Integrated die-cast floor connecting production line

Abstract

The invention relates to an integrated die-cast floor connecting production line which comprises a feeding station, a plurality of connecting process stations, a discharging station and a control system, a feeding unit is arranged on the feeding station, the feeding unit is used for transferring a rear floor, and a visual scanning system used for scanning the rear floor and obtaining actual position information is arranged on the feeding unit; the multiple connecting process stations are arranged on the downstream of the feeding station, and connecting process units used for executing connecting operation on the rear floor are arranged on the connecting process stations; the discharging station is arranged on the downstream of the multiple connecting process stations and provided with a quality detection unit and a product distribution unit, the quality detection unit detects finished products, and the product distribution unit treats qualified products and unqualified products according to detection results; the control system is electrically connected with all the stations and collects and records process parameters and quality information. A continuous technological process is formed through a plurality of connecting process stations, and the transfer time and the positioning error of the workpiece are reduced.

Description

Technical Field

[0001] This application relates to the field of new energy vehicle manufacturing technology, and in particular to an integrated die-casting rear floor connection production line. Background Technology

[0002] With the new energy vehicle industry's relentless pursuit of lightweighting and production efficiency, integrated die casting technology has become a revolutionary direction in vehicle body manufacturing. As the core load-bearing structure of the vehicle body frame, the integrated die casting of the rear floor has gradually replaced the traditional method of assembling dozens or even hundreds of stamped parts through welding, significantly reducing the number of parts, lowering costs, and improving production efficiency.

[0003] However, the integrated die-cast rear floor is only a large structural component, which needs to be precisely connected and assembled with other parts of the body-in-white (such as side panels, front floor, battery pack tray beams, etc.) and various accessories (such as seat brackets, wiring harness brackets, sound insulation pads, etc.).

[0004] Currently, the subsequent connection and assembly process faces severe challenges: 1. Precision matching difficulties: The integrated die-cast parts are large in size (usually exceeding 1.5 meters), with inherent manufacturing tolerances and slight deformation after demolding. Traditional rigid positioning fixtures and pre-programmed robot paths cannot effectively compensate for these errors, leading to mismatches in assembly holes or mating surfaces, resulting in assembly stress or inability to install. 2. Complex multi-material connection processes: The rear floor needs to be connected to components made of various materials such as steel plates, aluminum profiles, and fasteners. This requires the production line to integrate multiple connection processes, such as self-piercing riveting (SPR), flowing screw drilling (FDS), rivet, threaded fitting, and adhesive bonding. The coordination and non-interference between these processes is a technical challenge. 3. Production cycle mismatch: The production cycle of integrated die casting is fast, while the traditional manual or semi-automatic connection and assembly cycle is slow, creating a production bottleneck and failing to leverage the efficiency advantages of integrated die casting. 4. Difficulties in quality monitoring and traceability: The quality of connection points (such as riveting strength, screw torque, and sealing performance) directly affects vehicle body safety and performance. Traditional manual sampling inspections cannot achieve full monitoring and it is difficult to uniquely link quality data to a specific product. Summary of the Invention

[0005] This application provides an integrated die-casting post-floor connection production line, which can solve the problems of slow cycle time, difficulty in quality monitoring and traceability in traditional manual or semi-automatic connection assembly in related technologies.

[0006] In a first aspect, embodiments of this application provide an integrated die-casting post-floor connection production line, comprising: a loading station, multiple connection process stations, an unloading station, and a control system. The loading station is equipped with a loading unit for transferring the post-floor and a visual scanning system for scanning the post-floor and acquiring its actual position information. The multiple connection process stations are located downstream of the loading station and are equipped with connection process units for performing connection operations on the post-floor. The unloading station is located downstream of the multiple connection process stations and includes a quality inspection unit and a product sorting unit. The quality inspection unit inspects the finished products, and the product sorting unit processes qualified and unqualified products according to the inspection results. The control system is electrically connected to each station and collects and records process parameters and quality information.

[0007] In one embodiment, the feeding unit is a feeding robot, and the vision scanning system is fixed to the gripper of the feeding robot; The feed robot is also equipped with flexible grippers on its gripper.

[0008] In one embodiment, the connection process unit includes at least two of the following: a riveting unit, a threaded sleeve installation unit, a stud welding unit, an adhesive application unit, an FDS connection unit, and an SPR connection unit. The connection process stations are arranged sequentially along the production line transport direction so that each connection process unit performs the corresponding connection process in a preset order.

[0009] In one embodiment, the riveting unit includes a riveting robot, a riveting gun, a force sensor, and a quality inspection device. The robot has an end effector, the riveting gun is mounted on the end effector, the force sensor is installed inside the rivet joint and electrically connected to the control system, and the quality inspection device is fixed to the end effector of the robot and electrically connected to the control system. The quality inspection device is used to inspect the quality of the rear floor connection after riveting is completed.

[0010] In one embodiment, the threaded sleeve installation unit includes a threaded sleeve installation robot, an installation head, and a quality inspection device. The threaded sleeve installation robot has an end effector, the installation head is mounted on the end effector, and the quality inspection device is fixed to the end effector of the threaded sleeve installation robot and electrically connected to the control system. The quality inspection device is used to inspect the installation quality after the threaded sleeve installation is completed.

[0011] In one embodiment, the stud welding unit includes a stud welding robot, a stud welding torch, and a quality inspection device. The stud welding robot has an end effector, the stud welding torch is mounted on the end effector, and the quality inspection device is fixed to the end effector of the stud welding robot and electrically connected to the control system. The quality inspection device is used to inspect the welding quality after the stud welding is completed.

[0012] In one embodiment, the glue application unit includes a glue application robot, a glue gun, and a glue quantity control system. The glue application robot has an end effector, the glue gun is mounted on the end effector, and the glue quantity control system is electrically connected to the control system. The glue quantity control system automatically adjusts the glue quantity and application path according to the shape of the connection area of ​​the die-cast floor to ensure that the glue layer is uniform and meets the process requirements.

[0013] In one embodiment, the FDS connection unit includes an FDS robot, an FDS screw supply system, and an FDS connector. The FDS robot has an end effector, and the FDS connector is mounted on the end effector. The FDS connector includes a rotary drive mechanism and an axial pressure control system. The axial pressure control system can automatically adjust the pressure parameters according to the material thickness and connection strength requirements to ensure stable connection quality.

[0014] In one embodiment, the SPR connection unit includes an SPR robot, a riveting head, and a riveting parameter control system. The SPR robot has an end effector, and the riveting head is mounted on the end effector. The riveting parameter control system is used to adjust the riveting speed, pressure, and depth according to the connection point location and material properties.

[0015] In one embodiment, the connection process station is provided with at least two reserved stations, each of the reserved stations including a workbench and a robot installation area. The workbench is used to support the rear floor, and the robot installation area is used as a manual operation area when the initial production capacity is low, and is used to install robots when the production capacity demand increases. The quality inspection unit includes a scanner and a test result output terminal. The product diversion unit includes a first conveyor belt, a second conveyor belt, a qualified product packing area, and an abnormal product exit box. The control system includes a product information database, a quality judgment module, an alarm device, and a QR code recognition unit. The product information database is electrically connected to the test result output terminal of the quality inspection unit. The output terminal of the quality judgment module is electrically connected to the control terminal of the product diversion unit. The alarm device includes an audible and visual alarm and a display screen. The first conveyor belt leads to the qualified product packing area, and the second conveyor belt leads to the abnormal product exit box. A rework operation area is provided next to the abnormal product exit box.

[0016] The beneficial effects of the technical solutions provided in this application include: This application provides an integrated die-casting rear floor connection production line. The actual position information of the rear floor is obtained through a vision scanning system on the loading station, enabling the connection process unit to operate based on accurate position reference. Since the vision scanning system is directly set on the loading unit, position information can be obtained synchronously during the transfer process, reducing additional positioning steps and time. Multiple connection process stations are sequentially set downstream of the loading station, forming a continuous process flow. Each connection process unit performs connection operations in sequence according to the process order. This assembly line layout allows for close connection of each process link, reducing the transfer time and positioning error of the workpiece between different processes.

[0017] The quality inspection unit at the unloading station conducts comprehensive inspections of the finished products. The product sorting unit automatically distinguishes between qualified and unqualified products based on the inspection results. This real-time quality monitoring and automatic sorting mechanism ensures that only products meeting quality standards can proceed to the next process, avoiding further processing waste from defective products. The control system is electrically connected to each station and collects and records process parameters and quality information, enabling complete recording and analysis of data throughout the entire production process. This provides a data foundation for process optimization and also achieves full lifecycle quality traceability for the product. The collaborative work of each station forms a closed-loop quality control system, allowing the production line to maintain high-speed production while ensuring product quality stability. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the overall structure provided for an embodiment of this application.

[0020] In the diagram: 1. Riveting station; 2. Threaded sleeve installation station; 3. First stud welding station; 4. First reserved station; 5. Manual installation station; 6. Second stud welding station; 7. Second reserved station; 8. Adhesive application station; 9. FDS connection station; 10. SPR connection station; 11. Material unloading station; 12. Material loading station. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0022] This application provides an integrated die-casting post-floor connection production line, which can solve the problems of slow cycle time, difficulty in quality monitoring and traceability in traditional manual or semi-automatic connection assembly in related technologies.

[0023] This application provides an integrated die-casting post-floor connection production line, comprising: a loading station 12, multiple connection process stations, an unloading station 11, and a control system. The loading station 12 is equipped with a loading unit for transferring the post-floor and a vision scanning system for scanning the post-floor and acquiring its actual position information. The multiple connection process stations are located downstream of the loading station 12 and are equipped with connection process units for performing connection operations on the post-floor. The unloading station 11 is located downstream of the multiple connection process stations and is equipped with a quality inspection unit and a product diversion unit. The quality inspection unit inspects the finished products, and the product diversion unit processes qualified and unqualified products according to the inspection results. The control system is electrically connected to each station and collects and records process parameters and quality information.

[0024] This application obtains the actual position information of the rear floor through a vision scanning system on the loading station 12, enabling the connection process unit to operate based on accurate position reference. Since the vision scanning system is directly set on the loading unit, position information can be obtained synchronously during the transfer process, reducing additional positioning steps and time. Multiple connection process stations are set sequentially downstream of the loading station 12, forming a continuous process flow. Each connection process unit performs connection operations in sequence according to the process order. This assembly line layout enables each process link to be closely connected, reducing the transfer time and positioning error of the workpiece between different processes.

[0025] The quality inspection unit at unloading station 11 conducts comprehensive inspections of finished products. The product sorting unit automatically distinguishes between qualified and unqualified products based on the inspection results. This real-time quality monitoring and automatic sorting mechanism ensures that only products meeting quality standards can proceed to the next process, avoiding further processing waste from defective products. The control system is electrically connected to each station and collects and records process parameters and quality information, enabling complete recording and analysis of data throughout the production process. This provides a data foundation for process optimization and also achieves full lifecycle quality traceability for the product. The collaborative work of each station forms a closed-loop quality control system, allowing the production line to maintain high-speed production while ensuring product quality stability.

[0026] In one embodiment, this application includes a material loading station 12, a threaded sleeve installation station 2, a first stud welding station 3, a first reserved station 4, a manual installation station 5, a second stud welding station 6, a second reserved station 7, an adhesive application station 8, an FDS connection station 9, an SPR connection station 10, and a material unloading station 11. The connection process units include at least two of the following: a riveting unit, a threaded sleeve installation unit, a stud welding unit, an adhesive application unit, an FDS connection unit, and an SPR connection unit. The connection process stations are arranged sequentially along the production line transport direction so that each connection process unit executes its corresponding connection process in a preset order.

[0027] This production line adopts a linear layout. This linear layout design fully considers the physical characteristics of the die-cast floor and the logical sequence of the connection processes, avoiding the cumulative positioning errors caused by repeated product reversals in traditional circular or U-shaped layouts. At the beginning of the production line, a 3D scan of the floor is performed to ensure that all subsequent connection processes can be accurately performed based on the actual product condition. The riveting unit is executed before other connection processes because the rivet nut, as the basic connection point, needs to be completed when the product is in optimal rigidity to avoid subsequent welding thermal deformation affecting the riveting quality. The threaded sleeve installation follows immediately, ensuring a reliable threaded connection foundation is established before the product is affected by heat.

[0028] The stud welding unit is arranged after the riveting and threaded sleeve to take into account the local heat-affected zone generated during the welding process, which needs to be avoided to prevent thermal stress interference with the already installed precision connectors. The sequential arrangement of the SPR / FDS connection station 9 and the adhesive application system is based on material properties. The mechanical connection is completed first, followed by adhesive sealing, to ensure that the adhesive can fully fill the connection gaps without being damaged by the connection process.

[0029] Maintaining a consistent coordinate system reference during product transfer between workstations avoids the accumulation of errors caused by multiple positioning operations.

[0030] In one embodiment, the feeding unit is a feeding robot, and the vision scanning system is fixed to the gripper of the feeding robot; the gripper of the feeding robot is also equipped with a flexible clamp.

[0031] In this application, the integrated die-cast rear floor is transported to the loading station 12 of the production line by an AGV conveyor with a material frame, and is placed on the material frame positioning device. The loading robot first performs a 3D scan of the rear floor using a vision scanning system on its gripper to obtain the actual shape of the product and the position information of the positioning holes. The system compares the scan results with the theoretical model to calculate the deformation and positioning deviation of the die-cast part. The flexible fixture automatically adjusts the clamping position and force according to the calculation results. Its multi-degree-of-freedom clamping mechanism can adapt to the irregular deformation of the die-cast part surface and avoid secondary deformation of the product caused by rigid clamping.

[0032] Since the assembly of the rear floor involves multiple orientations and angles, including the front, side, and back, traditional turntable flexible clamps are limited to 180-degree rotation in the horizontal direction. However, the flexible clamps in this production line, in addition to the horizontal rotation structure, also integrate a 180-degree horizontal flipping mechanism. This flipping mechanism adopts a double-rotating-axis design, which can realize the transformation of the product posture without disengaging from the clamping state.

[0033] When it is necessary to connect the reverse side of the rear floor, the flexible fixture rotates the product smoothly 180 degrees through the flipping mechanism, so that the originally downward side is turned upward. This ensures that the subsequent process unit can operate from the optimal angle. This design eliminates the need to transfer the product to another station for reverse operation in the traditional solution, and reduces the positioning error caused by intermediate handling.

[0034] The close integration of the vision scanning system and the flexible fixture enables closed-loop control of scanning-compensation-clamping. The loading robot continuously monitors the clamping status during the gripping process. When abnormal clamping force or product position deviation is detected, the system will automatically fine-tune the clamping parameters to ensure that the product remains stable during the transfer process.

[0035] Furthermore, the gripper surface of the flexible clamp adopts a special texture design, which increases the coefficient of friction with the die-cast part and avoids leaving indentations on the surface. The pressure sensor integrated inside the gripper feeds back the clamping force data to the control system in real time, preventing the product from slipping due to excessive clamping force causing deformation of thin-walled areas or insufficient clamping force.

[0036] In one embodiment, the riveting unit includes a riveting robot, a riveting gun, a force sensor, and a quality inspection device. The robot has an end effector, the riveting gun is mounted on the end effector, the force sensor is mounted inside the rivet joint and electrically connected to the control system, and the quality inspection device is fixed on the end effector of the robot and electrically connected to the control system. The quality inspection device is used to inspect the quality of the rear floor connection after riveting is completed.

[0037] In this application, the riveting unit is located at riveting station 1 ( Figure 1 On OP10 (as shown), the riveting robot ( Figure 1 The R1 robot is also equipped with a loading vision system, which is fixed to the gripper of the R1 robot. The gripper can accurately grasp the material by precisely locating the positioning hole on the back floor through vision.

[0038] The riveting robot is equipped with a dedicated end effector, which integrates an electric servo riveting gun, a force sensor, and a quality detection device, forming a complete closed-loop riveting operation system. The electric servo riveting gun monitors pressure changes in real time during the riveting process through its internally integrated force sensor. When the detected pressure reaches a preset threshold that meets the material properties and connection strength requirements, it automatically stops operating to avoid thread damage or material deformation due to overpressure. This adaptive control method is particularly suitable for large die-cast parts with minute dimensional differences caused by cooling shrinkage.

[0039] The front end of the rivet gun is designed with a floating mechanism, which can automatically absorb the hole displacement caused by the deformation of the die-casting part when the rivet head approaches the rivet hole. This allows the rivet head to automatically compensate within a radial range of ±1.5mm and an angular range of ±3°, ensuring that the riveting process is carried out smoothly without collision or jamming.

[0040] The loading vision system works in conjunction with the riveting unit. After the R1 robot accurately locates the positioning holes on the rear floor using the vision system on its gripper, the system compares the acquired actual deformation data with the theoretical model to calculate the compensation coordinates of each riveting point, guiding the riveting robot to adjust its operating path. During the riveting operation, the system automatically calls the corresponding process curves based on the characteristic parameters of three different sizes of rivet nuts, including riveting speed, stroke, and final pressure value, ensuring that the installation quality of all 15 rivet points meets the requirements.

[0041] The quality inspection device is integrated into the end effector and includes a high-resolution industrial camera and a ring light source. It performs visual inspection on each connection point immediately after riveting is completed, mainly checking the height consistency, perpendicularity deviation and surface integrity of the rivet nuts, and transmits the inspection results to the control system in real time and binds them to the product information.

[0042] For thin-walled areas of the die-cast floor, the system has a local pressure compensation mechanism. When a slight deformation is detected in the area, the riveting speed is automatically reduced and the final pressure value is finely adjusted to prevent the thin-walled area from sinking due to local stress concentration.

[0043] The design of the riveting unit's connection with subsequent workstations takes into account process continuity. When the product is transferred from riveting station 1 to threaded sleeve installation station 2, the system automatically transfers the coordinate system reference of the current station to the next station, avoiding the accumulation of errors caused by repositioning. The entire riveting process is completed at station OP10 on the production line. After riveting, robot R1 smoothly transfers the rear floor to threaded sleeve installation station 2 (i.e., Figure 1 The subsequent threaded sleeve installation process (as shown in OP20 and OP30) ensures the continuity and consistency of the connection process.

[0044] In one embodiment, the threaded sleeve installation unit includes a threaded sleeve installation robot, an installation head, and a quality inspection device. The threaded sleeve installation robot has an end effector, the installation head is mounted on the end effector, and the quality inspection device is fixed to the end effector of the threaded sleeve installation robot and electrically connected to the control system. The quality inspection device is used to inspect the installation quality after the threaded sleeve installation is completed.

[0045] The threaded sleeve installation unit is located at threaded sleeve installation station 2. This unit mainly consists of a threaded sleeve installation robot, a special installation head, and an integrated quality inspection device. The threaded sleeve installation robot (… Figure 1 The R2 / 3 robot adopts a dual-robot collaborative working mode, which is responsible for the installation of two different types of wire threaded sleeves.

[0046] The robot end effector integrates an installation head and a quality inspection device. The installation head has an automatic feeding channel and a rotary drive mechanism inside, which can accurately insert the wire thread sleeve according to the preset thread hole position on the die-cast floor.

[0047] The quality inspection device is coaxially mounted with the mounting head and includes a high-resolution vision sensor and a coaxial light source. It performs quality verification immediately after the wire threaded sleeve is installed. The main inspection items include the insertion depth of the threaded sleeve, perpendicularity deviation, and surface integrity. The inspection results are transmitted to the control system in real time and linked to the product information.

[0048] The control system automatically calculates the compensation coordinates of each threaded installation point based on the deformation data of the die-casting parts obtained by the feeding vision system, and guides the robot to adjust the installation path to ensure high-precision installation even when there is slight deformation of the die-casting parts.

[0049] For two different models of wire threaded inserts, the system has an independent library of feeding and testing parameters, which can automatically identify and call up the corresponding process parameters, including rotation speed, torque curve and testing standards, to ensure that the installation quality of threaded inserts of different specifications meets the requirements.

[0050] Furthermore, during installation, the system monitors torque changes in real time. When an abnormal increase in torque is detected, the system automatically stops operation and records the abnormal information to avoid thread damage caused by forced installation. The threaded sleeve installation unit is closely integrated with the upstream and downstream process steps. Upstream, it receives the rear floor unit from the riveting unit after 15 rivet nuts have been installed. Downstream, it transfers the product to the aluminum stud welding system. The system maintains a unified coordinate system reference during product transfer to avoid error accumulation caused by repositioning.

[0051] In one embodiment, the stud welding unit includes a stud welding robot and a stud welding torch. The stud welding robot has an end effector, and the stud welding torch is mounted on the end effector.

[0052] In this embodiment, the first stud welding station 3 ( Figure 1 OP40) and second stud welding station 6 ( Figure 1 Each of the OP60 models is equipped with a stud welding unit. The stud welding robot includes... Figure 1 R4 and R8 robots.

[0053] The end effector of the stud welding robot is equipped with a stud welding torch and a quality inspection device. The stud welding torch adopts capacitor energy storage welding technology and has an internal current monitoring module and welding time control unit, which can automatically adjust the welding parameters according to the material thickness and connection strength requirements of the die-cast floor.

[0054] The R4 robot is responsible for the automatic stud welding of the OP30 process parts, completing the welding task of 12 studs. The system automatically calculates the compensation coordinates of each welding point based on the deformation data of the die casting obtained by the loading vision system, and guides the robot to adjust the welding path to ensure that precise welding can still be achieved even when there is slight deformation of the die casting.

[0055] Furthermore, the connecting process station is equipped with at least two reserved stations (first reserved station 4 and second reserved station 7). Each reserved station includes a workbench and a robot installation area. The workbench is used to support the rear floor, and the robot installation area is used as a manual operation area when the initial production capacity is low, and is used to install robots when the production capacity demand increases.

[0056] Specifically, the production line is specially designed with a process buffer zone. After the R4 robot completes welding, the OP40 part is smoothly transferred to the manual installation station 5. Figure 1The OP50 station automatically transfers the coordinate system reference of the current station to the next station, avoiding the accumulation of errors caused by repositioning. The OP50 station adopts a flexible design. When the initial production capacity is low, it serves as a manual installation station 5 for installing three types of wire threaded sleeves. When the production capacity demand increases, automated installation can be achieved by installing R5, R6, and R7 robots. The turntable structure and robot mounting base of the first reserved station 4 (equipped with R5 and R6 robots) have been pre-installed in the early stage of the production line. Only the corresponding equipment and programs need to be added to quickly switch to automatic mode without large-scale modification of the production line structure.

[0057] The R8 robot is positioned at the second stud welding station 6 and is responsible for the secondary welding of the OP50 process parts. It completes the welding of 11 studs of 3 types. Its welding parameters are dynamically adjusted according to the deformation data of the previous process. In particular, for the connection of dissimilar materials such as aluminum and steel, the system has a special heat-affected zone control algorithm, which reduces the impact of thermal stress on the die castings by optimizing the welding energy distribution.

[0058] Second reserved workstation 7 ( Figure 1 The OP70 station also adopts a flexible design, which is a station reserved for capacity increase. When the capacity is low, the OP70 station is used for manual assembly. When the capacity is increased in the future, the 9 steel wire threaded sleeves installed manually at the OP70 station will be replaced by the automated installation of the R9 robot.

[0059] Currently, there is no reliable automated testing method for the strength of aluminum studs, so this step still relies on manual inspection. However, the system has reserved a data interface, allowing for rapid integration into the production line when suitable automated testing equipment is developed in the future. The stud welding unit is closely connected to the upstream and downstream processes. Upstream, it receives the rear floor assembly from the threaded sleeve installation unit, and downstream, it transfers the product to the adhesive application system. The entire process maintains a unified coordinate system reference to ensure consistent connection accuracy, providing a reliable connection foundation for subsequent SPR / FDS connection processes.

[0060] In one embodiment, the glue application unit includes a glue application robot, a glue gun, and a glue quantity control system. The glue application robot has an end effector, the glue gun is mounted on the end effector, and the glue quantity control system is electrically connected to the control system. The glue quantity control system automatically adjusts the glue quantity and application path according to the shape of the connection area of ​​the die-cast floor to ensure that the glue layer is uniform and meets the process requirements.

[0061] The glue application unit is located at glue application station 8. This unit consists of an R10 glue application robot, a dedicated glue gun, and a glue quantity control system. The glue application robot is equipped with an end effector, and the glue gun is installed on the end effector through a quick-change interface to ensure positioning accuracy and quick replacement capability during frequent use.

[0062] The glue quantity control system communicates in real time with the main control system of the production line. It not only automatically adjusts the glue quantity and application path according to the shape of the connection area of ​​the die-casting floor, but also dynamically corrects the application trajectory by combining the actual deformation data of the die-casting parts obtained by the loading vision system, so as to adapt to the slight dimensional changes caused by the cooling and shrinkage of the die-casting.

[0063] After the R10 robot picks up the steel-aluminum connecting assembly, it first uses the vision sensor integrated at the end effector to quickly scan the key connection area to verify the surface cleanliness and the quality of the previous process. Once it confirms that the adhesive application conditions are met, it begins the adhesive application operation. After adhesive application, the part is placed in FDS connection station 9 (OP80 station). At this time, the system automatically records the adhesive application parameters (including adhesive amount, path, speed, etc.) and binds them to the product information to provide data support for subsequent quality traceability.

[0064] FDS connection units are set up at 9 FDS connection stations. Each FDS connection unit includes an FDS robot (R11 and R12 robots), an FDS screw supply system, and an FDS connector. The FDS robot has an end effector, and the FDS connector is mounted on the end effector. The FDS connector includes a rotary drive mechanism and an axial pressure control system. The axial pressure control system can automatically adjust the pressure parameters according to the material thickness and connection strength requirements to ensure stable connection quality.

[0065] The FDS robot (such as R11 / R12) is equipped with an end effector. The FDS connector is installed on the end effector via a quick-change interface, ensuring connection accuracy and rapid replacement capability. The FDS connector integrates a rotary drive mechanism and an axial pressure control system. The rotary drive mechanism is driven by a servo motor, which can precisely control the rotation speed and torque of the screw. The axial pressure control system monitors the axial force during the connection process in real time through a built-in pressure sensor and dynamically adjusts the pressure parameters according to the actual material thickness of the die-cast floor and the connection strength requirements.

[0066] During the connection process, the system first calculates the compensation coordinates based on the deformation data of the die-casting obtained by the loading vision system, and guides the FDS robot to adjust the operation path to ensure that a precise connection can still be achieved even when the die-casting has slight deformation.

[0067] The axial pressure control system is specifically optimized for the characteristics of steel-aluminum dissimilar material connections. When a change in the material interface is detected, the pressure curve is automatically adjusted to avoid the aluminum material tearing due to excessive pressure or the connection strength being insufficient due to insufficient pressure.

[0068] The FDS screw supply system uses a combination of a vibratory feeder and a linear feeder to ensure that screws can be stably and continuously delivered to the connection position. It is also equipped with an automatic detection device to verify the screw specifications and condition, preventing screws of incorrect specifications or damage from entering the connection process.

[0069] To address the large size and symmetrical design of the rear floor product, two FDS robots (R11 and R12) are symmetrically arranged to synchronously execute the connection process. A time-synchronization control algorithm ensures coordinated operation between the two robots, preventing interference and improving production line cycle efficiency. After connection, the system automatically records key process parameters (including rotational speed, torque curve, axial pressure, etc.) and links them to product information, providing data support for subsequent quality traceability.

[0070] In one embodiment, the SPR connection unit includes an SPR robot, a riveting head, and a riveting parameter control system. The SPR robot has an end effector, and the riveting head is mounted on the end effector. The riveting parameter control system is used to adjust the riveting speed, pressure, and depth according to the location of the connection point and the material properties.

[0071] The SPR connection unit is located at SPR connection station 10 (OP90 station). This unit mainly consists of an SPR robot, a special riveting head, and an intelligent riveting parameter control system. The two SPR robots, R13 and R14, are arranged symmetrically to jointly complete the self-piercing riveting task at the OP90 station.

[0072] The SPR robot is equipped with an end effector, and the riveting joint is installed on the end effector via a quick-change interface, ensuring positioning accuracy and rapid changeover capability during frequent use. The riveting parameter control system communicates in real time with the main control system of the production line. It not only automatically adjusts the riveting parameters according to the position of the connection point, but also dynamically optimizes the riveting speed, pressure, and depth parameters by combining the actual deformation data and material thickness information of the die-cast parts obtained by the loading vision system, and performs precise control, especially for the characteristics of joining dissimilar materials such as steel and aluminum.

[0073] After robot R15 smoothly places the steel-aluminum connecting assembly at station OP90, robots R13 and R14 begin synchronously executing the SPR connection process, completing the connection of 40 riveting points and improving production line cycle efficiency. The system also integrates real-time monitoring, immediately detecting the riveting height and diameter after each riveting point is completed, comparing the detection data with preset standards, and automatically recording and triggering quality alarms when anomalies are detected.

[0074] Given the large size and symmetrical design of the rear floor product, two SPR robots are used to handle the connection tasks on the left and right sides respectively. This symmetrical arrangement not only solves the problem of a single robot being unable to complete all connection points within the cycle time, but also avoids the decrease in positioning accuracy caused by long-distance movement. The SPR connection unit is closely integrated with the upstream and downstream processes. Upstream, it receives the rear floor components from the FDS connection unit, and downstream, it transfers the product to the unloading station 11. The entire process maintains a unified coordinate system reference, avoiding the accumulation of errors caused by multiple positioning operations.

[0075] The system is specially designed with a self-learning function for riveting parameters, which can continuously optimize parameter settings based on historical connection data, adapt to the slight differences between different batches of die-cast parts, ensure the stability and consistency of connection quality, meet the strict requirements of new energy vehicle bodies for the strength and reliability of steel-aluminum connections, and provide complete process parameter records for subsequent quality traceability.

[0076] Furthermore, a quality inspection unit is located at unloading station 11 (OP100 station). The quality inspection unit includes a scanner and a test result output terminal. The product diversion unit includes a first conveyor belt, a second conveyor belt, a qualified product packing area, and an abnormal exit box. The control system includes a product information database, a quality judgment module, an alarm device, and a QR code recognition unit. The product information database is electrically connected to the test result output terminal of the quality inspection unit. The output terminal of the quality judgment module is electrically connected to the control terminal of the product diversion unit. The alarm device includes an audible and visual alarm and a display screen. The first conveyor belt leads to the qualified product packing area, and the second conveyor belt leads to the abnormal exit box. A rework operation area is located next to the abnormal exit box.

[0077] The quality inspection unit is located at position OP100 of the unloading station 11. It consists of a 3D scanner, a multi-angle vision inspection system, and a data processing terminal. After the R15 robot places the rear floor assembly, which has completed all connection processes, at the unloading station 11, the 3D scanner first performs a rapid scan of the overall shape of the product to obtain the actual three-dimensional model and compare it with the theoretical CAD model to calculate the positional deviation of key connection points and the overall deformation. At the same time, the multi-angle vision inspection system performs high-resolution imaging of key connection areas such as 40 SPR points, 11 FDS points, and 15 rivet points to automatically identify whether there are any problems such as missing, offset, deformation, or surface damage at the connection points.

[0078] The quality data collected by the scanner and vision system is transmitted to the product information database in real time. This database fully records all process parameters of the product from material loading to final inspection, including process parameters of each connection point, visual scanning results, and process quality information, forming a complete product quality file. The quality judgment module automatically analyzes the inspection data according to preset quality standards. For minor deviations that do not affect the product's function and safety, the system judges it as a qualified product and allows it to continue to the subsequent process. For quality problems that exceed the allowable range but do not affect the structural integrity of the product (such as slight loosening of some threaded sleeves), the system judges it as a reworkable product and records the specific location of the problem. For quality problems that seriously affect the product's performance (such as missing or severely deformed critical connection points), the system immediately judges it as a non-qualified product and triggers the alarm device.

[0079] The alarm device's audible and visual alarms emit warning signals, while the display screen clearly shows the serial number of the problematic product, the specific quality issue, and suggested handling methods, facilitating rapid on-site identification and response.

[0080] The product sorting unit automatically performs sorting operations based on the quality judgment results. Qualified products are transported to the robot packing area via the first conveyor belt, where the packing robot neatly stacks them according to the preset quantity. When the box is full, the AGV automatically transports the finished box to the designated storage location. Defective products or sampled products are transported to the abnormal exit box via the second conveyor belt. The rework operation area next to the abnormal exit box is equipped with a dedicated workbench and tools. After the rework personnel scan the product's QR code, the system automatically displays the product's detailed non-conformance information and rework instructions. After the rework is completed, the product re-enters the inspection process. Products that pass the random inspection are re-entered into the packing process through a specially designed return line channel.

[0081] Furthermore, in this application, the control system, as the core coordinating mechanism of the integrated die-casting post-floor connection production line, is electrically connected to the loading station 12, multiple connection process stations, and unloading station 11. It realizes real-time acquisition of equipment status, fault information, process parameters, quality parameters, and energy consumption parameters through the standard data communication interface provided by the industrial equipment in the production line.

[0082] The control system adopts a layered architecture design. The bottom layer is the equipment control layer, which is directly connected to the PLC controllers of various process units such as the riveting unit, threaded sleeve installation unit, and stud welding unit, and is responsible for executing specific process actions. The middle layer is the data acquisition layer, which collects the operating data of each device in real time through industrial Ethernet, and the acquisition frequency is dynamically adjusted according to the importance of the data. The top layer is the data processing layer, which is responsible for associating the collected data with the product information database to form a complete product quality file.

[0083] The communication interface of the control system ensures the real-time, accuracy and reliability of data transmission. When network fluctuations occur, the system automatically switches to the backup channel and starts the data retransmission mechanism to prevent the loss of critical quality data.

[0084] In terms of data processing, the control system not only records the original parameter values ​​but also performs feature extraction and correlation analysis on the process parameters. For example, it correlates the deformation data of the die-cast parts acquired by the loading vision system with the compensation parameters of subsequent connection processes, providing more accurate process guidance for subsequent products. To address potential systematic deviations during the connection of the die-cast flooring, the control system is equipped with a self-learning algorithm. This algorithm can identify process trends based on historical data and automatically fine-tune the process parameters of subsequent products. However, this adjustment is strictly limited to a preset safety range and will not exceed the process specification requirements.

[0085] All industrial equipment on the production line must meet the requirements of the factory's production execution management system and data acquisition platform to achieve real-time acquisition of data such as equipment status, fault information, process parameters, quality parameters, and energy consumption parameters through communication interfaces and standard communication protocols.

[0086] In summary, this application solves the core challenge of precision matching: by combining "visual scanning + flexible fixtures," it actively compensates for deformation and positioning errors in die-cast parts, ensuring assembly accuracy and eliminating assembly stress. It achieves efficient multi-process integration: modular robotic units enable seamless integration of multiple connection processes within a single production line, meeting the complex requirements of multi-material connections in new energy vehicle bodies. It achieves an extremely high level of automation and intelligence: from loading, positioning, assembly to inspection, the entire process is unmanned, and through an integrated data acquisition and traceability system, it achieves transparency in the production process and predictability of quality. It improves production flexibility and efficiency: the production line can quickly adapt to the production of different vehicle models or versions of rear flooring through program switching, perfectly matching the high-speed cycle of integrated die casting and significantly improving overall manufacturing efficiency.

[0087] In the description of this application, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0088] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0089] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. An integrated die-casting post-floor connection production line, characterized in that, It includes: The loading station (12) is equipped with a loading unit, which is used to transfer the floor and is equipped with a visual scanning system for scanning the floor and obtaining actual position information. Multiple connection process stations are located downstream of the loading station (12), and each connection process station is equipped with a connection process unit for performing connection operations on the rear floor. The unloading station (11) is located downstream of multiple connecting process stations and is equipped with a quality inspection unit and a product diversion unit. The quality inspection unit inspects the finished products, and the product diversion unit processes qualified products and unqualified products according to the inspection results. The control system is electrically connected to each workstation and collects and records process parameters and quality information.

2. The integrated die-casting post-floor connection production line as described in claim 1, characterized in that: The feeding unit is a feeding robot, and the vision scanning system is fixed to the gripper of the feeding robot; The feed robot is also equipped with flexible grippers on its gripper.

3. The integrated die-casting post-floor connection production line as described in claim 1, characterized in that: The connection process unit includes at least two of the following: riveting unit, threaded sleeve installation unit, stud welding unit, glue application unit, FDS connection unit, and SPR connection unit. The connection process stations are arranged sequentially along the production line transmission direction so that each connection process unit performs the corresponding connection process in a preset order.

4. The integrated die-casting post-floor connection production line as described in claim 3, characterized in that: The riveting unit includes a riveting robot, a riveting gun, a force sensor, and a quality inspection device. The robot has an end effector, the riveting gun is mounted on the end effector, the force sensor is installed inside the rivet joint and electrically connected to the control system, and the quality inspection device is fixed on the end effector of the robot and electrically connected to the control system. The quality inspection device is used to inspect the quality of the rear floor connection after riveting is completed.

5. The integrated die-casting post-floor connection production line as described in claim 3, characterized in that: The threaded sleeve installation unit includes a threaded sleeve installation robot, an installation head, and a quality inspection device. The threaded sleeve installation robot has an end effector, the installation head is mounted on the end effector, and the quality inspection device is fixed to the end effector of the threaded sleeve installation robot and electrically connected to the control system. The quality inspection device is used to inspect the installation quality after the threaded sleeve is installed.

6. The integrated die-casting post-floor connection production line as described in claim 3, characterized in that: The stud welding unit includes a stud welding robot and a stud welding torch. The stud welding robot has an end effector, and the stud welding torch is mounted on the end effector.

7. The integrated die-casting post-floor connection production line as described in claim 3, characterized in that: The glue application unit includes a glue application robot, a glue gun, and a glue quantity control system. The glue application robot has an end effector, the glue gun is mounted on the end effector, and the glue quantity control system is electrically connected to the control system. The glue quantity control system automatically adjusts the glue quantity and application path according to the shape of the connection area of ​​the die-cast floor to ensure that the glue layer is uniform and meets the process requirements.

8. The integrated die-casting post-floor connection production line as described in claim 3, characterized in that: The FDS connection unit includes an FDS robot, an FDS screw supply system, and an FDS connector. The FDS robot has an end effector, and the FDS connector is mounted on the end effector. The FDS connector includes a rotary drive mechanism and an axial pressure control system. The axial pressure control system adjusts the pressure parameters according to the material thickness and connection strength requirements.

9. The integrated die-casting post-floor connection production line as described in claim 1, characterized in that: The SPR connection unit includes an SPR robot, a riveting head, and a riveting parameter control system. The SPR robot has an end effector, and the riveting head is mounted on the end effector. The riveting parameter control system is used to adjust the riveting speed, pressure, and depth according to the connection point position and material properties.

10. The integrated die-casting post-floor connection production line as described in claim 1, characterized in that: The connection process station is provided with at least two reserved stations. Each reserved station includes a workbench and a robot installation area. The workbench is used to support the rear floor. The robot installation area is used as a manual operation area when the production capacity is low in the early stage. When the production capacity demand increases, it is used to install robots. The quality inspection unit includes a scanner and a test result output terminal. The product diversion unit includes a first conveyor belt, a second conveyor belt, a qualified product packing area, and an abnormal product exit box. The control system includes a product information database, a quality judgment module, an alarm device, and a QR code recognition unit. The product information database is electrically connected to the test result output terminal of the quality inspection unit. The output terminal of the quality judgment module is electrically connected to the control terminal of the product diversion unit. The alarm device includes an audible and visual alarm and a display screen. The first conveyor belt leads to the qualified product packing area, and the second conveyor belt leads to the abnormal product exit box. A rework operation area is provided next to the abnormal product exit box.

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