Equipment and method for assembling and packaging screw assembly

Abstract

The invention provides assembling and packaging equipment and method for a screw assembly. The assembling and packaging equipment for the screw assembly comprises a jig rotating disc unit and a packaging unit, wherein the jig rotating disc unit comprises a rotating disc provided with a plurality of stations and a plurality of sets of jig grooves formed in the edge of the rotating disc; the plurality of automatic feeding units are sequentially arranged around the jig turntable unit; the automatic flat washer feeding unit comprises a camera, a light source and a rejecting air source, the camera is configured to photograph the flat washers reaching the detection position and distinguish the front faces and the back faces of the flat washers through image comparison, and the rejecting air source is configured to blow the flat washers with the upward back faces away from the assembly line; an automatic screw grabbing unit; the anti-pad-off lifting sleeve unit comprises an anti-pad-off connecting groove, a screw pressing mechanism and at least two stages of jacking air cylinders, and the two stages of jacking air cylinders selectively act according to the length of a screw; a finished product detection unit; and a conveying and packaging unit. According to the assembling and packaging scheme of the screw assembly, the automation level of assembling and packaging of the screw assembly can be improved.

Description

Technical Field

[0001] This disclosure relates to the field of automated assembly technology, and in particular to an assembly and packaging device and method for screw assemblies. Background Technology

[0002] In related technologies, most screw assembly methods adopt vertical rolling assembly or rely on a single guiding mode with the screw head facing up / down. These methods have insufficient positioning accuracy when assembling shorter screws, and cannot effectively prevent the spring washers and flat washers from falling off during transmission without nut constraints.

[0003] At the same time, existing production lines generally lack end-of-line automated packaging functions that are seamlessly integrated with the assembly process, often requiring additional manual intervention or separate packaging units, which leads to a break in the overall process.

[0004] These systemic deficiencies not only significantly increase the complexity of equipment integration and debugging, but also directly affect the consistency of the assembly process and the reliability of finished products. This is especially evident in high-standard application scenarios where the direction of washers is sensitive and screw sizes vary, and has become a key bottleneck restricting the automation upgrade and overall improvement of product quality in the industry. Summary of the Invention

[0005] In view of this, the present disclosure provides an assembly and packaging device and method for screw assemblies to solve the technical problems of complex and inconsistent assembly and packaging processes for screw assemblies in the prior art.

[0006] To achieve the above objectives, the technical solution adopted in this disclosure is: The assembly and packaging equipment for screw assemblies provided in the first aspect of this disclosure includes: a jig turntable unit, the jig turntable unit including a turntable with multiple workstations and multiple sets of jig slots disposed on the edge of the turntable, the jig slots being designed to accommodate and position flat washers and spring washers; and multiple automatic feeding units sequentially arranged around the jig turntable unit, including at least an automatic feeding unit for flat washers, an automatic feeding unit for spring washers, an automatic feeding unit for screws, and an automatic feeding unit for anti-loosening washers; the automatic feeding unit for flat washers includes a camera, a light source, and a rejection air source, the camera being configured to take pictures of the flat washers arriving at the detection position, and to distinguish the front and back sides by image comparison, and to reject the air source. The system includes: a source configuration to blow the reverse-facing flat washer off the production line; an automatic screw gripping unit configured to grip the screw from the automatic screw feeding unit and place it on the pre-positioned washer in the fixture slot; an anti-detachment pad lifting unit including an anti-detachment pad receiving slot, a screw pressing mechanism, and at least two lifting cylinders, which selectively operate according to the screw length to insert the anti-detachment pad in the anti-detachment pad receiving slot into the screw shank pressed by the screw pressing mechanism; a finished product inspection unit located at one station of the fixture turntable unit, configured to perform visual inspection and screening of the assembled finished screw assembly; and a conveying and packaging unit for conveying, cleaning, counting, packaging, and boxing the finished products.

[0007] In some embodiments, the fixture slot of the fixture turntable unit has a double-layer structure, with the upper layer used to accommodate spring washers and the lower layer used to accommodate flat washers; the turntable is driven to rotate by a servo motor, which can sequentially transport the fixture slot to the workstations corresponding to each automatic feeding unit and finished product inspection unit.

[0008] In some embodiments, a finished product unloading unit is also included. The finished product unloading unit includes a bracket, a translation cylinder mechanism, a guide mechanism, a lifting cylinder, and a lever. After the turntable delivers the finished screw assembly to the unloading position, the translation cylinder mechanism extends, the lifting cylinder descends, the lever extends behind the finished screw assembly, the translation cylinder mechanism retracts, and the qualified finished screw assembly is moved from the fixture slot onto the conveyor belt.

[0009] In some embodiments, the automatic feeding unit for flat washers, the automatic feeding unit for spring washers, and the automatic feeding unit for anti-detachment pads all include a vibratory feeder, a linear vibration track, a material distribution mechanism, and a pushing mechanism; wherein, the material distribution mechanism is used to transfer a single material from the linear vibration track to a predetermined position, and the pushing mechanism is used to push the material from the predetermined position into the fixture slot of the fixture turntable unit; the automatic feeding unit for spring washers includes a vibratory feeder, a linear vibration track, a material distribution mechanism, and a pushing mechanism.

[0010] In some embodiments, the automatic screw gripping unit includes a lifting cylinder, a first rotary cylinder, and a second rotary cylinder driven therefrom. The second rotary cylinder is provided with at least two sets of switchable gripper cylinders to accommodate gripping different types of screws.

[0011] In some embodiments, the finished product inspection unit includes a camera, a light source, and a rejection mechanism, configured to determine whether the screw assembly is fully assembled by visual image comparison and to reject defective products.

[0012] In some embodiments, the conveying and packaging unit includes a conveyor belt and a dust removal unit. The conveyor belt is used to transport the finished screw assembly to the packaging position, and the dust removal unit includes a blowing air knife disposed above the conveyor belt for blowing off iron filings from the surface of the finished screw assembly, and an iron filings collection trough is provided below it.

[0013] In some embodiments, the conveying and packaging unit includes a packaging counting unit, which includes a feeding port, a counting optical fiber, and a packaging machine. The counting optical fiber is used to count the falling finished screw assemblies. When the number reaches a preset value, the packaging machine is triggered to perform packaging.

[0014] In some embodiments, the conveying and packaging unit includes a finished product lifting and conveying unit, including a finished product elevator, a roller conveyor, a blocking mechanism, a position sensor, and a manual blocking plate. The finished product elevator lifts the material into the material box. After reaching the fixed requirement, the roller conveyor conveys the material box filled with material forward. When the unloading position sensor sends a signal, the blocking mechanism drops, and the next material box is conveyed forward. When the unloading position sensor sends a signal, the roller conveyor stops, and the blocking mechanism rises. When the full box of material is conveyed to the unloading position of the roller conveyor, the manual blocking plate blocks the material box, and the position sensor sends a signal.

[0015] The second aspect of this disclosure provides a method for assembling and packaging screw assemblies based on the assembly and packaging equipment of the second aspect of this disclosure, comprising: automatically feeding and assembling flat washers, spring washers, screws, and anti-loosening washers sequentially into the fixture slots of a fixture turntable unit via each automatic feeding unit; taking pictures of the flat washers reaching the detection position via the automatic flat washer feeding unit, distinguishing the front and back sides by image comparison, and using a rejection air source to blow the flat washers with the back side facing up away from the production line; grabbing the screws from the automatic screw feeding unit via the automatic screw gripping unit and placing them on the washers already in place in the fixture slot; selectively actuating the lifting cylinder of the anti-loosening washer lifting unit according to the screw length to insert the anti-loosening washers in the anti-loosening washer receiving slots into the screw shanks clamped by the screw pressing mechanism; visually inspecting and screening the assembled finished screw assemblies via the finished product inspection unit; and conveying, cleaning, counting, packaging, and boxing the finished products via the conveying and packaging unit.

[0016] The beneficial effects of this disclosure compared to the prior art are as follows: The screw assembly and packaging equipment in this disclosure coordinates various automatic feeding, assembly, testing, and packaging units through a jig turntable unit, realizing unmanned continuous production from loose parts to packaged finished products. It integrates automatic visual identification and rejection functions for the front and back of flat washers, ensuring consistent assembly quality; and it features an anti-loosening washer lifting mechanism that can adaptively adjust according to screw length, effectively solving the industry problem of difficult and easy-to-fall-off anti-loosening washers in the case of short screws or no nuts, significantly improving the equipment's versatility, assembly accuracy, and overall reliability, and increasing the assembly efficiency of screw assemblies. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this disclosure, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the assembly and packaging equipment for screw assemblies provided in the embodiments of this disclosure; Figure 2 This is a schematic diagram of the jig turntable unit provided in an embodiment of this disclosure; Figure 3 This is a schematic diagram of the automatic detection structure for the front and back sides of a flat washer provided in an embodiment of this disclosure; Figure 4 This is a schematic diagram of the automatic flat washer feeding unit provided in an embodiment of this disclosure; Figure 5 This is a schematic diagram of the automatic spring washer feeding unit provided in an embodiment of this disclosure; Figure 6 This is a schematic diagram of the automatic screw feeding unit provided in an embodiment of this disclosure; Figure 7 This is a schematic diagram of the automatic screw gripping unit provided in an embodiment of this disclosure; Figure 8 This is a schematic diagram of the automatic anti-detachment pad feeding unit provided in an embodiment of this disclosure; Figure 9 This is a schematic diagram of the anti-detachment pad lifting unit provided in an embodiment of this disclosure; Figure 10 This is a schematic diagram of the finished product testing unit provided in an embodiment of this disclosure; Figure 11 This is a schematic diagram of the finished product feeding unit provided in an embodiment of this disclosure; Figure 12 This is a schematic diagram of the conveyor belt and dust removal unit provided in the embodiments of this disclosure; Figure 13 This is a schematic diagram of the packing counting unit provided in an embodiment of this disclosure; Figure 14 This is a schematic diagram of the finished product lifting and conveying unit provided in an embodiment of this disclosure; Figure 15 This is a schematic flowchart of the assembly and packaging method for screw assemblies provided in the embodiments of this disclosure.

[0019] Figure label: 110. Fixture turntable unit; 111. Fixture slot; 112. Turntable; 113. Turntable support; 114. Turntable; 115. Servo motor system; 116. Feeding retainer ring; 117. Zero-point positioning detector; 120. Automatic flat washer feeding unit; 121. Flat washer vibratory feeder; 122. Flat washer presence / absence detection system; 123. Vertical vibration track; 124. Flat washer material distribution mechanism; 125. Flat washer pushing mechanism; 130. Automatic spring washer feeding unit; 131. Spring washer vibratory feeder; 132. Spring washer presence / absence detection system; 133. Vertical vibration track; 134. Spring washer material distribution mechanism; 135. 140. Spring washer pushing mechanism; 141. Automatic screw feeding unit; 142. Screw elevator; 143. Screw linear vibration track; 144. Screw distribution mechanism; 150. Automatic screw gripping unit; 151. Lifting cylinder; 152. First rotary cylinder; 153. Column; 154. Cylinder positioning buffer mechanism; 155. Left gripper control mechanism; 156. Left double-station double-jaw mechanism; 157. Right gripper control mechanism; 158. Right double-station double-jaw mechanism; 159. Spring washer straightening mechanism; 160. Automatic anti-detachment washer feeding unit; 161. Anti-detachment washer pushing mechanism; 162. Anti-detachment washer distribution mechanism; 163. 164. Vibration track; 165. Anti-detachment pad detection system; 170. Anti-detachment pad vibratory feeder; 171. Anti-detachment pad lifting unit; 172. First-stage lifting cylinder; 173. Slide rail motion mechanism; 174. Second-stage cylinder; 175. Anti-detachment pad receiving groove; 176. Anti-detachment pad lifting sleeve; 180. Pressing screw mechanism; 181. Finished product inspection unit; 182. Camera; 183. Light source; 184. Support machine; 185. Rejection mechanism; 190. Dropping hopper; 191. Finished product unloading unit; 192. Support; 193. Translation cylinder mechanism; 194. Guide mechanism; 195. Lifting cylinder; 196. Lever; 301 302. Support rod; 303. Camera; 304. Light source; 315. Conveyor belt and dust removal unit; 316. Conveyor belt; 317. Dust removal equipment cover; 318. Air distribution block; 319. Blowing air knife; 320. Collection trough; 321. Collection box; 322. Packaging and counting unit; 323. Material drop port; 324. Counting fiber optic cable; 325. Packaging machine; 326. Plastic film support; 327. Sealing mechanism; 338. Packaged finished product drop pallet; 339. Finished product lifting and conveying unit; 330. Finished product elevator; 331. Roller conveyor; 332. Blocking mechanism; 333. Position sensor; 335. Manual blocking plate. Detailed Implementation

[0020] To make the technical problems, technical solutions, and beneficial effects to be solved by this disclosure clearer, the disclosure will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining this disclosure and are not intended to limit this disclosure.

[0021] Figure 1 This is a schematic diagram of the assembly and packaging equipment for screw assemblies provided in the embodiments of this disclosure; Figure 2 This is a schematic diagram of the jig turntable unit provided in an embodiment of this disclosure; Figure 3 This is a schematic diagram of the automatic detection structure for the front and back sides of a flat washer provided in an embodiment of this disclosure; Figure 4 This is a schematic diagram of the automatic flat washer feeding unit provided in an embodiment of this disclosure; Figure 5 This is a schematic diagram of the automatic spring washer feeding unit provided in an embodiment of this disclosure; Figure 6 This is a schematic diagram of the automatic screw feeding unit provided in an embodiment of this disclosure; Figure 7 This is a schematic diagram of the automatic screw gripping unit provided in an embodiment of this disclosure; Figure 8 This is a schematic diagram of the automatic anti-detachment pad feeding unit provided in an embodiment of this disclosure; Figure 9 This is a schematic diagram of the anti-detachment pad lifting unit provided in an embodiment of this disclosure; Figure 10 This is a schematic diagram of the finished product testing unit provided in an embodiment of this disclosure; Figure 11 This is a schematic diagram of the finished product feeding unit provided in an embodiment of this disclosure; Figure 12 This is a schematic diagram of the conveyor belt and dust removal unit provided in the embodiments of this disclosure; Figure 13 This is a schematic diagram of the packing counting unit provided in an embodiment of this disclosure; Figure 14 This is a schematic diagram of the finished product lifting and conveying unit provided in an embodiment of this disclosure; Figure 15 This is a schematic flowchart illustrating the assembly and packaging method for screw assemblies provided in this disclosure. The following is in conjunction with... Figures 1 to 15 The assembly and packaging equipment and method for screw assemblies provided in the embodiments of this disclosure will be described together.

[0022] like Figure 1 The assembly and packaging equipment for screw assemblies provided in the embodiments of this disclosure includes: a jig turntable unit 110. For example... Figure 2 As shown, the jig turntable unit includes a turntable 112 with multiple workstations and multiple sets of jig slots 111 located on the edge of the turntable. The jig slots are designed to accommodate and position flat washers and spring washers. Multiple automatic feeding units are sequentially arranged around the jig turntable unit, including at least a flat washer automatic feeding unit 120, a spring washer automatic feeding unit 130, a screw automatic feeding unit 140, and an anti-loosening pad automatic feeding unit 160. Figure 3 As shown, the automatic flat washer feeding unit includes, as follows: Figure 3The automatic detection structure for the front and back sides of flat washers shown includes a support rod 301, a camera 302, a light source 303, and a rejection air source. The camera is configured to take pictures of the flat washers arriving at the detection position and distinguish the front and back sides by image comparison. The rejection air source is configured to blow the flat washers with the back side facing up away from the production line. The automatic screw gripping unit 150 is configured to grip the screws from the automatic screw feeding unit and place them on the washers that are already in place in the fixture slot. The anti-detachment pad lifting unit 170 includes an anti-detachment pad receiving slot, a screw pressing mechanism, and at least two lifting cylinders. The two lifting cylinders selectively operate according to the screw length to fit the anti-detachment pad in the anti-detachment pad receiving slot into the screw shank pressed by the screw pressing mechanism. The finished product inspection unit 180 is located at one station of the fixture turntable unit and is configured to perform visual inspection and screening of the assembled finished screw assemblies. The unit also includes a conveying and packaging unit for conveying, cleaning, counting, packaging, and boxing the finished products.

[0023] The screw assembly and packaging equipment of this disclosure consists of multiple component structures, which have functions such as compatibility with screws of different lengths, photo recognition of the front and back of flat washers, and photo recognition of whether the materials are fully assembled. It can prevent spring washers and flat washers from falling off without turning the nut, and can hold different numbers of the same flat washers. These functions do not require manual adjustment, but only require selection of the required function on the operation screen. Therefore, it can meet the needs of various manufacturers, has a wider range of applications, and greatly improves assembly efficiency, reduces manpower, and has good market promotion value.

[0024] The automatic detection structure for the front and back of the flat washer in this embodiment uses a detection sensor and a rejection air source below the detection position when the flat washer vibrates to the detection position to detect whether the material has arrived. Then, a visual image is taken and compared to distinguish the front and back of the flat washer. Flat washers that meet the requirements are allowed to pass through, while flat washers that do not meet the requirements are blown away by airflow. This kind of detection replaces the manual assembly work that does not distinguish the front and back of the flat washer. The visual distinction is highly efficient, reduces the difficulty of installation work, and greatly improves the installation accuracy.

[0025] like Figure 2 As shown, the fixture slot 111 of the fixture turntable unit has a double-layer structure, with the upper layer used to accommodate spring washers and the lower layer used to accommodate flat washers; the turntable 112 is driven to rotate by a servo motor, which can transport the fixture slots sequentially to the workstations corresponding to each automatic feeding unit and finished product inspection unit.

[0026] Specifically, the jig turntable unit consists of a turntable support 113, a turntable 114, a servo motor system 115, a turntable 112, a jig slot 111, a feeding retainer ring 116, and a zero-point positioning detector 117. The jig turntable unit has multiple working positions, and multiple sets of jig slots are set on the edge of the turntable for rotational positioning and material feeding. The material is fed sequentially to the flat washer station, spring washer station, screw station, and anti-detachment pad station by the turntable rotation. Qualified products are sent to the finished product unloading station for dust removal and packaging. A visual image comparison is set at the finished product inspection station to remove defective products.

[0027] This double-layer fixture slot structure enables pre-positioning and orderly separation of flat washers and spring washers, providing a stable benchmark for the precise gripping and placement of subsequent screws and avoiding interference and misalignment during assembly. Combined with a servo motor-driven precision indexing turntable, it ensures that each fixture slot can circulate through each functional station with high precision and efficiency, forming a stable and reliable core of a cycle-based production line.

[0028] In this embodiment, the automatic feeding unit for flat washers, the automatic feeding unit for spring washers, and the automatic feeding unit for anti-detachment pads all include a vibratory feeder, a linear vibration track, a material distribution mechanism, and a pushing mechanism.

[0029] like Figure 4 As shown, the automatic flat washer feeding unit is used to sort flat washers and send them to the flat washer position in the fixture slot. It includes a vibratory plate, a linear vibration track, a material distribution mechanism, and a pushing mechanism. The material distribution mechanism is used to transfer individual materials from the linear vibration track to a predetermined position, and the pushing mechanism is used to push the materials from the predetermined position into the fixture slot of the fixture turntable unit.

[0030] Specifically, the automatic flat washer feeding unit consists of a flat washer vibrating plate 121, a flat washer presence detection system 122, a vertical vibration track 123, a flat washer sorting mechanism 124, and a flat washer pushing mechanism 125. The vibrating plate vibrates, and flat washers are successively fed into the vertical vibration track. During this process, flat washers placed upside down can be eliminated through visual image comparison. The flat washers reach the sorter via the vertical vibration track. After the flat washers are in place, the sorter moves them to the fixture slot, and the pushing mechanism then delivers them to the fixture slot. The automatic flat washer feeding unit repeats the above actions until the equipment stops. This solution can completely replace manual assembly of flat washers, accurately replace manual differentiation of the front and back of the flat washers, and improve sorting speed.

[0031] like Figure 5 As shown, the automatic spring washer feeding unit is used to arrange spring washers and deliver them to the spring washer position in the fixture slot. It includes a vibratory feeder, a linear vibratory track, a material distribution mechanism, and a pushing mechanism. The material distribution mechanism is used to transfer individual materials from the linear vibratory track to a predetermined position, and the pushing mechanism is used to push the materials from the predetermined position into the fixture slot of the fixture turntable unit.

[0032] Specifically, the automatic spring washer feeding unit consists of a spring washer vibrating plate 131, a spring washer presence detection system 132, a linear vibration track 133, a spring washer distribution mechanism 134, and a spring washer pushing mechanism 135. The vibrating plate vibrates, and spring washers are successively fed into the linear vibration track. The linear vibration track transports spring washers in a directional manner, with the opening of the spring washer facing the vibrating plate. The spring washers reach the distributor via the linear vibration track. After the spring washers are in place, the distributor moves them to the fixture slot, and the pushing mechanism then delivers the spring washers to the fixture slot. The automatic spring washer feeding unit repeats the above actions until the equipment stops. This solution can completely replace manual assembly of spring washers, improving assembly speed.

[0033] By employing a feeding method combining a vibratory feeder and a linear vibratory track, the automatic, orderly, and directional conveying of flat washers and spring washers is achieved. Through the coordinated action of the material distribution mechanism and the jacking mechanism, the flat washers and spring washers can be accurately and reliably delivered into the designated layers of the fixture slot. The system boasts a high degree of automation, stable feeding rhythm, and completely replaces manual placement, significantly improving feeding efficiency and consistency.

[0034] like Figure 6 The automatic screw feeding unit shown is used to arrange screws and send them to the screw gripping position. The unit consists of a screw elevator 141, a screw vibration track 142, and a screw sorting mechanism 143. The screw elevator lifts the screws onto the conveying track, where they are then conveyed to the vibration track. The screws are vibrated and sent to the screw sorting position. Once in place, the sorting mechanism moves the screws to the gripping position, where they await gripping by the screw gripping mechanism. The automatic screw feeding unit repeats this process until the equipment stops. This solution offers high screw handling efficiency and can improve assembly speed.

[0035] like Figure 7 As shown, the automatic screw gripping unit 150 is used to grip the screws sent to a fixed position by the screw distribution mechanism onto the fixture slot. It includes a lifting cylinder, a first rotary cylinder, and a second rotary cylinder driven by the first rotary cylinder. The second rotary cylinder is equipped with at least two sets of switchable gripper cylinders to accommodate gripping different types of screws.

[0036] Specifically, the automatic screw gripping unit consists of a column 153, a lifting cylinder 151, a first rotating cylinder 152, a cylinder positioning buffer mechanism 154, a second rotating cylinder including a left gripper control mechanism 155 and a right gripper control mechanism 157, a left double-position double-gripper mechanism 156 including a left first gripper cylinder and a left second gripper cylinder, a right double-position double-gripper mechanism 158 including a right first gripper cylinder and a right second gripper cylinder, and a spring-loaded washer straightening mechanism 159. After the screw is in place, the lifting cylinder descends, the left gripper cylinder picks up the screw, the gripping unit lifting cylinder rises, and the first rotary cylinder rotates to the gripping position, i.e., the feeding position. During this process, the screw distribution mechanism delivers the second screw, the lifting cylinder descends, the left gripper cylinder places the screw into the fixture, and simultaneously the right gripper cylinder picks up the screw. The gripping unit lifting cylinder rises, and the first rotary cylinder rotates to the gripping position. During this process, the screw distribution mechanism delivers the second screw, the lifting cylinder descends, the left gripper cylinder places the screw into the fixture, and simultaneously the right gripper cylinder picks up the screw. The gripping unit lifting cylinder rises, and the automatic screw gripping unit repeats the screw-grabbing action until production is complete. Similarly, when producing small flat washers, the gripper cylinders used are the left second gripper cylinder and the right first gripper cylinder working together. This solution can replace manual screw assembly and is highly efficient and fast.

[0037] Employing a multi-cylinder compound motion and a switchable multi-set gripper design, the automatic screw gripping unit possesses high flexibility and adaptability. It can not only perform a series of complex actions such as gripping, lifting, rotating, and precisely placing screws, but also adapt to different screw models or sizes by quickly switching grippers, enhancing the equipment's flexible production capabilities and reducing changeover time and costs.

[0038] like Figure 8 As shown, the automatic anti-detachment pad feeding unit is used to arrange the anti-detachment pads and send them to the anti-detachment pad distributor. The automatic anti-detachment pad feeding unit consists of an anti-detachment pad vibratory feeder 165, an anti-detachment pad presence detection system 164, a vertical vibration track 163, an anti-detachment pad distributor mechanism 162, and an anti-detachment pad pushing mechanism 161. The vibratory feeder vibrates, and the anti-detachment pads are successively fed into the vertical vibration track. The vertical vibration track transports the anti-detachment pads to the distributor. After the anti-detachment pads are in place, the distributor moves to the anti-detachment pad lifting unit, and the pushing mechanism then completes the placement of the anti-detachment pads into the anti-detachment pad lifting unit. The automatic anti-detachment pad feeding unit repeats the above actions until the equipment stops. This design can completely mimic manual assembly of anti-detachment pads, with fast assembly speed and high efficiency.

[0039] like Figure 9As shown, the anti-detachment pad lifting unit can lift the anti-detachment pad and fit it onto the screw. Specifically, the anti-detachment pad lifting unit consists of a first-stage lifting cylinder 171, a slide rail movement mechanism 172, a second-stage cylinder 173, an anti-detachment pad receiving groove 174, an anti-detachment pad lifting sleeve 175, and a screw pressing mechanism 176. When the anti-detachment pad is pushed into the anti-detachment pad receiving groove, the screw pressing mechanism descends, and the anti-detachment pad lifting cylinder lifts according to the length of the screw. When the screw length is greater than 30mm, the first-stage cylinder lifts, lifting the anti-detachment pad and fitting it onto the screw; when the screw length is less than 30mm, the first-stage cylinder lifts to its position, and the second-stage cylinder also lifts, lifting the anti-detachment pad and fitting it onto the screw; the anti-detachment pad lifting unit repeats the above actions until the equipment stops. This solution can efficiently and accurately fit the anti-detachment pad, improving assembly efficiency.

[0040] like Figure 10 As shown, the finished product inspection unit is used to inspect whether the assembled finished screw assembly is qualified. It includes a camera, a light source and a rejection mechanism. It is configured to determine whether the screw assembly is assembled successfully through visual image comparison and to reject unqualified products.

[0041] Specifically, the finished product inspection unit consists of a camera 181, a light source 182, a support machine 183, a rejection mechanism 184, and a material discharge bin 185. When the turntable delivers screws to the finished product inspection unit, the camera takes a picture and compares it with a stored image of the finished product. Qualified products pass the inspection, while unqualified products are rejected by the rejection mechanism. The finished product inspection unit repeats the above actions until the equipment stops. This solution has high efficiency and high accuracy.

[0042] This solution utilizes machine vision for online full inspection, enabling rapid and non-contact identification of assembly integrity and component placement. For example, it checks for missing washers and properly inserted screws, achieving 100% quality control. An automatic rejection mechanism immediately removes defective products, preventing them from entering subsequent packaging stages and significantly improving the reliability of the final product's quality.

[0043] like Figure 11 As shown, the screw assembly and packaging equipment also includes a finished product unloading unit 190, used to unload inspected screws onto the conveyor belt. The finished product unloading unit includes a bracket 191, a translation cylinder mechanism 192, a guide mechanism 193, a lifting cylinder 194, and a lever 195. After the turntable delivers the finished screw assembly to the unloading position, the translation cylinder mechanism extends, the lifting cylinder descends, the lever extends behind the finished screw assembly, and the translation cylinder mechanism retracts. The inspected and qualified finished screw assembly is then moved from the fixture slot onto the conveyor belt. The finished product unloading unit repeats the above actions until the equipment stops. This solution offers high efficiency and high speed.

[0044] This mechanical unloading unit uses a combination of translation, descent, and tossing movements driven by cylinders to smoothly, reliably, and without damage transfer qualified finished products from the jig slot to the conveyor belt. Its simple and efficient structure and precise movements ensure a smooth connection between the assembly line and the subsequent packaging line, avoiding the efficiency bottlenecks and quality risks associated with manual unloading.

[0045] like Figure 12 As shown, the conveying and packaging unit includes a conveyor belt and a dust removal unit 310. The conveyor belt is used to transport the finished screw assembly to the packaging position. The dust removal unit blows the residual iron filings on the screws into the iron filings collection trough. The dust removal unit includes a blowing air knife set above the conveyor belt to blow off the iron filings on the surface of the finished screw assembly, and an iron filings collection trough is provided below.

[0046] Specifically, the dust removal unit includes a dust removal equipment cover 312, an air distribution block 313, a blowing knife 314, a collection trough 315, and a collection box 316, all positioned above the conveyor belt 311. After the finished screw assembly falls onto the conveyor belt, it is transported to the middle of the conveyor belt. The blowing mechanism blows air, causing metal shavings on the screws to fall into the metal shavings collection trough. The dust removal unit repeats this process until the equipment stops. Integrated into the conveying process, the dust removal unit effectively removes metal shavings, oil, and other impurities adhering to the screws during processing and assembly using the blowing knife. This not only improves the cleanliness of the product's appearance but also prevents impurities from being introduced into the packaging or final use, improving product quality and customer satisfaction. Furthermore, the collection trough facilitates cleaning and maintenance.

[0047] like Figure 13 As shown, the conveying and packaging unit includes a packing and counting unit 320, which is used to pack the finished screw assemblies into a fixed quantity. The packing and counting unit includes a feeding port, a counting optical fiber, and a packaging machine. The counting optical fiber is used to count the falling finished screw assemblies. When the quantity reaches a preset value, the packaging machine is triggered to seal them.

[0048] Specifically, the packaging and counting unit consists of a feeding port 321, a counting fiber optic cable 322, a packaging machine 323, a plastic film support 324, a sealing mechanism 325, and a packaged finished product feeding tray 326. Finished screw assemblies are conveyed to the feeding port by a conveyor belt, fall through the counting fiber optic cable, and then into the packaging machine. Once the quantity reaches the packaging requirement, the packaging bag is automatically sealed, and the sealed material falls onto an elevator. The packaging and counting unit repeats the above actions until the equipment stops. Using this solution, the quantity can be automatically counted and packaged without manual intervention, saving labor costs.

[0049] This solution enables automated and precise counting and packaging of finished products. The counting fiber optic cable ensures absolute accuracy in the quantity of each package, replacing error-prone manual counting. Integrated with a packaging machine, it achieves automatic sealing, transforming scattered finished products into standardized packaging units, facilitating subsequent warehousing, transportation, and sales, and further enhancing the automation level of the later stages of production.

[0050] like Figure 14 As shown, the conveying and packaging unit includes a finished product lifting and conveying unit 330, used to convey packaged materials to material boxes and then to the manual unloading station. This unit includes a finished product elevator 331, a roller conveyor 332, a blocking mechanism 332, a position sensor 334, and a manual blocking plate 335. The finished product elevator lifts the materials into the material box. Once a fixed position is reached, the roller conveyor conveys the full material box forward. When the unloading position sensor sends a signal, the blocking mechanism lowers, and the next material box is conveyed forward. When the unloading position sensor sends a signal, the roller conveyor stops, and the blocking mechanism rises. A full box of material is conveyed to the unloading position of the roller conveyor, where the manual blocking plate blocks the material box. When the position sensor sends a signal, the operator removes the full box. The finished product lifting and conveying unit repeats the above actions until the equipment stops. This solution eliminates the need for manual boxing and loading, reducing labor costs.

[0051] This unit achieves fully automated logistics processing from individual packaging to full case stacking. Through the coordinated control of elevators, conveyor lines, sensors, and blocking mechanisms, it automatically completes a series of actions such as case loading, full case replacement, empty case replenishment, and conveying to designated workstations. This significantly reduces the labor intensity of operators, improves case loading efficiency and space utilization, and makes the entire production line fully integrated from raw materials to full case shipment.

[0052] like Figure 15 As shown, this disclosure provides a method for assembling and packaging screw assemblies using an assembly and packaging device for screw assemblies according to the above-described technical solution. The assembly and packaging method includes: Step S1501: The flat washer, spring washer, screw and anti-loosening pad are automatically fed and assembled into the fixture slot of the fixture turntable unit in sequence by each automatic feeding unit. Step S1502: The flat washer that arrives at the detection position is photographed by the flat washer automatic feeding unit, and the front and back sides are distinguished by image comparison. The flat washer with the back side facing up is blown away from the production line by the rejection air source. Step S1503: The screws from the automatic screw feeding unit are picked up by the automatic screw gripping unit and placed on the washers that are already in place in the fixture slot. Step S1504: The lifting cylinder of the anti-detachment pad lifting unit is selectively operated according to the screw length to insert the anti-detachment pad in the anti-detachment pad groove into the screw rod portion pressed by the screw pressing mechanism. Step S1505: Visual inspection and screening of the assembled finished screw assembly is carried out by the finished product inspection unit; Step S1506: The finished products are conveyed, cleaned, counted, packaged, and boxed through the conveyor packaging unit.

[0053] In this embodiment, the automatic feeding unit for flat washers, the automatic feeding unit for spring washers, and the automatic feeding unit for anti-detachment pads are all located on one side of the fixture turntable unit. This makes it convenient for operators to feed materials from one side at a time, and all prepared materials are also placed on one side for convenience and neatness, but it is not limited to this form.

[0054] Flat washers, spring washers, anti-loosening washers, and screws are placed in the automatic flat washer feeding unit, the automatic spring washer feeding unit, the automatic screw feeding unit, and the automatic anti-loosening washer feeding unit, respectively. The materials are sorted by a circular vibrating plate and fed by a straight vibrating track. They are then loaded into the fixture slot of the fixture turntable unit in one go by the distributor assembly. The installation sequence is flat washers, spring washers, screws, and anti-loosening washers, thus completing the assembly of the finished screw assembly. Finished screw assemblies are sent to the finished product inspection unit, where a camera takes pictures. By comparing these pictures with stored images, qualified products pass the inspection, while unqualified products are rejected. Qualified finished screw assemblies are then sent to the finished product unloading unit, where a mechanism delivers the screws to a conveyor belt and a dust removal unit, completing the unloading process.

[0055] Finished screw assemblies are conveyed to the packaging and counting unit by a conveyor belt and dust removal unit. After packaging according to requirements, they fall to the finished product lifting and conveying unit, completing one cycle of packaging and boxing. By continuously repeating the above process, mass production can be achieved.

[0056] This method defines a complete, orderly, and intelligent automated process flow. Its core effect lies in the step-by-step integration of visual inspection, adaptive assembly, and fully automated logistics, achieving not only efficient and precise assembly of screw components but also ensuring controllable quality throughout the entire process from parts to packaging. In particular, the online alignment of flat washers and the adaptive fitting of anti-loosening washers for screw length systematically solve long-standing quality pain points and flexible manufacturing challenges in this field, significantly improving overall production efficiency and product consistency.

[0057] According to the assembly and packaging equipment and method for screw assemblies provided in this disclosure, the automatic feeding, assembly, testing, and packaging units are coordinated by a jig turntable unit, realizing unmanned continuous production from loose parts to packaged finished products. It integrates automatic visual identification and rejection functions for the front and back of flat washers, ensuring consistent assembly quality; and designs an anti-loosening washer lifting mechanism that can adaptively adjust according to screw length, effectively solving the industry problem of difficult and easy-to-fall-off anti-loosening washers in the case of short screws or no nuts, significantly improving the equipment's versatility, assembly accuracy, and overall reliability, and increasing the assembly efficiency of screw assemblies.

[0058] The above are merely preferred embodiments of this disclosure and are not intended to limit this disclosure. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this disclosure should be included within the scope of protection of this disclosure.

Claims

1. A screw assembly and packaging device, characterized in that, include: A fixture turntable unit includes a turntable with multiple workstations and multiple sets of fixture slots located on the edge of the turntable. The fixture slots are designed to accommodate and position flat washers and spring washers. Multiple automatic feeding units arranged sequentially around the fixture turntable unit include at least a flat washer automatic feeding unit, a spring washer automatic feeding unit, a screw automatic feeding unit, and an anti-loosening pad automatic feeding unit. The automatic flat washer feeding unit includes a camera, a light source, and a rejection air source. The camera is configured to take pictures of the flat washers that arrive at the detection position and distinguish the front and back sides by image comparison. The rejection air source is configured to blow the flat washers with the back side facing up away from the production line. An automatic screw gripping unit is configured to grip screws from the automatic screw feeding unit and place them on washers that are already in place in the fixture slot. The anti-detachment pad lifting unit includes an anti-detachment pad groove, a screw pressing mechanism, and at least two lifting cylinders. The two lifting cylinders selectively operate according to the screw length to insert the anti-detachment pad in the anti-detachment pad groove into the screw rod portion pressed by the screw pressing mechanism. The finished product inspection unit is located at one station of the fixture turntable unit and is configured to perform visual inspection and screening of the assembled finished screw assemblies. And conveyor packaging units for conveying, cleaning, counting, packaging and boxing finished products.

2. The assembly and packaging equipment for screw assemblies according to claim 1, characterized in that, The fixture slot of the fixture turntable unit has a double-layer structure, with the upper layer used to accommodate spring washers and the lower layer used to accommodate flat washers. The turntable is driven to rotate by a servo motor, which can sequentially transport the fixture slot to the workstations corresponding to each automatic feeding unit and the finished product inspection unit.

3. The assembly and packaging equipment for screw assemblies according to claim 1, characterized in that, It also includes a finished product unloading unit, which includes a bracket, a translation cylinder mechanism, a guide mechanism, a lifting cylinder, and a lever. After the turntable delivers the finished screw assembly to the unloading position, the translation cylinder mechanism extends, the lifting cylinder descends, the lever extends behind the finished screw assembly, and the translation cylinder mechanism retracts. The qualified finished screw assembly is then moved from the fixture slot onto the conveyor belt.

4. The assembly and packaging equipment for screw assemblies according to claim 1, characterized in that, The automatic feeding unit for flat washers, the automatic feeding unit for spring washers, and the automatic feeding unit for anti-detachment pads all include a vibratory feeder, a linear vibration track, a material distribution mechanism, and a pushing mechanism; wherein, the material distribution mechanism is used to transfer a single material from the linear vibration track to a predetermined position, and the pushing mechanism is used to push the material from the predetermined position into the fixture slot of the fixture turntable unit.

5. The assembly and packaging equipment for screw assemblies according to claim 1, characterized in that, The automatic screw gripping unit includes a lifting cylinder, a first rotary cylinder, and a second rotary cylinder driven by the first rotary cylinder. The second rotary cylinder is equipped with at least two sets of switchable gripper cylinders to accommodate gripping different types of screws.

6. The assembly and packaging equipment for screw assemblies according to claim 1, characterized in that, The finished product inspection unit includes a camera, a light source, and a rejection mechanism, configured to determine whether the screw assembly is fully assembled by visual image comparison and to reject defective products.

7. The assembly and packaging equipment for screw assemblies according to claim 1, characterized in that, The conveying and packaging unit includes a conveyor belt and a dust removal unit. The conveyor belt is used to transport the finished screw assembly to the packaging position. The dust removal unit includes a blowing air knife set above the conveyor belt to blow off iron filings from the surface of the finished screw assembly, and an iron filings collection trough is provided below.

8. The assembly and packaging equipment for screw assemblies according to claim 1, characterized in that, The conveying and packaging unit includes a packaging and counting unit, which includes a feeding port, a counting optical fiber, and a packaging machine. The counting optical fiber is used to count the falling finished screw assemblies. When the number reaches a preset value, the packaging machine is triggered to perform packaging.

9. The assembly and packaging equipment for screw assemblies according to claim 1, characterized in that, The conveying and packaging unit includes a finished product lifting and conveying unit, which includes a finished product elevator, a roller conveyor, a blocking mechanism, a positioning sensor, and a manual blocking plate; The finished product elevator lifts the material into the material box. After reaching the fixed requirement, the roller conveyor transports the material box filled with material forward. When the discharge position sensor sends a signal, the blocking mechanism falls, and the next material box is transported forward. When the discharge position sensor sends a signal, the roller conveyor stops, and the blocking mechanism rises. When the full box of material is transported to the discharge position of the roller conveyor, the manual blocking plate blocks the material box, and the position sensor sends a signal.

10. A method for assembling and packaging a screw assembly based on the screw assembly assembly and packaging equipment according to any one of claims 1 to 9, characterized in that, include: Through each automatic feeding unit, flat washers, spring washers, screws and anti-loosening pads are automatically fed in sequence and assembled into the fixture slots of the fixture turntable unit; The flat washer automatic feeding unit takes pictures of the flat washers that arrive at the detection position, and distinguishes the front and back sides by image comparison. The flat washer with the back side facing up is blown away from the production line by the rejection air source. The screws from the automatic screw feeding unit are picked up by the automatic screw gripping unit and placed on the washers that are already in place in the fixture slot. The lifting cylinder of the anti-detachment pad lifting unit selectively operates according to the screw length to insert the anti-detachment pad in the anti-detachment pad groove into the screw rod part pressed by the screw pressing mechanism; The assembled screw assembly is visually inspected and screened using a finished product inspection unit. Finished products are transported, cleaned, counted, packaged, and boxed through a conveyor packaging unit.

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