Pedal support shaft sleeve semi-automatic multi-station intelligent assembling equipment and control method thereof

Abstract

The invention discloses semi-automatic multi-station intelligent assembling equipment for a pedal support shaft sleeve and a control method of the semi-automatic multi-station intelligent assembling equipment. The equipment comprises a machine table, a left station and a right station, wherein the left station and the right station are arranged side by side and used for pressing shaft sleeves of different specifications into the same workpiece. Each station is provided with a lifting mechanism and a shaft sleeve press-in mechanism, and the press-in mechanism is driven by a servo motor and provided with a pressure sensor. The core lies in that the equipment control system not only can monitor whether the pressure is qualified or not in real time in the press-in process, but also can monitor the return resistance in real time in the return process of the shaft sleeve opening assembly; and when the resistance exceeds a preset anti-pinch force threshold value, returning can be stopped immediately, an alarm is given, and clamping stagnation damage is effectively prevented. In addition, a plurality of groups of parameter formulas are pre-stored in the system, so that product specifications can be conveniently and quickly switched, and flexible production is realized. Intelligent monitoring and safety protection of the whole process of press fitting operation are achieved, and the assembly quality, the equipment safety and the production efficiency are remarkably improved.

Description

Technical Field

[0001] This invention belongs to the field of mechanical manufacturing automation technology, specifically relating to a semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings and its control method. Background Technology

[0002] With the continuous improvement of industrial automation, the assembly precision and efficiency requirements for key components such as pedal brackets are increasing in the automotive, motorcycle, and general machinery manufacturing sectors. The assembly of pedal bracket shafts typically involves pressing bushings into bracket holes. This process places stringent requirements on the control of pressing force, the fit precision between the bushing and the hole, and operational safety. Traditional manual pressing is not only inefficient and labor-intensive, but also makes it difficult to accurately control the pressing pressure and detect abnormal conditions in real time. This can easily lead to bushing deformation, workpiece damage, or uneven assembly quality, directly affecting product reliability and service life.

[0003] Currently, while some automated press-fitting equipment on the market has improved efficiency to some extent, it still has significant limitations in functionality. For example, most equipment lacks multi-dimensional intelligent monitoring of the press-fitting process, especially lacking effective detection and protection mechanisms for the potential clamping or jamming risks that may occur when the mold or bushing retracts from the workpiece after press-fitting. In addition, facing the flexible production needs of multiple varieties and small batches, existing equipment often involves cumbersome parameter adjustments, making it difficult to quickly adapt to the press-fitting process of different specifications of workpieces and bushings. The low switching efficiency and high error rate restrict the overall flexibility and intelligence level of the production line.

[0004] Therefore, the present invention proposes a semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings and its control method to at least partially solve the above problems. Summary of the Invention

[0005] To address the aforementioned problems in the existing technology, this invention provides a semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings and its control method. This solves the problem that existing automated pressing equipment, during the retraction stage after bushing pressing is completed, is prone to jamming due to the lack of a real-time monitoring and protection mechanism for abnormal resistance, which can lead to equipment or workpiece damage.

[0006] The objective of this invention can be achieved through the following technical solution: a semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings, comprising: a machine base, and a left station and a right station arranged side by side on the machine base, wherein the left station and the right station are used to press bushings of different specifications into the same pedal bracket workpiece; each station includes a lifting mechanism and a bushing pressing mechanism disposed on the lifting mechanism; the bushing pressing mechanism includes a servo motor, a bushing opening component driven by the servo motor, and a pressure sensor for real-time monitoring of the pressing pressure; the equipment also includes a control system connected to each station, wherein the control system is used to monitor the retraction resistance in real time during the retraction process after the bushing opening component performs the pressing action, and when the retraction resistance exceeds a preset anti-pinch force threshold, control the bushing opening component to stop retraction and issue an alarm.

[0007] As a preferred technical solution of the present invention, the control system has multiple parameter formulas pre-stored with different pedal bracket models and bushing specifications, and the operator can select and retrieve different parameter formulas for the left and right workstations respectively.

[0008] As a preferred embodiment of the present invention, the parameter formula includes at least an upper limit and a lower limit of the pressure qualified range, and the anti-pinch force threshold.

[0009] As a preferred embodiment of the present invention, the control system is further configured to: during the pressing process, compare the pressure value measured by the pressure sensor with the upper and lower pressure limits in the current parameter formula in real time, and issue an alarm when the pressure value exceeds the qualified range.

[0010] As a preferred embodiment of the present invention, each workstation has two pressure sensors, which are symmetrically arranged on both sides of the bushing support assembly.

[0011] As a preferred embodiment of the present invention, a manual switch is also included. The manual switch is connected to the control system and is used to trigger the bushing pressing mechanism of the currently selected station to perform automatic pressing after the workpiece and bushing are manually placed.

[0012] As a preferred embodiment of the present invention, it also includes status indicator lights corresponding to each workstation; the control system is configured to control the status indicator lights of the corresponding workstations to light up or turn off based on the determination results of the pressing pressure and the retraction resistance after one pressing operation cycle is completed.

[0013] A semi-automatic multi-station intelligent assembly control method for pedal bracket bushing includes the following steps: S1: Select the parameter formulas corresponding to the specifications of the bushings to be pressed for the left and right workstations respectively; S2: After the workpiece and bushing are placed manually at the corresponding workstation, a start signal is received; S3: Control the servo motor of the current workstation to drive the bushing to open the component and perform the pressing action; S4: After the pressing action is completed, control the bushing opening assembly to perform the retraction action, and monitor the retraction resistance in real time during the retraction process; S5: If the retraction resistance exceeds the anti-pinch force threshold in the current parameter formula, control the bushing opening assembly to stop retraction and trigger an alarm.

[0014] As a preferred technical solution of the present invention, step S3 specifically includes: S31: Control the servo motor to drive the bushing to open the assembly and perform a pressing action; S32: Real-time acquisition of press-fitting pressure data via the pressure sensor; S33: Real-time determination of whether the pressure data is within the qualified range formed by the upper and lower pressure values ​​in the current parameter formula; S34: If the pressure data exceeds the specified acceptable range, it is determined that the pressure is unacceptable, and the control equipment will stop and trigger an alarm.

[0015] As a preferred embodiment of the present invention, the method further includes the following steps: S6: After a complete pressing and retraction cycle is completed, the status indicator light of the corresponding workstation is controlled to indicate the status based on the judgment results of the pressing pressure and retraction resistance; if no alarm is triggered throughout the process, the indicator light representing the qualified status will be lit.

[0016] The beneficial effects of this invention are as follows: By introducing a dual-station parallel operation and a full-process force control intelligent monitoring mechanism, it effectively solves many shortcomings in the existing technology. Its beneficial effects are mainly reflected in the following aspects: First, it significantly improves production efficiency and flexible production capabilities. The dual-station design allows for the simultaneous pressing of two types of bushings onto the same workpiece, and enables rapid switching between different specifications of products through pre-stored parameter formulas. Second, it comprehensively ensures assembly quality and process safety. It not only monitors the pressing pressure in real time to ensure it remains within the acceptable range, but also innovatively monitors resistance and sets anti-pinch thresholds during the retraction phase, proactively preventing jamming risks and avoiding damage to equipment and workpieces. Third, it improves the convenience and reliability of operation. Through human-machine interaction design such as manual triggering, status indicator lights, and symmetrically arranged pressure sensors, the work process is clear and monitoring is comprehensive, reducing operational difficulty and the risk of misjudgment. Attached Figure Description

[0017] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0018] Figure 1This is a front view structural schematic diagram of a semi-automatic multi-station intelligent assembly equipment for a pedal bracket bushing according to the present invention.

[0019] Figure 2 This is another structural schematic diagram of a semi-automatic multi-station intelligent assembly equipment for a pedal bracket bushing according to the present invention.

[0020] Figure 3 This is another structural schematic diagram of a semi-automatic multi-station intelligent assembly equipment for a pedal bracket bushing according to the present invention.

[0021] Explanation of main component symbols 100. Equipment platform; 200. Left workstation; 300. Right workstation; 400. Bushing pressing mechanism; 401. Servo motor; 402. Pressure sensor; 403. Bushing opening assembly; 500. Material box; 600. Lifting mechanism. Detailed Implementation

[0022] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided.

[0023] Please see Figures 1 to 3 This invention provides a semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings. This equipment is mainly used in the pedal bracket assembly process of automobiles, motorcycles, and other vehicles, enabling the precise and reliable pressing of bushings (copper bushings) of different specifications into the corresponding shaft holes of the bracket.

[0024] like Figure 1 As shown, on the worktable of the machine tool 100, there are two structurally similar but independently operating left workstations 200 and 300. The core purpose of this dual-workstation design is to enable the sequential or simultaneous pressing of two different specifications of bushings on the same pedal bracket workpiece, greatly improving production efficiency and assembly flexibility. For example, bushings with different inner diameters need to be assembled at both ends of a bracket. The left workstation 200 and the right workstation 300 are basically the same in mechanical structure and control logic. Their main difference lies in the size of the bushing opening component 403 and the pressing parameters called in the control system, in order to accommodate bushings of different specifications.

[0025] The core actuators of each workstation (taking the left workstation 200 as an example) include a lifting mechanism 600 and a bushing pressing mechanism 400 mounted on it. The lifting mechanism 600 can be a linear drive device such as a cylinder, electric cylinder, or servo slide, and its function is to drive the entire bushing pressing mechanism 400 to adjust its position in the vertical direction to adapt to different working heights or to facilitate loading and unloading. The bushing pressing mechanism 400, which is set on the lifting mechanism 600, is a key component for completing the pressing action, and it mainly includes a servo motor 401, a bushing opening assembly 403, and a pressure sensor 402.

[0026] The servo motor 401 serves as the core power source, driving the bushing opening assembly 403 to perform precise linear reciprocating motion via a precision transmission mechanism. The bushing opening assembly 403 may include a guide shaft and a radially expandable mold, the front end of which is used to accommodate and position the bushing to be pressed in. During operation, the servo motor 401 drives the bushing opening assembly 403 forward, pushing the bushing at its front end into and pressing it into the predetermined shaft hole of the pedal bracket workpiece. To monitor the force applied to the bushing during the pressing process in real time and accurately, the bushing pressing mechanism 400 is equipped with a pressure sensor 402. In a preferred embodiment of the invention, two pressure sensors 402 are used at each station, symmetrically arranged on both sides of the drive center line of the bushing opening assembly 403. This symmetrical arrangement helps to obtain more balanced and accurate pressing force data, avoiding measurement errors caused by uneven loading, thereby more reliably judging the pressing quality.

[0027] The equipment platform 100 is usually also equipped with a material box 500, which is used to store the bushings to be pressed, making it convenient for operators to take them out.

[0028] The intelligence and safety of this equipment are primarily achieved through an integrated control system. This control system typically includes components such as a programmable logic controller (PLC), servo drivers, and a touchscreen. One of the core innovative functions of the control system is the real-time monitoring of the resistance encountered by the bushing opening assembly 403 during its retraction after the pressing action. This resistance can be obtained indirectly or directly by monitoring the real-time current and torque of the servo motor 401 or through an additional force sensor. The control system has a preset "anti-pinch force threshold." When the real-time monitored retraction resistance exceeds this preset anti-pinch force threshold, the control system immediately determines that jamming or the presence of foreign objects has occurred and quickly sends a command to the servo driver to stop the servo motor 401, thereby immediately stopping the retraction of the bushing opening assembly 403. Simultaneously, an audible and visual alarm is triggered to notify the operator to intervene. This anti-pinch function effectively prevents equipment jamming and component damage caused by bushing deformation, impurities in the workpiece hole, or mechanical misalignment, significantly improving the safety and reliability of equipment operation.

[0029] Furthermore, to achieve rapid changeover and flexible production, the control system pre-stores multiple sets of parameter formulas corresponding to different models of pedal brackets and different specifications of bushings. Operators can conveniently select and retrieve the required parameter formulas for the left station 200 and the right station 300 via the touchscreen. Each set of parameter formulas includes at least several key process parameters: the upper and lower acceptable limits of the pressing pressure, and the aforementioned anti-pinch force threshold. During the pressing process, the control system is configured to compare the pressure value fed back by the pressure sensor 402 with the upper and lower pressure limits in the currently used formula in real time. Once the pressure value exceeds the acceptable range (too high may damage the workpiece or bushing, too low may mean incomplete pressing), the control system will immediately alarm and stop the machine to ensure that the pressing quality of each product meets the preset standards.

[0030] The specific workflow and intelligent control method of this device are as follows, and its core steps embody the control logic of this invention: S1: Recipe Selection and Parameter Setting. The operator first accesses the parameter page via the touchscreen. The control system pre-stores multiple sets of parameter recipes corresponding to different pedal bracket models and bushing specifications. Based on the current production task, the operator selects and retrieves the corresponding parameter recipes for both left station 200 and right station 300. These recipes at least preset the upper and lower acceptable pressure limits for bushing press-fitting of that specification, as well as the critical anti-pinch force threshold.

[0031] S2: Loading and Start-up. Following the formula requirements, the operator places the corresponding specification bushing into the guide shaft of the bushing support assembly 403 at the target station (e.g., left station 200), and places the pedal bracket workpiece to be pressed into position. After loading is complete, the operator presses the manual switch. This start signal is transmitted to the control system, triggering the corresponding station to begin the automatic pressing cycle.

[0032] S3: Pressing Action and Pressure Monitoring. After receiving the start signal, the control system executes the pressing action control, which specifically includes: S31: The servo motor 401 of the current station (such as the left station 200) drives the bushing opening component 403 to move forward and perform the pressing action to press the bushing into the workpiece hole.

[0033] S32: During the pressing process, symmetrically arranged pressure sensors 402 collect pressing pressure data in real time and feed it back to the control system.

[0034] S33: The control system compares the collected pressure data with the qualified range formed by the upper and lower pressure limits in the current formula in real time to make a judgment.

[0035] S34: If the real-time pressure data exceeds the acceptable range, the control system immediately determines that the pressing is unqualified, controls the servo motor 401 to stop and triggers an audible and visual alarm, awaiting further processing. Through the above pressure monitoring mechanism, this invention can effectively ensure the pressing quality and avoid defects such as incomplete pressing of the bushing (incomplete product) or poor clearance between the bushing and the bracket hole caused by improper pressure. In specific application scenarios (e.g., the clearance between the bushing and the bracket hole after pressing needs to be less than 0.5mm), the process objective of controlling the clearance within a small range can be achieved by setting a corresponding acceptable pressure range.

[0036] Once the pressing action is completed and the pressure is deemed acceptable, the control system enters the retraction monitoring phase.

[0037] S4: Control the servo motor 401 to drive the bushing to open the assembly 403 and perform a retraction action.

[0038] S5: During the retraction process, the control system monitors the retraction resistance in real time by monitoring the current or torque of the servo motor 401. If the monitored retraction resistance exceeds the preset anti-pinch force threshold in the current parameter formula, the control system immediately determines that jamming has occurred, controls the bushing to open the assembly 403 to stop the retraction and issues an alarm.

[0039] S6: Result Indication and Cycle Completion. After a complete pressing and retraction cycle, the control system provides status indications based on the overall judgment results. Specifically: if the pressing pressure is qualified (S33 judgment passed) and the retraction process does not trigger the anti-pinch alarm (S5 judgment passed), the control system determines that the pressing operation is completely qualified and controls the status indicator light at the corresponding workstation to light up green, indicating that the next operation can proceed. If an alarm is triggered at any of the above stages, the red indicator light will light up and the alarm status will remain active.

[0040] Through the above steps, this invention not only automates the pressing operation but also ensures the assembly quality of each product and the safety of each equipment operation through dual intelligent closed-loop control of "real-time stability of pressing pressure" and "anti-pinch monitoring of return resistance." The equipment operation process is intuitive and convenient. First, the operator confirms that the power and air supply of the equipment are stable and selects the correct product parameter formula for the left and right workstations 300 via the touch screen. Then, after testing the operation of each mechanism in manual mode and confirming that it is normal, the operator switches to automatic mode. For the operation of a single workstation: the operator first places a bushing into the guide position at the front end of the bushing opening component 403 of that workstation, and then places the pedal bracket workpiece to be pressed into position, aligning the shaft hole to be pressed with the guide shaft. Subsequently, the operator presses the manual switch connected to the control system to trigger the automatic cycle. After receiving the start signal, the control system controls the servo motor 401 of the current workstation to drive the bushing opening component 403 to perform the pressing action and monitors the pressure simultaneously. After pressing is completed, the control system controls the bushing opening component 403 to retract and monitors the return resistance simultaneously. If both the pressing pressure and the retraction resistance are within acceptable ranges, then one work cycle is successfully completed.

[0041] To provide clear human-machine interaction, each workstation is equipped with a set of status indicator lights. After a complete pressing and retraction cycle, the control system will control the status indicator lights at the corresponding workstations to indicate the status based on the pressure and resistance determination results. For example, if no alarm is triggered throughout the process, meaning the pressing pressure is qualified and the retraction is normal, the control system will illuminate the green indicator light at that workstation, indicating that the pressing operation is successful; if an alarm is triggered at any stage, the red indicator light will illuminate along with an alarm prompt.

[0042] In summary, this invention constructs an efficient, precise, safe, and flexible intelligent pressing system for pedal bracket bushings through a dual-station parallel design, full-process force control monitoring (including pressing pressure and return resistance), parameter-based management, and intuitive status indication. It significantly improves production efficiency and flexible production capabilities, comprehensively ensuring assembly quality and equipment operation safety through dual closed-loop intelligent monitoring (pressure stabilization and anti-pinch protection), while also enhancing operational convenience and reliability.

[0043] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings, characterized in that, include: The equipment includes a machine base and two adjacent workstations, a left workstation and a right workstation, for pressing different specifications of bushings into the same pedal bracket workpiece. Each workstation includes a lifting mechanism and a bushing pressing mechanism mounted on the lifting mechanism. The bushing pressing mechanism includes a servo motor, a bushing spreading assembly driven by the servo motor, and a pressure sensor for real-time monitoring of the pressing pressure. The equipment also includes a control system connected to each workstation. The control system monitors the retraction resistance in real-time during the retraction process after the bushing spreading assembly performs the pressing action, and controls the bushing spreading assembly to stop retraction and issue an alarm when the retraction resistance exceeds a preset anti-pinch force threshold.

2. The semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings according to claim 1, characterized in that, The control system has multiple parameter formulas pre-stored for different pedal bracket models and bushing specifications, and the operator can select and retrieve different parameter formulas for the left and right workstations respectively.

3. The semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings according to claim 2, characterized in that, The parameter formula includes at least the upper and lower limits of the pressure acceptable range, as well as the anti-pinch force threshold.

4. The semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings according to claim 2, characterized in that, The control system is also configured to: during the pressing process, compare the pressure value measured by the pressure sensor with the upper and lower pressure limits in the current parameter formula in real time, and issue an alarm when the pressure value exceeds the qualified range.

5. The semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings according to claim 1, characterized in that, Each workstation has two pressure sensors, which are symmetrically arranged on both sides of the bushing support assembly.

6. The semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings according to claim 1, characterized in that, It also includes a manual switch, which is connected to the control system and is used to trigger the bushing pressing mechanism of the currently selected station to perform automatic pressing after the workpiece and bushing are manually placed.

7. The semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings according to claim 1, characterized in that, It also includes status indicator lights corresponding to each workstation; the control system is configured to control the status indicator lights of the corresponding workstations to light up or turn off after a pressing operation cycle is completed, based on the determination results of the pressing pressure and the retraction resistance.

8. A semi-automatic multi-station intelligent assembly control method for pedal bracket bushings, using the semi-automatic multi-station intelligent assembly equipment for pedal bracket bushings as described in any one of claims 1-7, characterized in that, Includes the following steps: S1: Select the parameter formulas corresponding to the specifications of the bushings to be pressed for the left and right workstations respectively; S2: After the workpiece and bushing are placed manually at the corresponding workstation, a start signal is received; S3: Control the servo motor of the current workstation to drive the bushing to open the component and perform the pressing action; S4: After the pressing action is completed, control the bushing opening assembly to perform the retraction action, and monitor the retraction resistance in real time during the retraction process; S5: If the retraction resistance exceeds the anti-pinch force threshold in the current parameter formula, control the bushing opening assembly to stop retraction and trigger an alarm.

9. The semi-automatic multi-station intelligent assembly control method for a pedal bracket bushing according to claim 8, characterized in that, Step S3 specifically includes: S31: Control the servo motor to drive the bushing to open the assembly and perform a pressing action; S32: Real-time acquisition of press-fitting pressure data via the pressure sensor; S33: Real-time determination of whether the pressure data is within the qualified range formed by the upper and lower pressure limits in the current parameter formula; S34: If the pressure data exceeds the specified acceptable range, it is determined that the pressure is unacceptable, and the control equipment will stop and trigger an alarm.

10. The semi-automatic multi-station intelligent assembly control method for a pedal bracket bushing according to claim 8, characterized in that, It also includes the following steps: S6: After a complete pressing and retraction cycle is completed, the status indicator light of the corresponding workstation is controlled to indicate the status based on the judgment results of the pressing pressure and retraction resistance; if no alarm is triggered throughout the process, the indicator light representing the qualified status will be lit.

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