significantly increases the assembly quantity per unit time through the stable operation of the mechanical mechanism and the precise control of visual inspection. At the same time, it significantly reduces the labor intensity of workers due to long-term repetitive operations, taking into account both efficiency and labor cost control.

[0012] By installing pressure sensing elements at key execution components and combining them with a display control terminal, a full-process quality monitoring system was constructed. This closed-loop control mode of pressure monitoring + visual feedback + automatic start and stop effectively ensures that the assembly quality of each product meets the standards, thereby effectively reducing the defect rate. At the same time, it provides reliable data support for quality control in the production process. In summary, the problems in the background technology are solved.

[0013] To solve the above-mentioned technical problems, the present invention is achieved through the following technical solution:

[0014] The present invention relates to an automatic fork bushing pressing and positioning system based on machine vision, comprising a base, a support seat fixedly mounted on the top of the base, and a lower fork tube mounted on the top of the support seat via a pressing assembly;

[0015] A lifting seat mechanism, comprising a first electric cylinder and a lifting plate, wherein the first electric cylinder is fixedly installed on the top of the base, the bottom center of the lifting plate is fixedly connected to the telescopic end of the first electric cylinder, and the top of the lifting plate is provided with two first sliding grooves longitudinally.

[0016] An adjusting seat mechanism includes a base, a ball screw, and a drive motor. The bottom of the base is slidably connected to a first slide groove via two T-shaped sliding connectors. The ball screw is rotatably mounted on the top of the lifting plate via two bearing seats. A transmission block is screwed onto the outside of the ball screw, and the top of the transmission block is fixedly connected to the bottom of the base. The drive motor is fixedly mounted on the top of the lifting plate via a motor seat, and the output end of the drive motor is connected to the shaft end of the ball screw. One side of the base is close to the support seat.

[0017] The pressing mechanism includes a fixed seat and a movable seat. The fixed seat is fixedly installed on the top of the base. Two second electric cylinders are fixedly installed through the fixed seat. The movable seat is L-shaped. The output ends of the two second electric cylinders are fixedly connected to the movable seat. Two three-jaw chucks are symmetrically arranged on the side of the movable seat away from the fixed seat. A bushing body is clamped in place by an internal support at the three-jaw chuck. The position height of the bushing body matches the position height of the lower fork tube.

[0018] A vision assist mechanism includes a first mounting plate and a second mounting plate. The first mounting plate is fixedly mounted on one side of the movable base. Two first industrial cameras are fixedly mounted on the bottom of the first mounting plate, and the two first industrial cameras are respectively located directly above the two bushing bodies with their shooting ends facing the bushing bodies. There are two second mounting plates, both of which are fixedly mounted on the top of the base. The two second mounting plates are respectively located on the front and rear sides of the lower fork tube opening. A second industrial camera is fixedly mounted on the opposite side of each of the two second mounting plates. The height of the two second industrial cameras matches the height of the lower fork tube, and their shooting ends face the lower fork tube.

[0019] Furthermore, four telescopic support rods are fixedly connected to the top of the base, and the telescopic ends of the four telescopic support rods are all fixedly connected to the bottom of the lifting plate, and the four telescopic support rods are arranged in a matrix.

[0020] Furthermore, the top of the base is provided with two second sliding grooves in the horizontal direction, and the bottom of the movable seat is slidably connected to the two second sliding grooves through two T-shaped sliding connectors.

[0021] Furthermore, the axis of the second electric cylinder coincides with the center of the three-jaw chuck, and the bottom of the movable seat is close to but does not contact the top of the base.

[0022] Furthermore, the clamping assembly includes a bearing seat and a mounting bracket. Two bearing seats are provided, and both bearing seats are fixedly installed on the top of the support seat. The mounting bracket is inverted U-shape and is fixedly installed on the top of the support seat. Two third electric cylinders are fixedly installed through the mounting bracket. The output ends of the two third electric cylinders are fixedly connected to clamping seats. The two clamping seats are located directly above the two bearing seats. Grooves are provided on opposite sides of the bearing seats and clamping seats. Lower fork tubes are movably placed in the grooves of the two bearing seats, and the open end of the lower fork tube faces the bushing body.

[0023] Furthermore, the groove is a V-shaped groove, and an anti-slip pad layer is bonded and fixed to the inner wall of the groove. The anti-slip pad layer is made of rubber material.

[0024] Furthermore, a first pressure sensor is connected in series at the output end of the second electric cylinder, and a second pressure sensor is connected in series at the output end of the third electric cylinder.

[0025] Furthermore, the first mounting plate has a ring-shaped first light source fixedly mounted on the outer circumference of the first industrial camera, and the second mounting plate has a ring-shaped second light source fixedly mounted on the outer circumference of the second industrial camera.

[0026] Furthermore, the first electric cylinder, the second electric cylinder, the third electric cylinder, the drive motor, the first industrial camera, the second industrial camera, the first pressure sensor, and the second pressure sensor are all externally connected to a display control terminal, which includes a display screen and a PLC controller.

[0027] The present invention has the following advantages over the prior art:

[0028] 1. This technical solution incorporates a vision-assisted mechanism. Its core function and purpose is to establish a precise control link of detection-adjustment-alignment during the critical stage when the bushing approaches the lower fork tube via the pressing mechanism: a first industrial camera captures the bushing body in real time and transmits image data, accurately capturing the real-time position coordinates of the bushing; simultaneously, a second industrial camera symmetrically captures the lower fork tube opening, clearly obtaining the opening's position information. When both the bushing body and the lower fork tube opening are simultaneously captured by the first and second industrial cameras, the two types of image data are synchronously transmitted to the PLC controller in the display control terminal for analysis and comparison. When a misalignment is detected between the bushing and the tube opening... When there is a deviation in height or longitudinal position, the PLC controller immediately sends adjustment commands to the lifting seat mechanism and the adjusting seat mechanism. The first electric cylinder of the lifting seat mechanism drives the lifting plate to lift the entire bushing, accurately correcting the height deviation. The drive motor of the adjusting seat mechanism drives the ball screw to rotate, which drives the base to slide back and forth along the first slide groove through the transmission block, synchronously adjusting the longitudinal position of the bushing. Through the dynamic coordination of visual inspection and mechanism adjustment, the bushing body and the lower fork tube opening are ensured to achieve millimeter-level precise docking, fundamentally avoiding problems such as failed pressing, tube opening scratches, and bushing deformation caused by misalignment, greatly improving assembly accuracy and product qualification rate.

[0029] 2. This technical solution constructs a highly automated assembly process through the coordinated linkage of the lifting seat mechanism, adjusting seat mechanism, pressing mechanism, and vision-assisted mechanism. Except for the manual placement of the lower fork tube on the bearing seat and the initial fixing of the bushing body into the three-jaw chuck, the remaining core assembly steps do not require excessive manual intervention: After the system is started, the third electric cylinder of the pressing component automatically drives the pressing seat to descend and press the lower fork tube. The vision-assisted mechanism automatically completes the position detection of the bushing and the tube opening. The lifting seat mechanism and adjusting seat mechanism automatically calibrate the bushing position according to the detection data. The second electric cylinder of the pressing mechanism drives the movable seat to automatically complete the pressing action of the bushing. The entire process is automatically controlled by the PLC controller according to the preset logic. This highly automated design not only eliminates tedious operations such as manual alignment and adjustment, but also significantly increases the assembly quantity per unit time through the stable operation of the mechanical mechanism and the precise control of visual inspection. At the same time, it significantly reduces the labor intensity of workers due to long-term repetitive operations, taking into account both efficiency and labor cost control.

[0030] 3. This technical solution constructs a full-process quality monitoring system by setting pressure sensing elements at key actuators and combining them with a display and control terminal: A first pressure sensor is connected in series at the output end of the second electric cylinder of the pressing mechanism to collect axial pressure data during the bushing pressing process in real time; a second pressure sensor is connected in series at the output end of the third electric cylinder of the clamping assembly to simultaneously monitor the clamping pressure data during the clamping of the lower fork tube; both types of pressure data and the position detection data of the vision-assisted mechanism are transmitted to the display and control terminal in real time. The PLC controller compares the collected pressure values ​​with the preset standard pressure range (such as the rated pressure for bushing pressing and the safe pressure for stable clamping of the lower fork tube) in real time: if the pressing pressure exceeds the upper limit, If the system detects a possible blockage at the pipe opening or an abnormal bushing size, it immediately stops the second electric cylinder and issues an alarm. If the clamping pressure is insufficient, the system drives the third electric cylinder to compensate for the pressure, preventing the lower fork pipe from shifting during insertion. Simultaneously, the display screen shows real-time pressure curves, alignment accuracy between the bushing and the pipe opening, and other key parameters. All assembly data (such as peak pressure, alignment deviation, and assembly time) is automatically stored by the PLC controller, facilitating subsequent quality traceability and problem troubleshooting. This closed-loop control mode, combining pressure monitoring, visual feedback, and automatic start / stop, effectively ensures that the assembly quality of each product meets standards, thereby significantly reducing the defect rate and providing reliable data support for quality control throughout the production process. Attached Figure Description

[0031] 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.

[0032] Figure 1 This is a schematic diagram of the overall three-dimensional structure of the present invention;

[0033] Figure 2 This is a schematic diagram of the structure from another perspective of the present invention;

[0034] Figure 3 This is an exploded view of the lifting plate and base installation of the present invention;

[0035] Figure 4 This is a schematic diagram of the exploded structure of the movable seat installation of the present invention;

[0036] Figure 5 This is a schematic diagram of the first industrial camera mounting structure of the present invention;

[0037] Figure 6 This is a schematic diagram of the second industrial camera mounting structure of the present invention;

[0038] Figure 7 This is a schematic diagram of the exploded structure of the clamping seat installation according to the present invention.

[0039] In the diagram: 1. Base; 2. Support seat; 3. Lower fork tube; 4. First electric cylinder; 5. Lifting plate; 6. First slide groove; 7. Base; 8. Ball screw; 9. Drive motor; 10. Bearing seat; 11. Transmission block; 12. Movable seat; 13. Second electric cylinder; 14. Three-jaw chuck; 15. Bushing body; 16. First mounting plate; 17. Second mounting plate; 18. First industrial camera; 19. Second industrial camera; 20. Telescopic support rod; 21. Second slide groove; 22. Bearing seat; 23. Mounting frame; 24. Third electric cylinder; 25. Clamping seat; 26. Groove; 27. First pressure sensor; 28. Second pressure sensor; 29. ​​Fixed seat. Detailed Implementation

[0040] 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.

[0041] In the description of this invention, it should be understood that the terms "surface", "side", "gap", "peripheral", etc., which indicate orientation or positional relationship, are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the components or elements referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting this invention.

[0042] Reference Figures 1-7 The machine vision-based automatic fork bushing pressing and positioning system includes a base 1, a support seat 2 fixedly installed on the top of the base 1, and a lower fork tube 3 installed on the top of the support seat 2 through a pressing component.

[0043] The lifting seat mechanism includes a first electric cylinder 4 and a lifting plate 5. The first electric cylinder 4 is fixedly installed on the top of the base 1. The bottom center of the lifting plate 5 is fixedly connected to the telescopic end of the first electric cylinder 4. Two first sliding grooves 6 are longitudinally opened on the top of the lifting plate 5.

[0044] The adjustment seat mechanism includes a base 7, a ball screw 8, and a drive motor 9. The bottom of the base 7 is slidably connected to the first slide groove 6 through two T-shaped sliding connectors. The ball screw 8 is rotatably mounted on the top of the lifting plate 5 through two bearing seats 10. A transmission block 11 is screwed to the outside of the ball screw 8. The top of the transmission block 11 is fixedly connected to the bottom of the base 7. The drive motor 9 is fixedly mounted on the top of the lifting plate 5 through a motor seat. The output end of the drive motor 9 is connected to the shaft end of the ball screw 8. One side of the base 7 is close to the support seat 2.

[0045] The pressing mechanism includes a fixed seat 29 and a movable seat 12. The fixed seat 29 is fixedly installed on the top of the base 7. Two second electric cylinders 13 are fixedly installed through the fixed seat 29. The movable seat 12 is L-shaped. The output ends of the two second electric cylinders 13 are fixedly connected to the movable seat 12. Two three-jaw chucks 14 are symmetrically arranged on the side of the movable seat 12 away from the fixed seat 29. The bushing body 15 is clamped by the internal support at the three-jaw chuck 14. The position height of the bushing body 15 matches the position height of the lower fork tube 3.

[0046] The visual aid mechanism includes a first mounting plate 16 and a second mounting plate 17. The first mounting plate 16 is fixedly mounted on one side of the movable base 12. Two first industrial cameras 18 are fixedly mounted on the bottom of the first mounting plate 16, and the two first industrial cameras 18 are respectively located directly above the two bushing bodies 15 with their shooting ends facing the bushing bodies 15. There are two second mounting plates 17. Both second mounting plates 17 are fixedly mounted on the top of the base 1, and the two second mounting plates 17 are respectively located on the front and rear sides of the opening end of the lower fork tube 3. A second industrial camera 19 is fixedly mounted on the opposite side of the two second mounting plates 17. The height of the two second industrial cameras 19 is matched with the height of the lower fork tube 3, and their shooting ends face the lower fork tube 3.

[0047] Four telescopic support rods 20 are fixedly connected to the top of the base 1. The telescopic ends of the four telescopic support rods 20 are all fixedly connected to the bottom of the lifting plate 5, and the four telescopic support rods 20 are arranged in a matrix. Two second sliding grooves 21 are opened horizontally on the top of the base 7. The bottom of the movable seat 12 is slidably connected to the two second sliding grooves 21 through two T-shaped sliding connectors. The axis of the second electric cylinder 13 is consistent with the center of the three-jaw chuck 14. The bottom of the movable seat 12 is close to the top of the base 7 but does not contact it.

[0048] The clamping assembly includes a bearing seat 22 and a mounting bracket 23. There are two bearing seats 22, both of which are fixedly installed on the top of the support seat 2. The mounting bracket 23 is inverted U-shape and is fixedly installed on the top of the support seat 2. Two third electric cylinders 24 are fixedly installed through the mounting bracket 23. The output ends of the two third electric cylinders 24 are fixedly connected to clamping seats 25. The two clamping seats 25 are located directly above the two bearing seats 22. The bearing seats 22 and the clamping seats 25 are respectively provided with grooves 26 on opposite sides. The lower fork tube 3 is movably placed in the grooves 26 of the two bearing seats 22. The open end of the lower fork tube 3 faces the bushing body 15.

[0049] The groove 26 is a V-shaped groove, and an anti-slip pad layer is bonded and fixed to the inner wall of the groove 26. The anti-slip pad layer is made of rubber material. The output end of the second electric cylinder 13 is connected in series with the first pressure sensor 27, and the output end of the third electric cylinder 24 is connected in series with the second pressure sensor 28. The first mounting plate 16 is fixedly mounted with a ring-shaped first light source on the outer circumference of the first industrial camera 18, and the second mounting plate 17 is fixedly mounted with a ring-shaped second light source on the outer circumference of the second industrial camera 19. The first electric cylinder 4, the second electric cylinder 13, the third electric cylinder 24, the drive motor 9, the first industrial camera 18, the second industrial camera 19, the first pressure sensor 27, and the second pressure sensor 28 are all externally connected to a display control terminal, which includes a display screen and a PLC controller.

[0050] The specific implementation process is as follows:

[0051] Initial preparation stage: The operator places the lower fork tube 3, which has been fixed by the fork bridge, into the two bearing seats 22V-shaped grooves 26 on the top of the support seat 2, ensuring that the open end of the lower fork tube 3 faces the three-jaw chuck 14; then, the two bushing bodies 15 are respectively installed into the two three-jaw chucks 14 on the movable seat 12, and the internal support of the three-jaw chuck 14 is activated to clamp the bushing bodies 15, completing the initial fixation of the workpiece; after the operation is completed, a start command is issued through the display control terminal, and the system enters the automatic assembly process;

[0052] Lower fork tube 3 clamping and positioning: The PLC controller of the display control terminal drives the two third electric cylinders 24 of the clamping assembly to move synchronously. The output end of the third electric cylinder 24 drives the clamping seat 25 to move vertically downward until the V-shaped groove 26 of the clamping seat 25 and the V-shaped groove 26 of the bearing seat 22 cooperate to clamp the lower fork tube 3. During this process, the second pressure sensor 28 connected in series at the output end of the third electric cylinder 24 collects the clamping pressure data in real time and transmits it to the PLC controller. When the pressure value reaches the preset safe clamping range (such as 5-8MPa), the PLC controller controls the third electric cylinder 24 to stop moving, completing the stable fixing of the lower fork tube 3.

[0053] In the visual alignment detection stage: the PLC controller synchronously activates the visual auxiliary mechanism, and the annular first light source at the first mounting plate 16 and the annular second light source at the second mounting plate 17 are turned on to provide uniform illumination for camera shooting; two first industrial cameras 18 shoot from directly above the bushing body 15 to acquire bushing image information; two second industrial cameras 19 symmetrically shoot from the front and rear sides of the opening end of the lower fork tube 3 to capture the tube opening information of the lower fork tube 3; subsequently, the PLC controller drives the two second electric cylinders 13 of the pressing mechanism to extend synchronously, and the output end of the second electric cylinder 13 drives the movable seat 12 along... The second slide groove 21 of the base 7 slides towards the lower fork tube 3. The bushing body 15 moves synchronously with the movable seat 12 and gradually approaches the opening of the lower fork tube 3. When the bushing body 15 and the opening of the lower fork tube 3 are simultaneously captured by the first industrial camera 18 and the second industrial camera 19, the PLC controller drives the two second electric cylinders 13 to stop. The two types of image data are synchronously transmitted to the PLC controller of the display control terminal for analysis and comparison. The controller calculates the height deviation, longitudinal deviation and coaxiality deviation between the bushing and the opening through the image recognition algorithm.

[0054] Automatic position calibration stage: If the PLC controller detects a height deviation, it immediately drives the first electric cylinder 4 of the lifting seat mechanism to move. The telescopic end of the first electric cylinder 4 drives the lifting plate 5 to rise and fall along the four matrix-distributed telescopic support rods 20, synchronously adjusting the overall height of the bushing until the bushing is at the same height as the pipe opening. If a longitudinal deviation is detected, the drive motor 9 of the adjusting seat mechanism starts, driving the ball screw 8 to rotate. The transmission block 11 drives the base 7 to slide back and forth along the first slide groove 6 of the lifting plate 5, accurately correcting the front and rear position of the bushing. During the calibration process, the vision auxiliary mechanism provides real-time feedback of position data until the bushing and the pipe opening are coaxially aligned (coaxiality error ≤ 0.05mm). After calibration, each mechanism is reset and ready to go.

[0055] Automatic bushing pressing stage: After calibration, the PLC controller drives the two second electric cylinders 13 of the pressing mechanism to extend synchronously. The output end of the second electric cylinder 13 drives the movable seat 12 to slide along the second slide groove 21 of the base 7 towards the lower fork tube 3. The bushing body 15 moves synchronously with the movable seat 12 and gradually enters the lower fork tube 3. During this process, the first pressure sensor 27 connected in series at the output end of the second electric cylinder 13 collects the pressing pressure data in real time. When the pressure value reaches the preset rated pressing pressure (such as 10-12MPa) and remains stable (for 2 seconds), it indicates that the bushing end face is flush with the lower fork tube 3 port. The PLC controller controls the second electric cylinder 13 to stop moving and retract back to the initial position.

[0056] Assembly completion and reset stage: After the pressing action is completed, the PLC controller drives the third electric cylinder 24 to retract, the clamping seat 25 moves upward to release the lower fork tube 3, and the operator takes out the assembled front fork assembly; at the same time, the three-jaw chuck 14 is released, waiting for the next bushing to be installed; the system automatically stores the pressure curve, alignment deviation value and assembly time of this assembly to the display control terminal. If an abnormal pressure occurs during the assembly process (exceeding 15MPa or falling below 8MPa) or the alignment deviation exceeds the standard, the system will immediately issue an audible and visual alarm and record the fault information to facilitate the staff to troubleshoot and handle the problem;

[0057] Among them, the four matrix-distributed telescopic support rods 20 work together with the first electric cylinder 4 to support the lifting plate 5, avoid uneven force on the lifting plate 5 causing tilting, improve the stability and accuracy of height adjustment, and ensure the reliability of bushing height calibration.

[0058] The sliding connection between the second slide groove 21 at the top of the base 7 and the movable seat 12 provides guidance for the movable seat 12, ensuring that the movable seat 12 drives the bushing to move in a straight line, avoiding bushing displacement during the pressing process and improving pressing accuracy.

[0059] The alignment of the axis of the second electric cylinder 13 with the center of the three-jaw chuck 14 ensures that the driving force of the electric cylinder is transmitted along the bushing axis, avoiding radial force during pressing that could cause bushing deformation or pipe scratches, thus ensuring assembly quality.

[0060] Among them, the V-shaped groove 26 and the rubber anti-slip pad layer are adapted to lower fork tubes 3 of different diameters, improving the versatility of the fixture. The rubber anti-slip pad layer increases the clamping friction, prevents the lower fork tube 3 from shifting during pressing, and avoids workpiece scratches caused by direct metal contact.

[0061] Among them, the first pressure sensor 27 and the second pressure sensor 28 monitor the clamping pressure and pressing pressure in real time, and achieve precise control through pressure feedback to avoid damage to the workpiece due to excessive clamping or displacement due to excessive clamping. At the same time, it prevents excessive or insufficient pressing and ensures assembly consistency.

[0062] Among them, the first and second ring-shaped light sources provide a uniform and stable lighting environment for industrial cameras, eliminate shadow interference, improve the accuracy of image recognition, and provide reliable data support for precise alignment and quality inspection.

[0063] The display control terminal integrates a display screen and a PLC controller to achieve fully automated control of the entire process. It displays parameters such as pressure and alignment accuracy in real time, automatically stores assembly data for easy quality traceability and process optimization, and handles faults in a timely manner through alarm functions.

[0064] 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 the specific implementations described. 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. A machine vision-based automatic pressing and positioning system for fork bushings, characterized in that, Includes a base (1), on the top of which a support seat (2) is fixedly installed, and on the top of the support seat (2) a lower fork tube (3) is installed by a clamping assembly; The lifting seat mechanism includes a first electric cylinder (4) and a lifting plate (5). The first electric cylinder (4) is fixedly installed on the top of the base (1). The bottom center of the lifting plate (5) is fixedly connected to the telescopic end of the first electric cylinder (4). The top of the lifting plate (5) has two first sliding grooves (6) longitudinally opened. The adjustment seat mechanism includes a base (7), a ball screw (8), and a drive motor (9). The bottom of the base (7) is slidably connected to the first slide groove (6) through two T-shaped sliding connectors. The ball screw (8) is rotatably mounted on the top of the lifting plate (5) through two bearing seats (10). A transmission block (11) is screwed to the outside of the ball screw (8). The top of the transmission block (11) is fixedly connected to the bottom of the base (7). The drive motor (9) is fixedly mounted on the top of the lifting plate (5) through a motor seat. The output end of the drive motor (9) is connected to the shaft end of the ball screw (8). One side of the base (7) is close to the support seat (2). The pressing mechanism includes a fixed seat (29) and a movable seat (12). The fixed seat (29) is fixedly installed on the top of the base (7). Two second electric cylinders (13) are fixedly installed through the fixed seat (29). The movable seat (12) is L-shaped. The output ends of the two second electric cylinders (13) are fixedly connected to the movable seat (12). Two three-jaw chucks (14) are symmetrically arranged on the side of the movable seat (12) away from the fixed seat (29). A bushing body (15) is clamped by an internal support at the three-jaw chuck (14). The position height of the bushing body (15) matches the position height of the lower fork tube (3). The visual aid mechanism includes a first mounting plate (16) and a second mounting plate (17). The first mounting plate (16) is fixedly mounted on one side of the movable seat (12). Two first industrial cameras (18) are fixedly mounted on the bottom of the first mounting plate (16). The two first industrial cameras (18) are respectively located directly above the two bushing bodies (15) and their shooting ends face the bushing bodies (15). There are two second mounting plates (17). The two second mounting plates (17) are fixedly mounted on the top of the base (1). The two second mounting plates (17) are respectively located on the front and rear sides of the opening end of the lower fork tube (3). A second industrial camera (19) is fixedly mounted on the opposite side of the two second mounting plates (17). The height of the two second industrial cameras (19) is matched with the height of the lower fork tube (3) and their shooting ends face the lower fork tube (3).

2. The automatic fork bushing pressing and positioning system based on machine vision according to claim 1, characterized in that, The base (1) is fixedly connected to four telescopic support rods (20), and the telescopic ends of the four telescopic support rods (20) are fixedly connected to the bottom of the lifting plate (5), and the four telescopic support rods (20) are arranged in a matrix.

3. The automatic fork bushing pressing and positioning system based on machine vision according to claim 1, characterized in that, The top of the base (7) is provided with two second sliding grooves (21) in the horizontal direction, and the bottom of the movable seat (12) is slidably connected to the two second sliding grooves (21) through two T-shaped sliding connectors.

4. The automatic pressing and positioning system for fork bushings based on machine vision according to claim 1, characterized in that, The axis of the second electric cylinder (13) is aligned with the center of the three-jaw chuck (14), and the bottom of the movable seat (12) is close to but does not contact the top of the base (7).

5. The automatic pressing and positioning system for fork bushings based on machine vision according to claim 1, characterized in that, The clamping assembly includes a bearing seat (22) and a mounting bracket (23). There are two bearing seats (22), and both bearing seats (22) are fixedly installed on the top of the support seat (2). The mounting bracket (23) is inverted U-shape and is fixedly installed on the top of the support seat (2). Two third electric cylinders (24) are fixedly installed through the mounting bracket (23). The output ends of the two third electric cylinders (24) are fixedly connected to clamping seats (25). The two clamping seats (25) are located directly above the two bearing seats (22). The bearing seats (22) and the clamping seats (25) are respectively provided with grooves (26) on opposite sides. The lower fork tube (3) is movably placed in the grooves (26) of the two bearing seats (22). The opening end of the lower fork tube (3) faces the bushing body (15).

6. The automatic pressing and positioning system for fork bushings based on machine vision according to claim 5, characterized in that, The groove (26) is a V-shaped groove, and an anti-slip pad layer is bonded and fixed to the inner wall of the groove (26). The anti-slip pad layer is made of rubber material.

7. The automatic fork bushing pressing and positioning system based on machine vision according to claim 5, characterized in that, The output end of the second electric cylinder (13) is connected in series with a first pressure sensor (27), and the output end of the third electric cylinder (24) is connected in series with a second pressure sensor (28).

8. The automatic pressing and positioning system for fork bushings based on machine vision according to claim 1, characterized in that, The first mounting plate (16) has a ring-shaped first light source fixedly mounted on the outer circumference of the first industrial camera (18), and the second mounting plate (17) has a ring-shaped second light source fixedly mounted on the outer circumference of the second industrial camera (19).

9. The automatic pressing and positioning system for fork bushings based on machine vision according to claim 7, characterized in that, The first electric cylinder (4), the second electric cylinder (13), the third electric cylinder (24), the drive motor (9), the first industrial camera (18), the second industrial camera (19), the first pressure sensor (27), and the second pressure sensor (28) are all externally connected to a display control terminal, which includes a display screen and a PLC controller.

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