Assembly method and system of bathroom quick-assembly part assembly, intelligent terminal and storage medium

Abstract

The invention relates to the technical field of bathroom accessory manufacturing and automatic control, in particular to an assembling method and system for a bathroom quick-assembly part assembly, an intelligent terminal and a storage medium. The first threaded sleeve is pressed into the first mounting hole, and the second threaded sleeve is pressed into the second mounting hole; press-in states of the first screw sleeve and the second screw sleeve are obtained; when the press-in state is that detection is passed, a first screw is sequentially screwed into a first connecting hole and a first screw sleeve, and a second screw is sequentially screwed into a second connecting hole and a second screw sleeve; obtaining screwing-in states of the first screw and the second screw; when the screwing-in state is that the detection is passed, the pin shaft and the pin head are locked; and the assembled quick-assembly part assembly is moved to a material containing disc. The method has the advantages that the problems that follow-up assembly materials are wasted and finished products are unqualified in batch due to the fact that hidden defects of the previous procedure are difficult to find in time are solved, and the production yield is increased.

Description

Technical Field

[0001] This application relates to the technical field of bathroom accessory manufacturing and automation control, and in particular to an assembly method, system, intelligent terminal and storage medium for a bathroom quick-installation assembly. Background Technology

[0002] In the automated assembly process of bathroom products, the quick-release assembly of shower enclosures, as a key connecting structure, is typically composed of multiple precision parts such as quick-release bases, quick-release discs, threaded sleeves, screws, and pins. When quick-release components are continuously assembled on the production line, the precision of the fit between these parts directly determines the reliability and lifespan of the final product. Therefore, it is necessary to ensure that each part is accurately installed in its preset position during the assembly process to guarantee the stability of the final product quality.

[0003] In related technologies, the automated assembly of multi-part products such as bathroom quick-installation assemblies typically employs an assembly line layout. This involves vibratory feeders for material feeding, robotic arms for gripping, and pneumatic pressure heads for pressing operations, embedding components such as sleeves, screws, and pins into the base. During assembly, mechanical limit switches or sensors are usually used to detect the presence of materials and determine whether parts have been dispensed. After all assembly processes are completed, the assembly quality of the finished product is verified through manual sampling or offline testing equipment to ensure that the product meets factory standards.

[0004] Regarding the aforementioned technologies, since quick-assembly parts involve numerous assembly steps, including pressing, tightening, and insertion, hidden defects such as incomplete screw insertion or insufficient screw tightening may occur in previous processes due to factors such as material size deviations and vibration interference from the pressing mechanism. These defects are difficult to detect in subsequent processes. Continuing to assemble other parts not only wastes materials but may also lead to batch defects in the final product due to the accumulation of problems, increasing rework costs and quality risks. Summary of the Invention

[0005] To improve the problem of wasted assembly materials and unqualified batches of finished products caused by the difficulty in timely detection of hidden defects in previous processes, and to improve production yield, this application provides an assembly method, system, intelligent terminal and storage medium for bathroom quick-assembly components.

[0006] In a first aspect, this application provides a method for producing a quick-install bathroom component assembly, employing the following technical solution: A method for producing a quick-install bathroom fixture assembly includes: The quick-assembly base is loaded using the quick-assembly base loading mechanism; The first threaded sleeve is pressed into the first mounting hole of the quick-release seat by the threaded sleeve installation mechanism, and the second threaded sleeve is pressed into the second mounting hole of the quick-release seat. Obtain the press-in state of the first and second threaded sleeves on the quick-release seat; When the press-in state is in the detection pass state, the quick-release plate is placed on the top of the quick-release seat by the quick-release plate feeding mechanism, so that the first connecting hole of the quick-release plate corresponds to the first threaded sleeve and the second connecting hole corresponds to the second threaded sleeve. The first screw is screwed into the first connecting hole and the first threaded sleeve in sequence through the screw installation mechanism, and the second screw is screwed into the second connecting hole and the second threaded sleeve in sequence. Obtain the screw-in state of the first and second screws; When the screw-in state is considered to have passed the test, the pin head is placed in the expansion column hole of the quick-release seat by the pin head feeding mechanism, and then the pin shaft is inserted into the connecting column hole of the quick-release plate and the expansion column hole of the quick-release seat by the pin shaft feeding mechanism, and locked with the pin head. Move the assembled quick-assembly assembly to the material tray.

[0007] By adopting the above technical solutions, a full-process online real-time detection mechanism is constructed, changing the traditional passive mode that relies on post-process sampling inspection. Immediately after key processes such as screw insertion, screw tightening, and pin locking, a status acquisition step is embedded to achieve closed-loop control with one inspection per step. This instantly identifies hidden defects such as incomplete insertion or abnormal screwing caused by material size deviations or mechanical vibrations, and stops subsequent assembly processes at the first sign of a defect. By intercepting defective products in preceding processes, it avoids the continued input of potentially hazardous semi-finished products into subsequent high-value processes, eliminating the risk of batch scrapping of finished products due to the accumulation of single-point defects. This reduces raw material waste and rework costs, ensures the connection reliability of the final product, and improves the overall operating efficiency and product yield of the production line.

[0008] Optionally, the steps for determining whether the screw-in state has passed the detection include: Obtain the screw-in state of the first screw and output the first detection state; Obtain the screw-in state of the second screw and output the second detection state; When both the first and second inspection states are qualified, the screwing-in state of the first and second screws is determined to be a successful inspection. If either the first or second detection state is unqualified, the screw-in state of the first and second screws is determined to be a failure.

[0009] By adopting the above technical solution, the single overall judgment mode is abandoned. A dual independent detection and logical interlocking mechanism is established to address the multi-screw symmetrical layout structure of shower enclosure accessories. The screw-in state of each screw is independently collected and evaluated, and the results of both tests are logically ANDed to ensure that the system only allows the next process when all connection points meet the qualification standard. This fine-grained judgment logic effectively identifies local defects such as unilateral screw installation failures, preventing uneven stress on the overall structure caused by loose or overtightened individual connection points. It eliminates blind spots that may exist in traditional testing, ensuring the structural integrity of the quick-assembly assembly under multi-dimensional stress scenarios, thereby improving the connection stability of the end product during long-term use.

[0010] Optionally, the steps for obtaining the screw-in state of the first screw and the second screw include: Real-time acquisition of the torque change curve of the screw during the screw-in process; The torque change curve is compared with a preset standard torque window. When the torque curve reaches the target torque value within a preset angle range, the test status is determined to be qualified. If the torque curve exceeds the preset angle range and still fails to reach the target torque value, or if the torque peak value is abnormal, the test status is determined to be unqualified.

[0011] By adopting the above technical solution, compared with the traditional endpoint torque judgment, using the full-cycle torque change curve as the core detection basis can more comprehensively reflect the dynamic characteristics of the screw tightening process. By comparing the real-time curve with the preset standard window throughout the entire process, the system can not only identify whether the final torque meets the standard, but also capture abnormal fluctuations such as stripping, misalignment, foreign object obstruction, or thread damage that occur during tightening. This process-characteristic-based detection method can overcome the misjudgment caused by relying solely on peak value judgment, and is particularly sensitive to early resistance anomalies caused by poor thread fit. It ensures that every tightening action is completed within a controlled process window, guaranteeing the tightness and anti-loosening ability of the threaded connection.

[0012] Optionally, the step of obtaining the screw-in state of the first screw and the second screw further includes: The screw-in process is divided into an initial contact stage and a tightening stage; During the initial contact phase, the torque change curve of the screw is acquired in real time and compared with the preset initial contact torque window. When the torque value reaches the initial contact torque value within the preset angle range, the initial contact phase is deemed qualified. During the tightening phase, the torque change curve of the screw is acquired in real time and compared with the preset tightening torque window. When the torque value reaches the target torque value within the preset angle range, the tightening phase is deemed qualified. When both the initial contact stage and the tightening stage are qualified, the screw's screw-in state is considered qualified. If any stage fails to meet the requirements, the screw's screw-in state is deemed unqualified.

[0013] By adopting the above technical solution, the screw-in process is decoupled into two independent stages: initial contact and final tightening. Targeted inspection windows are set for each stage, enabling deep and refined control of the fastening process. In the initial contact stage, the focus is on monitoring the smoothness and alignment of the thread engagement, promptly eliminating the risk of forced screwing due to misalignment. In the tightening stage, the focus is on the precise achievement of the final preload. This phased strategy solves the problem that traditional single-window methods cannot simultaneously address initial smoothness and final tightness, and can identify complex defects such as false tightening, loose connection, or initial jamming. Segmented control improves inspection accuracy, optimizes the mechanical transmission path during assembly, and enhances the structural reliability of the product.

[0014] Optionally, the calculation steps for the preset initial contact torque window and tightening torque window include: The preset initial contact torque window and tightening torque window are dynamically adjusted according to the material hardness value of the screw; The preset formula for calculating the initial contact torque window is: T initial =T base ×(H mat / H ref ); The preset tightening torque window calculation formula is: T tight =T base ×(H mat / H ref )×C; Among them, T base H is the reference torque value. mat H represents the hardness value of the screw material. ref f is the reference hardness value, and C is the preset stage coefficient.

[0015] By adopting the above technical solution and introducing a dynamic threshold calculation model based on material physical properties, the limitations of traditional fixed-parameter detection in adapting to different materials are overcome. By establishing a functional relationship between the torque window and the screw material hardness value, the system can automatically adjust the acceptance criteria based on the natural fluctuations in raw material hardness during actual production. The adaptive mechanism eliminates misjudgments or omissions caused by differences in material properties between batches, enabling the same production line to flexibly accommodate fasteners of various specifications or different alloy compositions without frequent shutdowns for recalibration. This expands the tolerance range of process parameters, improves the robustness of the production system, and ensures that each connection point achieves the optimal fastening state matching its physical properties under different material conditions, realizing intelligent and flexible manufacturing.

[0016] Optionally, the steps for obtaining the press-in state of the first and second threaded sleeves on the quick-release seat include: The threaded sleeve pressing process is divided into an initial pressing stage and a depth confirmation stage; During the initial pressing stage, the displacement curve of the screw sleeve is acquired in real time. The displacement curve is compared with the preset initial pressing displacement window. When the displacement value reaches the initial pressing displacement value within the preset angle range, the initial pressing stage is deemed qualified. During the depth confirmation stage, the depth value of the screw sleeve is acquired in real time and compared with the preset depth threshold. The preset depth threshold calculation formula is: D threshold =D base ×(H sleeve / H ref ); Among them, D base H is the reference depth value. sleeve H represents the hardness value of the threaded sleeve material. ref This is a reference hardness value; When the depth value is within the preset range, the depth confirmation stage is deemed qualified. When both the initial pressing stage and the depth confirmation stage are qualified, the pressing state of the screw sleeve is judged to have passed the test; If any stage fails to meet the requirements, the threaded sleeve pressing state is deemed as failing the test.

[0017] By adopting the above technical solution, a dual verification system combining displacement curves and depth thresholds was constructed for threaded sleeve press-in, and a dynamic correction mechanism for material hardness was introduced. By dividing the press-in process into two stages—initial press-in and depth confirmation—the system can monitor the stability of the press-in process and accurately verify the final absolute position. The depth threshold is dynamically adjusted according to the hardness of the threaded sleeve material, compensating for the differences in elastic recovery of materials with different hardness during the press-in process and avoiding depth measurement errors caused by material springback. The high-precision detection strategy can identify hidden defects such as threaded sleeve tilt, insufficient press-in, or excessive depth, ensuring an interference fit between the threaded sleeve and the base hole and improving the load-bearing capacity of the assembly structure.

[0018] Optionally, when the screw sleeve pressing state is determined to be a failure test, the method further includes: Based on the abnormal mode of the screw sleeve pressing depth value, the pressing depth parameter of the screw sleeve installation mechanism is automatically adjusted. The abnormal mode includes the depth value being lower than the preset depth threshold, the depth fluctuation exceeding the preset fluctuation threshold, or the pressing time being abnormal. The formula for calculating the indentation depth parameter is: D adjust =D base ×(1+γ), where γ is the anomaly coefficient; Based on historical anomaly reports, the preset depth threshold for the next production batch is automatically optimized; The preset depth threshold optimization formula is: D new =D old ×(1-δ), where D old δ is the preset depth threshold for the current batch, and δ is the optimization coefficient.

[0019] By adopting the above technical solutions, a self-evolving closed-loop process control system was constructed, transforming passive detection into proactive intervention. When an abnormality is detected, the system can not only instantly adjust the execution parameters of the current equipment, attempting repair or safe shutdown, but also automatically optimize the preset thresholds for the next batch based on historical anomaly data. The self-learning mechanism based on big data feedback effectively addresses slow-variable disturbances such as tool wear, environmental temperature changes, or raw material batch fluctuations, ensuring the production process remains optimal. This reduces reliance on external manual adjustments, minimizes continuous quality incidents caused by parameter drift, continuously iterates and optimizes parameters, and compresses the range of process fluctuations, thereby maintaining product consistency in long-cycle production.

[0020] Secondly, this application provides a production system for quick-install bathroom fixtures, which adopts the following technical solution: A production system for quick-install bathroom fixtures includes: The acquisition module is used to acquire the press-in state of the first and second threaded sleeves, and the screw-in state of the first and second screws; A memory for storing a program for a control method of a production system for quick-installation bathroom fixtures, as described in any of the first aspects; A control method for a production system of bathroom quick-installation parts, wherein the program in the processor and memory can be loaded and executed by the processor and implement any of the first aspects.

[0021] By adopting the above technical solution, the detection algorithm and control logic are solidified into a hardware system architecture. Through the collaboration of the acquisition module, memory, and processor, high-speed detection decision-making and automated execution are achieved. Deep integration of software and hardware ensures that sensor data can be collected, analyzed, and command issued in a short time, meeting the real-time requirements of high-speed production lines. The system can fully reproduce the refined detection and self-optimization functions of the aforementioned methods, and modularization improves the maintainability and scalability of the equipment. Complex process expert experience is transformed into executable code logic, eliminating the uncertainty of human operation and providing support for the standardized production of bathroom quick-installation components.

[0022] Thirdly, this application provides a smart terminal, which adopts the following technical solution: A smart terminal includes a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed as in any of the methods described above.

[0023] Fourthly, this application provides a computer storage medium capable of storing corresponding programs, employing the following technical solution: A computer-readable storage medium storing a computer program that can be loaded by a processor and executed in any of the above-described methods for producing bathroom quick-installation assemblies.

[0024] In summary, this application includes at least one of the following beneficial technical effects: This application abandons the traditional passive model that relies on post-inspection. Immediately after key processes such as inserting the screw and tightening the bolt, a real-time status acquisition step is embedded, performing a step-by-step inspection. Through closed-loop control throughout the entire process, hidden defects such as incomplete insertion or abnormal tightening caused by material size deviations or mechanical vibrations are instantly identified, automatically halting subsequent assembly processes at the first sign of a defect. By accurately intercepting defective semi-finished products in preceding processes, it effectively avoids the continued input of potentially hazardous components into high-value processes, eliminates the risk of batch scrapping of finished products due to the accumulation of single-point defects, reduces raw material waste and rework costs, and ensures the connection reliability of the final product and the overall yield of the production line. This application addresses the complexity of multi-part assembly by employing a phased, full-cycle depth detection strategy. In the screw insertion stage, the process is decoupled into two independent stages: initial contact and final tightening. Combined with full-cycle torque curve analysis, dynamic anomalies such as stripping, misalignment, false tightening, and initial stage jamming are captured, and the final torque is assessed to determine if it meets the standard. In the sleeve pressing stage, a dual verification system based on displacement curves and depth thresholds is constructed, introducing a dynamic correction mechanism based on material hardness to compensate for measurement errors caused by differences in material elastic recovery. Fine-grained judgment logic eliminates the blind spots of traditional single-peak judgment or fixed-threshold detection, ensuring that each connection point achieves optimal fit under multi-dimensional stress scenarios, thereby improving the structural integrity and long-term stability of the product. This application breaks through the limitations of traditional fixed-parameter control and constructs a closed-loop process system with self-evolution capabilities. By establishing a functional relationship between detection parameters and material physical properties, the system can automatically adjust the acceptance criteria based on batch fluctuations in raw materials, achieving flexible production. Simultaneously, a big data feedback mechanism based on historical anomaly reports enables the system to automatically identify slow-moving variables such as tool wear and environmental changes, dynamically optimizing the preset thresholds and equipment execution parameters for the next batch. This self-learning mechanism, from passive detection to active intervention and continuous optimization, reduces reliance on manual adjustments, suppresses long-term drift of process parameters, and ensures product consistency during long-cycle, large-scale production. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the assembly line layout for quick-install bathroom components in related technologies.

[0026] Figure 2This is a flowchart of a method for producing a bathroom quick-installation assembly according to an embodiment of this application.

[0027] Figure 3 This is a flowchart of the steps for determining whether the screw-in state detection has passed in the embodiments of this application.

[0028] Figure 4 This is a flowchart of the steps for obtaining the screw-in state of the first screw and the second screw in the embodiments of this application. Figure 1 .

[0029] Figure 5 This is a flowchart of the steps for obtaining the screw-in state of the first screw and the second screw in the embodiments of this application. Figure 2 .

[0030] Figure 6 This is a flowchart illustrating the calculation steps for the preset initial contact torque window and tightening torque window in the embodiments of this application.

[0031] Figure 7 This is a flowchart of the steps for obtaining the pressed-in state of the first and second threaded sleeves on the quick-release seat in this embodiment of the application.

[0032] Figure 8 This is a flowchart of the method for determining the screw sleeve pressing state as a failure detection in the embodiments of this application.

[0033] Figure 9 This is a block diagram of a method for producing a bathroom quick-installation assembly according to an embodiment of this application. Detailed Implementation

[0034] The present application will be further described in detail below with reference to the accompanying drawings.

[0035] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of this application.

[0036] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the appendices in the embodiments of this application will be described below. Figure 1-9 The technical solutions in the embodiments of this application are clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0037] Furthermore, the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this article, unless otherwise specified, generally indicates that the preceding and following related objects have an "or" relationship.

[0038] This application discloses a method for manufacturing a quick-install bathroom component assembly. (Refer to...) Figure 1 and Figure 2 The production methods for bathroom quick-installation assemblies include: Step S100: The quick-assembly base is loaded using the quick-assembly base loading mechanism.

[0039] The quick-release bracket is a core base component in bathroom shower enclosure systems used to connect glass doors to walls or floors. Its surface has multiple pre-drilled mounting holes with specific geometric tolerances to accommodate subsequent fastening components such as threaded sleeves, screws, and pins. The quick-release bracket loading mechanism includes a vibratory feeder sorting unit, a linear vibratory feeding track, and a servo-driven robotic gripper unit. It is also equipped with a visual positioning sensor and a position detection photoelectric switch to identify the quick-release bracket's posture and correct its orientation, ensuring it enters the assembly station with a uniform reference plane orientation.

[0040] Step S101: Press the first threaded sleeve into the first mounting hole of the quick-release seat through the threaded sleeve installation mechanism, and press the second threaded sleeve into the second mounting hole of the quick-release seat.

[0041] A threaded insert is a metal liner used to embed inside a quick-release holder to enhance the strength of the threaded connection. A threaded insert mounting mechanism refers to a servo press-fitting device, which includes a servo motor, ball screw drive pair, high-sensitivity pressure sensor, and displacement encoder, capable of real-time monitoring of the pressure-displacement curve during the pressing process.

[0042] Step S102: Obtain the pressed-in state of the first and second threaded sleeves on the quick-release seat.

[0043] The pressing state refers to a set of multi-dimensional indicators that characterize the installation quality of the threaded sleeve, including at least the final pressing depth, the peak value of the maximum pressing force, the curve matching degree during the pressing process, and whether there is any tilting or jamming.

[0044] The acquisition process is roughly as follows: First, the main control system calls the data interface to read the complete pressure-displacement curve data recorded for this pressing cycle from the controller of the servo pressing equipment. Then, the measured curve is compared point by point with the standard process window pre-stored in the database. The standard window contains the upper and lower envelopes derived from historical qualified product data statistics. Next, the system executes the feature value calculation logic to extract the endpoint depth value D of the measured curve. actual Peak pressure F maxand the area S of the curve integral area And these feature values ​​are respectively compared with the preset qualified threshold range ([D min D max ]、[F min ,F max The comparison results are then compared and judged. Finally, a status identifier is generated by combining the comparison results. If all feature values ​​fall within the qualified window and the curve shape does not have any abnormal sudden changes (such as an abnormal pressure drop indicating slippage), the pressing status is judged as "test passed". Otherwise, it is judged as "test failed" and the specific abnormal type code is recorded (such as E01-insufficient depth, E02-pressure over-limit).

[0045] For example, if the system reads that the insertion depth of the first threaded sleeve is 9.95mm (standard range 9.9-10.1mm) and the maximum pressure is 780N (standard range 750-850N), and the curve is smooth without jitter, it is marked as "passed"; if the depth of the second threaded sleeve is only 9.5mm, it is marked as "failed" and the reason is noted as "depth not up to standard".

[0046] In step S103, when the pressing state is detected as passed, the quick-release plate is placed on the top of the quick-release seat by the quick-release plate feeding mechanism, so that the first connecting hole of the quick-release plate corresponds to the first threaded sleeve and the second connecting hole corresponds to the second threaded sleeve.

[0047] A quick-release tray is a cover-like part that covers the quick-release base and has a first connecting hole and a second connecting hole that strictly correspond to the position of the threaded sleeve. The quick-release tray loading mechanism includes an automated unit consisting of a hopper, a lifting device, and a multi-axis transfer robot, and also has a high-precision vision alignment function.

[0048] When step S102 determines the pressing status as "detection passed", the general process is as follows: The main control system first sends a release command to the quick-assembly tray feeding mechanism. Then, the lifting device of the quick-assembly tray feeding mechanism pushes out a quick-assembly tray from the hopper, which is then picked up by the transfer robot. The robot carries the quick-assembly tray to the top of the quick-assembly base. At this time, the laser displacement sensor or vision camera installed at the end of the robot performs secondary precise positioning of the threaded sleeve hole position on the quick-assembly base and calculates the compensation offset. Finally, the robot adjusts its posture according to the compensation amount and slowly lowers the quick-assembly tray until the bottom surface of the quick-assembly tray is in contact with the top surface of the quick-assembly base, and the first and second connecting holes are precisely fitted onto the first and second threaded sleeves, completing the stacking assembly.

[0049] When step S102 determines the pressing status as "detection failed," the general process is as follows: The main control system immediately interrupts subsequent feeding instructions and triggers the exception handling subroutine. First, it controls the audible and visual alarm to issue a warning signal, and displays the specific fault code and location information on the human-machine interface (HMI). Then, it controls the production line to pause or skip the current workstation, drives the rejection robot to pick up the quick-release seat containing the defective screw sleeve from the positioning fixture, and puts it into the designated rework area or scrap collection box. The system records detailed data of this non-conforming event (such as timestamp, defect type, operator ID) to the local log and uploads it to the cloud quality traceability system.

[0050] For example, if the second threaded sleeve is detected to be pressed into the wrong depth, the system will not perform the action of placing the quick-release tray. Instead, it will control the robotic arm to pick up the defective quick-release seat and put it into the "NG" box, prompting "the pressing depth of hole 2 is abnormal" to avoid assembling the defective part.

[0051] In step S104, the first screw is screwed into the first connecting hole and the first threaded sleeve in sequence using the screw installation mechanism, and the second screw is screwed into the second connecting hole and the second threaded sleeve in sequence.

[0052] The first and second screws refer to standard fasteners used to lock the fasteners in place. The screw mounting mechanism refers to a fully automatic intelligent tightening shaft system that integrates a servo motor, a high-precision torque sensor, and an angle encoder.

[0053] Step S105: Obtain the screw-in state of the first screw and the second screw.

[0054] The screw-in condition refers to a comprehensive evaluation index that reflects the reliability of the screw connection, including at least the final torque value, tightening angle, tightening time, curve slope characteristics, and whether there are defects such as stripping, floating, or cross-slot slippage.

[0055] The acquisition process is roughly as follows: The system receives the end signal from the tightening shafts of the two screws and retrieves their respective complete tightening curves (a sequence of torque changes with angle / time). The system then compares the measured curves with a standard template, focusing on three key areas: the initial climb slope (to determine if there is misalignment), the linearity of the middle section (to determine the thread fit), and the stability of the torque plateau at the end. Next, a logical judgment algorithm is executed. If the measured final torque is within the range of [Tmin, Tmax], and the total rotation angle is within the range of [θmin, θmax], and the curve has no abnormal breaks or oscillations, the screw tightening status is determined to be "qualified". Only when the judgment results for both the first and second screws are "qualified" does the system mark the overall tightening status as "test passed"; otherwise, it marks it as "test failed," identifying the specific faulty screw number and the cause of the abnormality.

[0056] In step S106, when the screw-in state is in the detection pass state, the pin head is placed in the expansion column hole of the quick-release seat by the pin head feeding mechanism, and then the pin shaft is inserted into the connecting column hole of the quick-release plate and the expansion column hole of the quick-release seat by the pin shaft feeding mechanism, and locked with the pin head.

[0057] A pin head refers to a base insert with an elastic expansion structure, containing a hollow cavity or slit. It expands radially under pressure to achieve self-locking. A pin shaft refers to a rigid metal rod inserted into the pin head to expand it, forming a mechanical interlock. Expansion pin holes and connecting pin holes refer to aligned through holes located on the quick-release base and quick-release plate, respectively. Locking refers to the process where, after the pin shaft is inserted, the pin head deforms to fill the gap in the hole wall, and the resulting friction and mechanical interlocking force prevents the components from separating.

[0058] When step S105 determines the screw-in status as "detection passed," the general process is as follows: The system activates the pin assembly unit. Subsequently, the vibratory feeder of the pin feeding mechanism sorts the pins and sends them to the insertion station. The robotic arm grasps the pins and precisely presses them into the pre-reserved expansion pin holes in the quick-release base, ensuring that the top surface of the pin is flush with the base surface. The pin feeding mechanism transports the pins to the guide sleeve. A pneumatic pusher or servo press pushes the pins downward, causing them to pass sequentially through the connecting pin holes on the quick-release plate and the center holes of the already installed pins. During the downward movement of the pins, the pins undergo elastic deformation under radial compression, tightly fitting the hole wall. When the pins reach the preset depth, the advancement stops, completing the mechanical locking. Finally, the sensor detects the height position of the pins, confirming that the locking is in place.

[0059] When step S105 determines the screw-in state as "inspection failed," the general process is as follows: The system prohibits the pin assembly action and initiates the defective product handling process. First, the current tightening axis is locked to prevent accidental operation, and the location of the defective screw is highlighted on the operation screen. Then, the rework robot or manual assistance device is controlled to transfer the current semi-finished product to the rework station. If it is determined to be an irreparable serious defect (such as stripped thread on the screw sleeve), the workpiece is directly rejected to the scrap area to prevent products with loose screws from entering the final locking process.

[0060] Step S107: Move the assembled quick-assembly assembly to the material tray.

[0061] A quick-assembly assembly refers to the final product that has completed all the above-mentioned processes, including loading, pressing, screwing, and pinning, and possesses complete structural functions and connection performance. A tray refers to a standardized container used to hold, isolate, and transfer finished products, with independent grooves or limiting compartments to prevent finished products from colliding and scratching each other during transportation.

[0062] Reference Figure 3 The steps to determine whether the screw-in state detection has passed include: Step S200: Obtain the screw-in state of the first screw and output the first detection state.

[0063] The screw-in state of the first screw refers to the set of multi-dimensional quality characteristics collected throughout the tightening process of the screw installed in the first connecting hole of the quick-release assembly, including the final torque value, tightening angle, tightening time, curve fit, and whether there are defect marks such as stripping, floating, or cross-slot slippage. The first detection state refers to the discretized result identifier generated after processing by the system's internal judgment algorithm, which is usually in the form of a numeric code or Boolean value, such as "1" or "PASS" to represent qualified, and "0" or "FAIL" to represent unqualified.

[0064] Step S201: Obtain the screw-in state of the second screw and output the second detection state.

[0065] The screw-in state of the second screw refers to the set of quality characteristics independently collected and evaluated for the screw installed in the second connecting hole position of the quick-assembly assembly. The evaluation dimensions are consistent with those of the first screw, based on the specific process parameters of the second screw sleeve and the second connecting hole (different torque or angle thresholds are set depending on the position). The second detection state refers to the discrete result identifier independently generated for the second screw, which is independent of the first detection state and does not interfere with each other. It is used to characterize the assembly quality of the second connection point separately.

[0066] Step S202: When both the first and second detection states are qualified, the screwing-in state of the first screw and the second screw is determined to be qualified.

[0067] "Both are qualified" means that the logic values ​​of the first and second inspection states are both True, indicating that there are no defect markers in the quality assessment results of both connection points. "Inspection passed" means that both double-screw connections meet the design requirements and are ready to proceed to the next assembly process. This is the system's final release instruction for the screw tightening process of the entire quick-assembly assembly.

[0068] The general process is described as follows: The main control logic unit simultaneously reads the values ​​of two variables, "first detection status" and "second detection status," from shared memory. Then, it performs an AND operation to determine if the condition (Status1 == PASS) AND (Status2 == PASS) is true. If the result of this logical expression is true, it indicates that the installation quality of both screws is under control, and the system generates a "detection passed" flag. Next, the system sends a "process completed, allow flow" signal to the production line control PLC, unlocking the interception mechanism at the downstream station and allowing the robot arm to perform subsequent pin loading and pin insertion actions.

[0069] For example, when the system reads that the first detection status is "PASS" and the second detection status is also "PASS", the logic gate outputs a high level, determining that the overall screw-in status is "detection passed", the production line continues to run, and the robot begins to grab the pin head for the next assembly step.

[0070] Step S203: When either the first detection state or the second detection state is unqualified, the screw-in state of the first screw and the second screw is determined to be unqualified.

[0071] "Any of the two is unqualified" means that at least one variable in the first and second inspection states is false, including three scenarios: "first unqualified and second qualified", "first qualified and second unqualified", and "both unqualified". A failed inspection indicates that the product has potential quality issues and must be intercepted and prohibited from entering subsequent processes. This is a rejection instruction issued by the system for the entire screw tightening process to prevent the accumulation of defects.

[0072] The general process is as follows: The main control logic unit simultaneously reads the values ​​of two variables, "first detection status" and "second detection status," from shared memory, and then performs a logical "OR" operation, that is, it judges whether the condition (Status1==FAIL)OR(Status2==FAIL) is true. If the result of this logical expression is true, it indicates that at least one screw is not installed properly, and the system immediately generates a "overall inspection failed" flag and triggers an exception handling process (such as stopping the machine, alarming, and rejecting the workpiece); if the result is false (that is, both statuses are PASS), it is determined that "inspection passed."

[0073] For example, if the first detection status is "PASS" and the second detection status is "FAIL", the logical expression result is true, the system determines the overall screw-in status as "detection failed", immediately stops the machine and prompts "screw No. 2 is unqualified".

[0074] Reference Figure 4 The steps for obtaining the screw-in state of the first screw and the second screw include: Step S300: Real-time acquisition of the torque change curve of the screw during the screwing process.

[0075] The torque variation curve refers to a dynamic function image composed of a series of discrete data points (Ti,θi) or (Ti,ti) continuously collected and recorded by a high-precision torque sensor over the entire time or angle domain from the moment the screw begins to contact the workpiece surface until it is finally tightened. Here, T represents the real-time torque value, θ represents the cumulative rotation angle, and t represents time.

[0076] The general process is as follows: When the servo motor of the screw mounting mechanism starts and begins to rotate, the system triggers a data capture interrupt, initializes an empty data buffer to store the upcoming sequence data, and then, within each microsecond-level time slice of screw insertion, the torque sensor converts the resistance it senses into an analog voltage signal, which is quantized into a digital torque value by an A / D converter. Simultaneously, the angle encoder outputs the current cumulative rotation angle. The system packages these two values ​​into a data pair (T, θ) and appends it to the buffer. As the screw continues to screw in and the data accumulates, the system dynamically plots a continuous curve rising from zero in memory, fully recording the characteristics of the initial climbing segment, the linear growth segment in the middle segment, and the yield plateau segment at the end of the thread engagement. Finally, when the tightening shaft receives a stop signal (such as reaching the preset cutting torque or angle), data capture ends, and the system encapsulates the complete timing data into an object, defined as the current screw's "torque change curve," and passes it to the subsequent analysis module.

[0077] Step S301: Compare the torque change curve with the preset standard torque window. When the torque curve reaches the target torque value within the preset angle range, the test status is determined to be qualified.

[0078] The standard torque window refers to the upper limit envelope T in the torque-angle coordinate system. upper (θ) and a lower bound envelope T lower (θ) represents a closed region, which is a pass / fail criterion constructed based on the statistical distribution of a large number of historical qualified samples. The preset angle range refers to the effective angle interval [θ] within which the target torque should occur, as set according to process requirements. start ,θ end This is used to rule out abnormal situations where the torque is reached too early or too late. The target torque value refers to the standard value T of the final tightening torque specified in the process specification. target and its allowable tolerance zone [T] min ,T max ].

[0079] The general process is described as follows: The analysis module loads a standard torque window model pre-stored in the database. This model defines the legal upper and lower limits of torque values ​​under different rotation angles. Then, the system maps the measured torque change curve obtained in step S300 point by point to the same coordinate system, executes a full-path inclusion detection algorithm, and determines whether each data point (Ti, θi) on the measured curve satisfies Tlower(θi) ≤ Ti ≤ Tupper(θi). The system focuses on monitoring the curve within the preset angle range [θi]. start ,θ end Within the range, check if a certain angle point θ exists. k This makes the corresponding torque value T kFalling into the target torque range [T min ,T max The curve shows a stable plateau or downward trend after this point (indicating that it is in place). If the measured curve does not exceed the window boundary throughout the entire process and successfully reaches the target torque value within the specified angle range, the assembly process of the screw is determined to be fully controlled, generating a "qualified" test result. At the same time, the system records the confidence score of this matching as a basis for quality traceability.

[0080] For example, the preset standard window requires the torque to reach 5.0 ± 0.3 N·m between 30 and 40 degrees of rotation. The system detected that the measured curve showed a torque of 5.1 N·m at 35 degrees, and the entire curve (from 0 to 45 degrees) remained within the upper and lower limit envelopes without any boundary violations. Therefore, the detection status was determined to be "qualified".

[0081] Step S302: When the torque curve exceeds the preset angle range and still fails to reach the target torque value or the torque peak value is abnormal, the detection status is determined to be unqualified.

[0082] The target torque value has not been reached even when the preset angle range has been exceeded, meaning the screw has rotated beyond the maximum permissible angle θ. end (e.g., exceeding 45 degrees), but the real-time torque value is still lower than the target lower limit T. min This usually indicates a stripped thread, insufficient insertion of the threaded insert, a broken screw, or a screw made of an excessively hard material that prevents tightening. Abnormal peak torque refers to unexpected and drastic fluctuations in the torque curve during screwing, including peak torque far exceeding the upper limit (overtightening / jamming), a sudden drop in torque (broken screw / stripped thread), or a curve shape that deviates significantly from the standard window (such as multiple sawtooth oscillations).

[0083] When an angle exceeds the limit and fails to meet the standard, the general process is as follows: The system monitors the cumulative rotation angle in real time. When the angle value θ is detected... current >θ end When the maximum permissible angle is preset, immediately check the current real-time torque value T. current If T at this time current <T min If the target torque lower limit is exceeded, it is judged as an "angle exceeding the limit and not meeting the standard" defect, and the system marks this state as "unqualified" and sets the error code to "ERR_UNDER_TORQUE". This usually means that the screw is spinning freely in the hole or the thread fit is ineffective, and an effective preload cannot be established.

[0084] When an abnormal torque peak occurs, the general process is as follows: During curve comparison, the system calculates the rate of change of torque (slope dT / dθ) and extreme points in real time. If the torque value instantaneously exceeds the upper limit envelope T before reaching the target angle... upperIf the torque value (θ) remains unchanged, it is considered an "overtight / jammed" anomaly. If the torque value suddenly drops from a high level to near zero or an extremely low value during screwing (the drop exceeds a preset threshold, such as 50%), it is considered an "broken screw / stripped thread" anomaly. If the curve exhibits irregular high-frequency oscillations and the envelope matching degree is lower than a preset threshold (such as <80%), it is considered an "thread damage / foreign object" anomaly. If any of the above situations occur, the system will immediately mark the status as "unqualified" and record the specific anomaly type code (such as "ERR_OVER_PEAK" or "ERR_DROP").

[0085] Once a defect is determined to be "unqualified," the system immediately executes the following blocking and handling logic: 1. Immediate shutdown protection: Sends an emergency stop command to the servo driver to prevent the equipment from forcibly tightening, which could lead to complete damage to the workpiece or tool wear. 2. Defect location and alarm: Highlights the abnormal torque curve segment on the HMI screen, marking its deviation from the standard window with a red dashed line, visually indicating whether it is "insufficient angle" or "excessive peak value," and announces the specific cause of the fault via voice. 3. Automatic rejection or rework decision: For "angle exceeding the limit and not meeting the standard" (suspected stripping), the system determines it as irreversible damage and directly controls the robot to grab the workpiece to the scrap area, avoiding attempts to rework and scrapping the screw sleeve; for minor "peak value abnormalities" (such as recovery after a brief pause), if the system is equipped with an intelligent retry function, it can try to unscrew the screw in reverse, clean the threaded hole, and re-tighten it. If the second inspection is still unqualified, a rejection operation is performed. 4. Data Encapsulation: The complete torque curve, anomaly type, occurrence time, and workstation information of the non-conformance are packaged and uploaded to the quality server, triggering an SPC (Statistical Process Control) warning. If similar anomalies occur repeatedly, the engineer is automatically notified to check the bit wear or the quality of the material batch.

[0086] Reference Figure 5 The step of obtaining the screw-in state of the first screw and the second screw further includes: Step S400 divides the screw-in process into an initial contact stage and a tightening stage.

[0087] The initial contact phase refers to the transition process from the start of screw rotation to the initial tight contact between the screw head and the workpiece surface, where the torque slowly increases with the angle. This phase is used to eliminate assembly gaps, correct screw posture, and confirm proper thread engagement. The tightening phase refers to the final locking process after the screw completes surface contact, continuing to rotate until the preset target torque or angle is reached. The torque increases rapidly with the angle, either linearly or non-linearly, and is used to establish effective axial preload. Segmentation refers to the process by which the control system, based on real-time acquired torque-angle curve feature points (such as torque slope abrupt change points, torque absolute value threshold points, or timestamps), logically divides the continuous tightening data stream into two independent data subsets.

[0088] The general process is described as follows: When the tightening program is started, the system initializes a "two-stage state machine" and sets a dynamic "stage switching threshold" T. switch (e.g., 0.5 N·m) or “switching angle threshold” θ switch (For example, 15 degrees), this threshold is pre-calibrated based on screw specifications and workpiece material. Subsequently, during screw insertion, the system monitors the torque value T in real time. current The change when T current <T switch And the rotation angle θ < θ switch At this time, the state machine remains in the "initial contact phase" flag, and the data collected at this time is marked as Dataset. contact Once T is detected current ≥T switch or ≥θ≥θ switch (Based on the first condition met), the state machine immediately jumps to the "tightening stage" flag, and the data collected thereafter is marked as Dataset. tighten Continue tightening until the process is complete. Finally, the system logically divides the complete torque curve into two independent sequences in memory, and passes them to the corresponding stage evaluation modules for parallel or serial processing, ensuring that the process requirements of the two stages are independently verified.

[0089] For example, for M6 screws, the system sets 0.6 N·m as the switching point. When the torque increases from 0 to 0.5 N·m, the data is assigned to the "initial contact stage". When the torque exceeds 0.6 N·m, the subsequent data is assigned to the "tightening stage", thus achieving decoupled analysis of the two physical processes of "alignment" and "locking".

[0090] Step S401: In the initial contact stage, the torque change curve of the screw is acquired in real time, and the torque change curve is compared with the preset initial contact torque window. When the torque value reaches the initial contact torque value within the preset angle range, the initial contact stage is deemed qualified.

[0091] The initial contact torque window refers to the low torque range (e.g., 0 to T). switch Within this range, the allowable torque-angle fluctuation range, statistically derived from qualified samples, is used to identify whether the screw is misaligned, the thread is misaligned, or there is obstruction from foreign objects. The preset angle range refers to the maximum allowable rotation angle interval [θmin] during the initial contact phase. contact ,θmax contact This is used to limit freewheeling or premature contact. The initial contact torque value refers to the characteristic torque point T at which the screw is determined to be correctly engaged with the workpiece surface. seat This corresponds to the inflection point where the slope of the torque curve changes significantly.

[0092] The general process is described as follows: First, the evaluation module extracts the Dataset.contact A subset of data is loaded in the torque-angle coordinate system with a preset initial contact torque window envelope (including the upper limit Tupper). contact (θ) and lower bound Tlower contact (θ)). The system then matches the measured contact section curve point by point with the window, focusing on two indicators: first, whether the curve shape is smooth and within the window (excluding sawtooth oscillations, indicating smooth thread engagement); second, whether the curve is within the preset angle range [θmin]. contact ,θmax contact The characteristic torque value T was successfully reached within [time period]. seat (That is, the inflection point where the curve slope changes from gentle to steep). If the measured curve does not exceed the window boundary throughout its entire length, and the expected slope abrupt change point appears within the specified angle (indicating that the screw is properly aligned with the workpiece), then the "initial contact stage" is deemed qualified, and the angle value θ at this time is recorded. seat This serves as the starting point for the next stage. If the curve reaches the torque too early (possibly due to encountering foreign objects) or too late (possibly due to misaligned threads), it is considered unqualified.

[0093] For example, the system requires that the torque should smoothly increase to 0.6 N·m between 5 and 15 degrees of rotation. If the measured curve smoothly reaches 0.6 N·m at 10 degrees without any jitter, the initial contact is considered qualified; if the curve spikes to 0.6 N·m at 2 degrees (possibly hitting the edge of the hole), or fails to reach 0.6 N·m at 20 degrees (possibly stripping the thread), it is considered unqualified.

[0094] Step S402: During the tightening stage, the torque change curve of the screw is acquired in real time, and the torque change curve is compared with the preset tightening torque window. When the torque value reaches the target torque value within the preset angle range, the tightening stage is deemed qualified.

[0095] The tightening torque window refers to the high torque range (T). switch To T target Within this range, a high-precision torque-angle allowable range, statistically derived from material yield characteristics and friction coefficients, is used to ensure the accuracy of the preload. The target torque value refers to the final locking torque T specified in the process specification. final and its tolerance zone. The preset angle range refers to the angle from the contact point θ. seat Initially, the additional rotation angle increment range [Δθ] allowed by the target torque is reached. min ,Δθ max This is used to monitor whether the bolt elongation is normal.

[0096] The general process is described as follows: First, the evaluation module extracts the Dataset. tighten A subset of data, and the actual contact point θ determined in step S401. seatFor the new zero point, reconstruct the relative angle coordinate system. Subsequently, load the preset tightening torque window envelope, which strictly defines the curve trend from the contact point to the target torque point (usually linear or a specific power function relationship). The system compares the measured tightening curve with the window over the entire path. The core judgment logic is whether the measured curve is always between the upper and lower envelope lines and whether, within the relative rotation angle Δθ ∈ [Δθ min , Δθ max , the torque value accurately reaches T final ±ΔT. If the above conditions are met, it indicates that the screw has established a qualified pre-tightening force at the correct elongation, and the "tightening stage" is determined to be qualified. If the curve reaches the target torque but the angle is too small (too hard / stuck) or too large (too soft / stripped), or if there is an abnormal drop in the curve midway, it is determined to be unqualified.

[0097] For example, starting from the contact point, the system requires an additional rotation of 30 - 40 degrees to reach 5.0 N·m. If the measured curve accurately reaches 5.0 N·m at a rotation of 35 degrees and the trend conforms to the window, the tightening stage is determined to be qualified. If it only reaches 5.0 N·m after a rotation of 10 degrees (indicating that the base is not tightly pressed or there is thread interference), it is determined to be unqualified.

[0098] Step S403, when both the initial contact stage and the tightening stage are qualified, determine that the screwing state of the screw is qualified.

[0099] Both being qualified refers to the logical state where the "initial contact stage determination result" output by step S401 and the "tightening stage determination result" output by step S402 are both "PASS" simultaneously. The screwing state being qualified refers to the comprehensive quality certification of the screw throughout its entire assembly life cycle, meaning that the screw is correctly meshed (without misalignment or skew), the final locking force meets the standard, and it has reliable connection performance.

[0100] Step S404, when any stage is unqualified, determine that the screwing state of the screw is unqualified.

[0101] Any stage being unqualified refers to the logical state where the "initial contact stage determination result" is "FAIL" or the "tightening stage determination result" is "FAIL", or both are "FAIL". The screwing state being unqualified refers to the system's veto determination of the screw assembly quality, meaning that there is a potential risk of connection failure in the product (such as loose connection, stripped thread, fracture, etc.), and it must be intercepted.

[0102] The general process is as follows: First, the main control logic unit performs a logical "OR" operation, that is, checks whether the expression (Result_Contact==FAIL) OR (Result_Tighten==FAIL) is true. If the result is true, the system immediately locks the current screw into the "unqualified" state and generates a differentiated fault code (such as "ERR_CONTACT_FAIL" or "ERR_TIGHTEN_FAIL") according to the specific stage of failure.

[0103] The system then executes precise handling strategies based on the fault type: 1. Differentiated alarms: If the initial contact stage is unqualified (e.g., misaligned threads, skewed threads), the system determines it as a structural damage risk and immediately issues a "thread damage" alarm, warning against forced tightening to prevent damage to the quick-release sleeve; if the tightening stage is unqualified (e.g., insufficient torque, out-of-tolerance angle), the system issues a "preload abnormality" alarm, indicating that the screw strength may be insufficient or the tool precision may be off. 2. Automatic blocking and diversion: The system immediately stops the current tightening axis movement; if tightening is in progress, the screw is unscrewed in the opposite direction (if misaligned threads are detected, the screw is stopped immediately to prevent further damage); the robotic arm is controlled to pick up the unqualified workpiece and place it in a specific "rework area" or "scrap area." Workpieces with initial contact failure (severe misaligned threads) are directly deemed scrapped because the sleeve may be damaged. Workpieces with only minor abnormalities in the tightening stage (e.g., slightly low torque) can be sent to the rework station, where the robot automatically re-executes a complete "contact + tightening" process. 3. Data traceability and SPC early warning: Record the specific stage of failure, the torque / angle value at the time of failure, and the curve shape screenshot, and upload them to the MES system; if multiple "initial contact stage failures" occur consecutively, the system will automatically trigger an SPC early warning, prompting you to check the vibratory feeder feeding posture or the screw sleeve pressing quality; if "tightening stage failures" occur consecutively, it will prompt you to check the tightening shaft calibration or the hardness of the screw batch.

[0104] Reference Figure 6 The calculation steps for the preset initial contact torque window and tightening torque window include: In step S500, the preset initial contact torque window and tightening torque window are dynamically adjusted according to the material hardness value of the screw.

[0105] Material hardness value (H) mat The initial contact torque window and the tightening torque window refer to two sets of dynamic threshold ranges that scale linearly or nonlinearly with the hardness value. They are used to monitor the smoothness of engagement during the screw starting stage and the accuracy of the preload during the final tightening stage, respectively.

[0106] Step S501, the preset formula for calculating the initial contact torque window is: Tinitial =T base ×(H mat / H ref ).

[0107] T initial This refers to the target torque value (or window center value) during the initial contact stage after dynamic calculation, in N·m. base Refers to the standard reference hardness H ref The calibrated reference initial contact torque value, determined through extensive process testing, represents the theoretical torque required for the screw head to adhere to the workpiece surface under standard material conditions. H mat This represents the actual hardness value of the screw's material. H ref This is a preset reference hardness value (constant). (H) mat / H ref This refers to the hardness correction factor, which reflects the ratio of the current material's hardness to that of a standard material.

[0108] The control algorithm extracts the baseline initial contact torque T from the database. base (For example, set to 0.5 N·m) and reference hardness H ref (For example, set to HV240). Then read the screw hardness Hmat of the current batch (for example, measured as HV288). Perform floating-point arithmetic, first calculate the ratio R = 288 / 240 = 1.2, indicating that the current screw is 20% harder than the standard sample, then multiply the reference torque by this ratio T. initial =0.5 × 1.2 = 0.6 N·m. Finally, based on the calculated T... initial The initial contact torque window is typically set to [T]. initial ×(1−δ1),T initial [×(1+δ1)], where δ1 is the allowable relative tolerance zone (e.g., ±10%), thus obtaining the dynamic window [0.54, 0.66] N·m. This window will serve as the sole basis for determining whether the initial contact is qualified in step S401.

[0109] For example, if a batch of screws has a lower hardness (H) mat =200), calculate T initial =0.5×(200 / 240)≈0.42N·m. The system automatically lowers the qualified window to 0.38-0.46N·m to prevent misjudgment as "not in contact" or "slipped" due to the softness of the material and low friction.

[0110] Step S502, the preset tightening torque window calculation formula is: Ttight=Tbase×(Hmat / Href)×C. Where, Tbase is the base torque value, Hmat is the hardness value of the screw material, Hreff is the reference hardness value, and C is the preset stage coefficient.

[0111] T tight This refers to the target torque value (or window center value) of the tightening stage after dynamic calculation. C is the preset stage coefficient, a dimensionless constant, usually C>1, used to characterize the torque amplification factor required to establish the thread helix angle, friction accumulation, and axial preload during the process from "initial contact" to "final tightening". This coefficient is determined by the thread specification, pitch, and lubrication conditions, and the meanings of the other variables are the same as above.

[0112] The general process is described as follows: The algorithm first reuses the calculated hardness correction factor (H) mat / H ref and reference torque T base (T here) base This can refer to the base calibration value or share the same reference with the initial contact, depending on the specific process definition; it usually refers to the base torque contribution per unit hardness. Then, a pre-set stage coefficient C for the current screw size is applied (e.g., for an M6 coarse thread screw, C might be set to 10.0, meaning the final tightening torque is approximately 10 times the contact torque). Perform a multiplication operation T. tight =T base ×(H mat / H ref The physical meaning of this formula is that the final locking torque is not only proportional to the material hardness (the higher the hardness, the greater the friction, and the greater the required torque), but also needs to be multiplied by a specific stage amplification factor to achieve the designed preload. Finally, based on the calculated T... tight Construct a tightening torque window and set it to [T] tight ×(1−δ2),T tight [×(1+δ2)], where δ2 is the allowable tolerance during the tightening stage (usually stricter than the contact stage, such as ±5%), generating the final dynamic judgment range.

[0113] For example, let T base =0.5 N·m, H mat / H ref =1.2, C=10, then the calculated T tight =0.5×1.2×10=6.0N·m. Based on this, the system generates a dynamic acceptable range of 5.7-6.3N·m. If this formula is not used and a fixed standard of 5.0N·m is applied instead, this batch of high-hardness screws will be misjudged as having "excessive torque" or failing to meet the true preload requirement.

[0114] In addition, to ensure the robustness of the calculation, the system includes the following verification logic before executing the above formula: 1. Data validity verification, if the read H mat1. If the value is empty, zero, or exceeds the range of physical common sense (e.g., HV<50 or HV>1000), the system determines the hardness data to be invalid, immediately suspends production, issues a "material attribute missing" alarm, and forces the use of a conservative default safety window (usually taking 80% of the lower limit) for temporary production or directly stops the machine to await manual confirmation, preventing batch accidents caused by incorrect parameters. 2. Coefficient C matching check: The system automatically matches the corresponding C value library based on the currently selected screw model (e.g., M4 / M6 / M8). If an undefined or abnormal C value is found, calculation is prohibited and the engineer is prompted to update the process library. 3. Smooth window transition: If the production line is in a mixed material transition period (e.g., the previous batch was low hardness, the next batch is high hardness), when the system detects a hardness jump, it can use a "dual-window parallel judgment" strategy for the first few screws (i.e., simultaneously satisfying the old and new windows or taking the union), gradually transitioning to the new window to avoid misjudgment of the first piece. 4. Recording and traceability: The process data of each window calculation (input H...) is recorded. mat The C value used, the calculated T initial and T tight All of these are recorded in the shift production log and linked to the tightening curve of each product produced in that batch, achieving refined quality traceability with a "one product, one policy" approach.

[0115] Reference Figure 7 The steps for obtaining the pressed-in state of the first and second threaded sleeves on the quick-release seat include: Step S600 divides the threaded sleeve pressing process into an initial pressing stage and a depth confirmation stage.

[0116] The initial pressing stage refers to the transition process from when the pressing head contacts the top of the threaded sleeve until the sleeve is fully inserted into the base orifice and the initial gap is eliminated. The depth confirmation stage refers to the locking process where the threaded sleeve continues to descend after passing the orifice resistance peak until it reaches the final designed position. The division refers to the control system using real-time acquired "displacement-angle" curve feature points (such as pressure peak points or preset transition angles θ). switch In software logic, this is the process of dividing a continuous press data stream into two independent data subsets.

[0117] The general process is described as follows: When the system starts the pressing program, it initializes the "two-stage state machine" and sets the stage switching threshold to a preset angle θ. switch (For example, 10°), and then during the pressing process, the system monitors the displacement value S output by the displacement sensor in real time. current The rotation angle θ output by the angle encoder current When θ current <θ switch At this point, the state machine is marked as the "initial push phase," and the collected data is stored in the Dataset. initial When θ current ≥θ switchWhen this happens, the state machine immediately jumps to the "depth confirmation stage", and the data collected thereafter is stored in Dataset depth Finally, the system logically cuts the complete press-fitting curve according to the angle range and transfers it to the attitude evaluation module and the depth accuracy evaluation module respectively.

[0118] For example, if the system sets the preset angle range for the initial press-in stage to be from 0° to 10°, when the rotation angle of the bushing exceeds 10°, it automatically switches to the depth confirmation stage.

[0119] Step S601, in the initial press-in stage, the displacement curve of the bushing press-in is obtained in real time, and the displacement curve is compared with the preset initial press-in displacement window. When the displacement value reaches the initial press-in displacement value within the preset angle range, it is determined that the initial press-in stage is qualified.

[0120] The preset angle range refers to the allowable change interval of the rotation angle of the bushing preset by the system in the initial press-in stage (such as 0° to 10°), which is used to limit the timing when the displacement value reaches the initial press-in displacement value. The initial press-in displacement value refers to the theoretical displacement value that the bushing should reach in the initial contact stage (such as 2.0 mm), and this value is determined through process tests.

[0121] The general process is described as follows: The system first obtains the displacement curve of the bushing press-in in real time in the initial press-in stage. This curve uses the rotation angle as the abscissa and the displacement as the ordinate. Subsequently, the measured displacement curve is compared with the preset initial press-in displacement window. The system determines whether the measured displacement value reaches the initial press-in displacement value (such as 2.0 mm) within the preset angle range (such as 0° to 10°). If the condition is met, it is determined that the initial press-in stage is qualified; otherwise, it is determined as unqualified.

[0122] For example, the system preset angle range is 0° to 10°, and the initial press-in displacement value is 2.0 mm. When the displacement value reaches 2.0 mm at a bushing rotation angle of 5°, it is determined as qualified; if the displacement value reaches 2.0 mm at 15° (beyond the preset angle range), it is determined as unqualified.

[0123] Step S602, in the depth confirmation stage, the depth value of the bushing press-in is obtained in real time, and the depth value is compared with the preset depth threshold.

[0124] The depth value refers to the final vertical distance of the top surface of the bushing relative to the reference surface of the quick-mounting seat when the press-fitting is completed. The preset depth threshold refers to the qualified depth reference value dynamically calculated according to the material hardness of the bushing.

[0125] The general process is described as follows: When the press head reaches the end of the stroke and maintains the pressure holding state, the system reads the final stable value of the displacement sensor, which is defined as the depth value D actual. System call depth threshold calculation module (step S603), obtain the dynamically calculated depth threshold D threshold . Compare D actual with D threshold to determine whether the qualified condition is met.

[0126] For example, when the system reads a depth value of 5.10 mm and compares it with the dynamically calculated depth threshold of 5.05 mm, it determines whether it is within the preset range.

[0127] In step S603, the preset depth threshold calculation formula is: D threshold = D base × (H sleeve / H ref ). Where D base is the reference depth value, H sleeve is the hardness value of the bushing material, and H ref is the reference hardness value.

[0128] The general process is described as follows: The system reads the current bushing hardness Hsleeve (for example, HV300) from the material information database, extracts the reference parameters D base = 5.0 mm and H ref = HV250, calculates the hardness correction factor K = 300 / 250 = 1.2, and generates the dynamic target depth D threshold = 5.0 × 1.2 = 6.0 mm, and the final determination window is [5.9, 6.1] mm.

[0129] For example, if the bushing hardness is HV200, then D threshold = 5.0 × (200 / 250) = 4.0 mm, and the system automatically adjusts the qualified range to [3.9, 4.1] mm.

[0130] In step S604, when the depth value is within the preset range, it is determined that the depth confirmation stage is qualified.

[0131] The preset range refers to a dynamic qualified interval formed with D threshold as the center and a floating preset tolerance (such as ±0.05 mm).

[0132] The general process is described as follows: The system compares the depth value D actual with the preset range [D threshold - 0.05, D threshold + 0.05]. If D actual falls within this interval, it is determined that the depth confirmation stage is qualified; otherwise, it is determined to be unqualified.

[0133] For example, D thresholdWhen the thickness is 6.0mm, the depth value of 5.95mm falls within the range of [5.95, 6.05]mm, and is therefore deemed acceptable.

[0134] Step S605: When both the initial pressing stage and the depth confirmation stage are qualified, the pressing state of the screw sleeve is determined to be qualified.

[0135] "Both are qualified" means that the initial pressing stage judgment result is "PASS" and the depth confirmation stage judgment result is "PASS".

[0136] The general process is as follows: The system performs a logical AND operation: if (Result_Initial==PASS)AND(Result_Depth==PASS) is true, a "detection passed" flag is generated, allowing the process to proceed to the next step; otherwise, it is judged as "detection failed".

[0137] For example, if the initial pressing stage is qualified (the displacement value reaches 2.0mm within the preset angle range) and the depth confirmation stage is qualified (the depth value of 5.98mm is within the preset range), the overall pressing status is determined to be "test passed".

[0138] Step S606: If any stage fails to meet the requirements, the screw sleeve pressing state is determined to be a failure to pass the test.

[0139] Failure at any stage means being judged as "FAIL" in the initial push-in stage or the deep verification stage.

[0140] The general process is described as follows: The system executes a logical "OR" operation: if (Result_Initial==FAIL)OR(Result_Depth==FAIL) is true, the "detection failed" state is immediately locked. Then, the exception handling process is triggered: 1. Alarm and shutdown: The three-color indicator light turns red, a buzzer alarm sounds, and the HMI displays the specific fault (e.g., "initial pressing angle exceeds limit" or "insufficient depth"). 2. Automatic handling: If the initial pressing stage is unqualified, the robotic arm is directly controlled to remove the workpiece to the scrap area to avoid damage to the substrate opening; if the depth confirmation stage is unqualified, an attempt is made to repress (only for cases of shallow pressing); if the retest still fails, the workpiece is discarded. 3. Data traceability: The fault type, hardness value, and measured depth are recorded and uploaded to the quality database.

[0141] For example, if the threaded sleeve fails to reach the initial pressing displacement value (2.0mm) within the preset angle range (0°-10°), the initial stage is deemed unqualified, the system immediately stops and puts the workpiece into the scrap bin to prevent the accumulation of defects.

[0142] Reference Figure 8 When the screw sleeve pressing state is determined to be a failure test, the method further includes: Step S700: Based on the abnormal mode of the screw sleeve pressing depth value, automatically adjust the pressing depth parameter of the screw sleeve installation mechanism. The abnormal mode includes the depth value being lower than the preset depth threshold, the depth fluctuation exceeding the preset fluctuation threshold, or the pressing time being abnormal.

[0143] Abnormal depth values ​​refer to three specific defect types that occur during the pressing of the threaded insert: the depth value is lower than the preset depth threshold (indicating that the threaded insert has not been pressed in place), the depth fluctuation exceeds the preset fluctuation threshold (indicating that the pressing process is unstable, such as vibration causing depth jumps), or the pressing time is abnormal (indicating that the pressing speed is too fast or too slow, exceeding the allowable range of the process).

[0144] The general process is described as follows: When step S606 determines that the screw sleeve pressing status is "detection failed," the system immediately triggers the abnormal mode recognition module. The system then analyzes the depth value time-series data of the current pressing process to determine the specific type of abnormality. If the depth value is consistently lower than the preset depth threshold, it is determined to be an "insufficient depth" abnormality; if the depth fluctuation value (standard deviation) exceeds the preset fluctuation threshold, it is determined to be an "excessive fluctuation" abnormality; if the total pressing time exceeds the preset time window, it is determined to be a "time abnormality." The system dynamically generates an abnormality coefficient γ based on the abnormality type. For example, γ takes a positive value (e.g., +0.05) for "insufficient depth" and a negative value (e.g., -0.03) for "excessive fluctuation." Finally, the system substitutes the calculated γ value into the formula of step S701 to generate a new pressing depth parameter D. adjust It is then transmitted in real time to the servo drive unit of the screw sleeve installation mechanism via an industrial bus (such as EtherCAT) to achieve real-time compensation of the pressing depth.

[0145] Step S701, the formula for calculating the indentation depth parameter is: D adjust =D base ×(1+γ), where γ is the anomaly coefficient.

[0146] D adjust This refers to the new indentation depth target value after anomaly compensation. (D) base This refers to the preset baseline indentation depth value for the current batch. γ refers to the correction coefficient dynamically calculated based on the anomaly pattern; its value is determined by the severity of the anomaly and typically ranges from -0.1 to +0.1.

[0147] The general process is described as follows: The system obtains the anomaly coefficient γ from step S700 (for example, γ = +0.05 when the depth is insufficient, and γ = -0.03 when the fluctuation exceeds the limit). Calculate D. adjust =D base ×(1+γ), for example, D base =5.0mm, γ=+0.05, then D adjust =5.0 × 1.05 = 5.25 mm. The system will D adjustThe values ​​are converted into command values ​​(such as pulse count or displacement) that the servo drive can recognize. Finally, the commands are sent to the pressure head control system of the screw sleeve mounting mechanism via a high-precision communication protocol, driving the pressure head to execute the corrected depth parameters during this pressing process.

[0148] Step S702: Based on historical anomaly reports, automatically optimize the preset depth threshold for the next production batch.

[0149] Historical anomaly reports refer to the complete dataset of all abnormal events in the current batch and previous batches stored in the system, including the anomaly pattern, depth value, fluctuation value, pressing time, and corresponding batch ID.

[0150] The general process is as follows: At the end of the current batch, the system automatically summarizes the depth values ​​of all abnormal events and generates a batch-level anomaly statistical report (such as average depth deviation and anomaly frequency). Then, the "batch optimization algorithm" is activated to analyze the distribution trend of historical data. If multiple consecutive batches show "insufficient depth" anomalies, it is determined that the preset depth threshold needs to be increased; if "fluctuation exceeding limits" occurs frequently, the pressing speed parameter needs to be adjusted. The system calculates the optimization coefficient δ based on the statistical results (for example, if the average depth deviation is +0.1mm, then δ=0.02). Finally, the optimization results are written into the process parameter library for the next batch as the preset depth threshold benchmark for the new batch.

[0151] Step S703, the preset depth threshold optimization formula is: D new =D old ×(1-δ), where D old δ is the preset depth threshold for the current batch, and δ is the optimization coefficient.

[0152] D new This refers to the optimized new preset depth threshold. (D) old This refers to the preset depth threshold baseline value for the current batch. δ refers to the optimization coefficient calculated based on historical anomaly frequency and severity; its value is automatically determined by the system and is usually between [0, 0.1].

[0153] The general process is described as follows: The system first extracts the D of the current batch from historical anomaly reports. old (e.g., D) old =5.00mm) and the calculated optimization coefficient δ (e.g., δ=0.025). Then execute the formula calculation: D new =5.00×(1−0.025)=4.875mm. The system will D new The optimized value is written into the batch process parameter table of the MES system and used as the default depth threshold for the next production batch. This optimized value is automatically loaded into the control program of the screw sleeve installation mechanism when a new batch starts, ensuring that the preset depth threshold is continuously optimized with production experience.

[0154] For example, if the current batch D old =5.00mm, historical anomalies show an average depth deviation of +0.12mm (threshold needs to be increased), but the system statistically indicates that the threshold actually needs to be lowered to compensate for elastic rebound, δ=0.025, then D new =4.875mm. The default depth threshold for new batches is automatically lowered by 2.5% to prevent repeated insufficient depth defects.

[0155] Based on the same inventive concept, embodiments of this application provide a production system for quick-install bathroom fixtures, including: The acquisition module is used to acquire the press-in state of the first and second threaded sleeves, and the screw-in state of the first and second screws; A memory for storing a program for a control method of a production system for bathroom quick-installation components as described above; A control method for a production system of bathroom quick-installation parts, wherein the program in the processor and memory can be loaded and executed by the processor and implement any of the above-mentioned functions.

[0156] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0157] This application provides a computer-readable storage medium storing a computer program that can be loaded by a processor and executed to produce a method for manufacturing bathroom quick-installation components.

[0158] Computer storage media include, for example, USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, optical disks, and other media that can store program code.

[0159] Based on the same inventive concept, embodiments of this application provide a smart terminal, including a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed to produce a bathroom quick-installation assembly.

[0160] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0161] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Any feature disclosed in this specification (including the abstract and drawings) may be replaced by other equivalent or similar features unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is only one example of a series of equivalent or similar features.

Claims

1. A method for producing a quick-install bathroom component assembly, characterized in that, include: The quick-assembly base is loaded using the quick-assembly base loading mechanism; The first threaded sleeve is pressed into the first mounting hole of the quick-release seat by the threaded sleeve installation mechanism, and the second threaded sleeve is pressed into the second mounting hole of the quick-release seat. Obtain the press-in state of the first and second threaded sleeves on the quick-release seat; When the press-in state is in the detection pass state, the quick-release plate is placed on the top of the quick-release seat by the quick-release plate feeding mechanism, so that the first connecting hole of the quick-release plate corresponds to the first threaded sleeve and the second connecting hole corresponds to the second threaded sleeve. The first screw is screwed into the first connecting hole and the first threaded sleeve in sequence through the screw installation mechanism, and the second screw is screwed into the second connecting hole and the second threaded sleeve in sequence. Obtain the screw-in state of the first and second screws; When the screw-in state is considered to have passed the test, the pin head is placed in the expansion column hole of the quick-release seat by the pin head feeding mechanism, and then the pin shaft is inserted into the connecting column hole of the quick-release plate and the expansion column hole of the quick-release seat by the pin shaft feeding mechanism, and locked with the pin head. Move the assembled quick-assembly assembly to the material tray.

2. The method for producing a bathroom quick-install component assembly according to claim 1, characterized in that, The steps to determine whether the screw-in state has passed the detection include: Obtain the screw-in state of the first screw and output the first detection state; Obtain the screw-in state of the second screw and output the second detection state; When both the first and second inspection states are qualified, the screwing-in state of the first and second screws is determined to be a successful inspection. If either the first or second detection state is unqualified, the screw-in state of the first and second screws is determined to be a failure.

3. The method for producing a quick-install bathroom component assembly according to claim 2, characterized in that, The steps for obtaining the screw-in state of the first and second screws include: Real-time acquisition of the torque change curve of the screw during the screw-in process; The torque change curve is compared with a preset standard torque window. When the torque curve reaches the target torque value within a preset angle range, the test status is determined to be qualified. If the torque curve exceeds the preset angle range and still fails to reach the target torque value, or if the torque peak value is abnormal, the test status is determined to be unqualified.

4. The method for producing a bathroom quick-install component assembly according to claim 3, characterized in that, The steps for obtaining the screw-in state of the first screw and the second screw also include: The screw-in process is divided into an initial contact stage and a tightening stage; During the initial contact phase, the torque change curve of the screw is acquired in real time and compared with the preset initial contact torque window. When the torque value reaches the initial contact torque value within the preset angle range, the initial contact phase is deemed qualified. During the tightening phase, the torque change curve of the screw is acquired in real time and compared with the preset tightening torque window. When the torque value reaches the target torque value within the preset angle range, the tightening phase is deemed qualified. When both the initial contact stage and the tightening stage are qualified, the screw's screw-in state is considered qualified. If any stage fails to meet the requirements, the screw's screw-in state is deemed unqualified.

5. The method for producing a quick-install bathroom component assembly according to claim 1, characterized in that, The calculation steps for the preset initial contact torque window and tightening torque window include: The preset initial contact torque window and tightening torque window are dynamically adjusted according to the material hardness value of the screw; The preset formula for calculating the initial contact torque window is: T initial =T base ×(H mat / H ref ); The preset tightening torque window calculation formula is: T tight =T base ×(H mat / H ref )×C; Among them, T base H is the reference torque value. mat H represents the hardness value of the screw material. ref f is the reference hardness value, and C is the preset stage coefficient.

6. The method for producing a bathroom quick-install component assembly according to claim 1, characterized in that, The steps for obtaining the pressed-in state of the first and second threaded sleeves on the quick-release bracket include: The threaded sleeve pressing process is divided into an initial pressing stage and a depth confirmation stage; During the initial pressing stage, the displacement curve of the screw sleeve is acquired in real time. The displacement curve is compared with the preset initial pressing displacement window. When the displacement value reaches the initial pressing displacement value within the preset angle range, the initial pressing stage is deemed qualified. During the depth confirmation stage, the depth value of the screw sleeve is acquired in real time and compared with the preset depth threshold. The preset depth threshold calculation formula is: D threshold =D base ×(H sleeve / H ref ); Among them, D base H is the reference depth value. sleeve H represents the hardness value of the threaded sleeve material. ref This is a reference hardness value; When the depth value is within the preset range, the depth confirmation stage is deemed qualified. When both the initial pressing stage and the depth confirmation stage are qualified, the pressing state of the screw sleeve is judged to have passed the test; If any stage fails to meet the requirements, the threaded sleeve pressing state is deemed as failing the test.

7. A method for producing a quick-install bathroom component assembly according to claim 6, characterized in that, When the screw sleeve pressing state is determined to be a failure test, the method further includes: Based on the abnormal patterns of the screw sleeve pressing depth, the pressing depth parameters of the screw sleeve installation mechanism are automatically adjusted. The abnormal patterns include the depth value being lower than the preset depth threshold, the depth fluctuation exceeding the preset fluctuation threshold, or the pressing time being abnormal. The formula for calculating the indentation depth parameter is: D adjust =D base ×(1+γ), where γ is the anomaly coefficient; Based on historical anomaly reports, the preset depth threshold for the next production batch is automatically optimized; The preset depth threshold optimization formula is: D new =D old ×(1-δ), where D old δ is the preset depth threshold for the current batch, and δ is the optimization coefficient.

8. A production system for quick-install bathroom fixtures, characterized in that, include: The acquisition module is used to acquire the press-in state of the first and second threaded sleeves, and the screw-in state of the first and second screws; A memory for storing a program for a control method of a production system for quick-install bathroom components as described in any one of claims 1 to 7; The processor and the program in the memory are capable of being loaded and executed by the processor to implement the control method of the production system for bathroom quick-install parts as described in any one of claims 1 to 7.

9. A smart terminal, characterized in that, It includes a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed according to any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer program is stored that can be loaded by a processor and executed according to any one of claims 1 to 7.

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