Flexible intelligent production line

Abstract

According to the technical scheme, the flexible intelligent production line is characterized in that the flexible intelligent production line comprises at least one mounting plate and a forming module located above the mounting plate, a first flexible tool set and a second flexible tool set are arranged on the mounting plate, and at least one of the first flexible tool set and the second flexible tool set can move along the Y axis; the first flexible tool set and the second flexible tool set are arranged in the X-axis direction so that the distance between the first flexible tool set and the second flexible tool set can be adjusted, each of the first flexible tool set and the second flexible tool set comprises at least one flexible clamp arranged along the X-axis, a mold is connected to the bottom of the forming module, and the forming module drives the mold to move in the vertical direction and extrudes a shape corresponding to a target product on the flexible clamps. According to the invention, the transformation from a single rigid tool to a programmable flexible tool is realized, so that the same set of hardware system can be quickly and accurately reconstructed to adapt to various automobile ornament products with different sizes and shapes, and the universality and flexibility of a production line are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of automotive parts manufacturing technology, and more specifically to a flexible intelligent production line. Background Technology

[0002] As the automotive industry moves towards personalization, customization, and rapid iteration, OEMs' demand for automotive exterior trim (such as bumpers, grilles, side skirts, trim strips, wheel arches, door trim, etc.) is characterized by a wide variety of products, small batches, and high replacement frequency.

[0003] However, traditional automotive trim production lines mostly adopt a rigid automation model, designed for large-volume, single or a few model products. Their equipment layout, tooling fixtures, process flow and control systems are highly specialized, and they mostly use special non-standard fixtures that can only be used to clamp and position trim parts of specific specifications and structures. They have no universal adaptability and can no longer meet the current development of the automotive industry and the supporting needs of OEMs. Summary of the Invention

[0004] To address the above problems, the present invention provides the following technical solution:

[0005] A flexible intelligent production line includes at least one mounting plate and a forming module located above the mounting plate. The mounting plate is provided with a first flexible tooling group and a second flexible tooling group. At least one of the first flexible tooling group and the second flexible tooling group is movable along the Y-axis, so that the distance between them is adjustable. Both the first flexible tooling group and the second flexible tooling group include at least one flexible fixture arranged along the X-axis. The bottom of the forming module is connected to a mold. The forming module drives the mold to move in the vertical direction and press out a shape corresponding to the target product on the flexible fixture.

[0006] The present invention is further configured to include a pin unlocking module, which includes two electric screwdrivers movable along the X-axis. The two electric screwdrivers are located outside the first flexible tooling group and the second flexible tooling group, respectively. When the electric screwdrivers move to the position corresponding to the flexible fixture, they can unlock or lock the shape of the flexible fixture.

[0007] The invention is further configured to include a vision module disposed above the mounting plate, the vision module being movable along the Y-axis, a mark point being disposed on the mounting plate, and the vision module determining the distance it moves by the change in the distance between the first flexible tooling group and / or the second flexible tooling and the mark point.

[0008] The present invention is further configured such that: the ejector pin unlocking module includes two X-axis guide rails, the two electric screwdrivers are respectively mounted on the X-axis guide rails, and at least one of the X-axis guide rails can move along the Y-axis.

[0009] The present invention is further configured such that at least one of the X-axis guide rails is mounted on the transplanting module, the transplanting module including a linear motor arranged along the Y-axis direction, the linear motor driving the X-axis guide rail to move along the Y-axis direction.

[0010] The present invention is further configured such that: a Y-axis tooling guide rail is provided on the mounting plate, the first flexible tooling group and / or the second flexible tooling group are slidably connected to the Y-axis tooling guide rail and locked to the Y-axis tooling guide rail by a clamp, and a movable air supply system is provided for controlling the locking and unlocking of the clamp.

[0011] The present invention is further configured such that: the molding module includes a lifting cylinder located above the mounting plate, the output shaft of the lifting cylinder is vertically downward and fixed with a pressure plate, and the mold is fixed to the bottom of the pressure plate.

[0012] The present invention is further configured to include a workbench, on which a conveyor line flowing along the Y-axis is provided, and a plurality of mounting plates are provided on the conveyor line. Above the conveyor line, the workbench is provided with a spacing adjustment station and a forming station in sequence. The vision module is located at the spacing adjustment station, and the forming module is located at the forming station.

[0013] The invention is further configured such that: a lifting module is provided on the workbench below the conveyor line; when the mounting plate enters the spacing adjustment station or the forming station, the lifting module lifts the mounting plate and separates it from the conveyor line.

[0014] Compared with the prior art, the present invention has at least the following advantages: 1. By adjusting the distance between the first and second flexible tooling groups along the Y-axis to fit the width or length of the target product, the forming module drives the mold to press down, precisely imprinting a positioning shape corresponding to the contour of the target product onto the flexible fixture. This process realizes the transformation from a single rigid tooling to a programmable flexible tooling, enabling the same hardware system to be quickly and accurately reconfigured to adapt to various automotive trim products of different sizes and shapes, significantly improving the versatility and flexibility of the production line.

[0015] 2. By introducing a vision module that can move along the Y-axis and using fixed mark points set on the mounting plate as a reference, the system can measure the distance change between the tooling assembly and the reference in real time and non-contactly. This vision measurement result is directly used to determine whether the actual movement distance of the tooling matches the target value, and forms a closed-loop control with the servo drive system, enabling automatic deviation compensation. This design replaces the traditional method of relying on manual measurement and repeated debugging, integrating the accuracy control and verification of the changeover process into an automated workflow, greatly improving the accuracy, consistency, and reliability of the changeover process.

[0016] 3. By integrating the ejector pin unlocking module (electric screwdriver), forming module, conveyor line, lifting module and various axial drive mechanisms, and in conjunction with the central control system, this invention achieves full-process automation from tooling identification, spacing adjustment, locking mechanism control, shape imprinting to workpiece transfer. This highly integrated automation design significantly reduces product changeover time from hours on traditional lines to minutes, effectively supporting mixed-flow production modes of small batches and multiple varieties, improving flexibility while ensuring the efficiency of large-scale production. Attached Figure Description

[0017] Figure 1 This is an overall schematic diagram of this embodiment; Figure 2 This is a schematic diagram of the visual module; Figure 3 This is a diagram illustrating the movement and unlocking of the gas supply source; Figure 4 This is a structural diagram of the mounting plate; Figure 5 This is a schematic diagram of the lifting module; Figure 6 This is a schematic diagram of the molding module.

[0018] Explanation of reference numerals in the attached figures: 1. Mounting plate; 2. First flexible tooling assembly; 3. Second flexible tooling assembly; 4. Forming module; 401. Lifting cylinder; 402. Pressure plate; 403. Mold; 5. Ejector pin unlocking module; 501. Electric screwdriver; 502. X-axis guide rail; 6. Vision module; 601. Tooling positioning camera; 602. Distance positioning camera; 603. Mark point; 604. Y-axis vision guide rail; 7. Linear motor; 8. Y-axis tooling guide rail; 901. Lifting cylinder; 902. Lifting plate; 10. Clamping device; 11. Conveyor line; 12. Spacing adjustment station; 13. Forming station; 14. Moving unlocking air supply head; 15. Moving unlocking air supply source; 16. Air source pressing cylinder; 17. Cleaning air supply source; 18. Position detection device. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0020] like Figure 1As shown, a flexible intelligent production line is presented in this embodiment. The core components include: a workbench serving as the support and transfer base; a conveyor line 11 laid on the workbench and circulating along the Y-axis; and spacing adjustment stations 12 and forming stations 13 arranged sequentially along the conveyor line 11. Multiple mounting plates 1 serve as sub-production units, carrying a flexible tooling system that flows sequentially along the conveyor line 11, passing through each functional station to complete the corresponding reconstruction and forming operations.

[0021] like Figures 2 to 6 As shown, mounting plate 1 is the supporting base of the entire flexible tooling system. It is placed on conveyor line 11 and circulates on the production line. At the critical spacing adjustment station 12 and forming station 13, lifting modules are correspondingly installed below conveyor line 11. When mounting plate 1 reaches the target station, the lifting module is activated. Its lifting cylinder 901 drives the lifting plate 902 upward, smoothly lifting mounting plate 1, separating it from the transmission surface of conveyor line 11 and precisely positioning it. This provides a stable working reference for subsequent precision adjustments or imprinting operations, avoiding interference from vibrations of conveyor line 11. After completing the operation at this station, the lifting module descends, and mounting plate 1 falls back onto conveyor line 11, flowing to the next station.

[0022] Each mounting plate 1 is equipped with a complete flexible tooling system. This system mainly comprises a horizontally arranged first flexible tooling group 2 and a second flexible tooling group 3, which together define the processing area for placing or positioning automotive trim products. Both the first flexible tooling group 2 and the second flexible tooling group 3 contain at least one flexible clamp arranged along the X-axis. The flexible clamp here is preferably a matrix-type adjustable flexible clamp known in the industry, with multiple independently adjustable pins (or positioning pins, PINs) distributed in a matrix at its top. By changing the height combination of the pins, a support and positioning surface adapted to the three-dimensional curved contour of the product can be formed.

[0023] To accommodate products of different widths or lengths (Y-axis dimensions), at least one of the first flexible tooling group 2 and the second flexible tooling group 3 is designed to be movable along the Y-axis. In this embodiment, a parallel Y-axis tooling guide rail 8 is fixedly mounted on the mounting plate 1, and the bottom of the first flexible tooling group 2 (or the second flexible tooling group 3) is slidably connected to the Y-axis tooling guide rail 8 via a slider.

[0024] The power source driving its movement can be a lead screw mechanism driven by a servo motor, a linear motor 7, or other methods that are feasible for those skilled in the art. In this embodiment, a clamp 10 is provided on the Y-axis tooling guide rail 8. When the tooling assembly moves to the target position, the clamp 10 can generate a clamping force after receiving a pneumatic or electrical signal, firmly locking the slider of the tooling assembly on the Y-axis tooling guide rail 8, ensuring that the position remains absolutely unchanged when subjected to various forces during the production process, and guaranteeing positioning accuracy and system rigidity.

[0025] Above the spacing adjustment station 12, a vision module 6 is installed, which can move along the Y-axis. The vision module 6 is mounted on a Y-axis vision guide rail 604Y via a bracket and is driven by a servo motor, enabling its vision range to cover the entire Y-axis adjustment area of ​​the mounting plate 1. The core functional components of the vision module 6 are two industrial cameras: a tooling positioning camera 601 and a distance positioning camera 602. Their collaborative operation realizes a unique differential measurement principle based on a fixed reference.

[0026] On the mounting plate 1, near the Y-axis tooling guide rail 8, a high-precision Mark point 603 is machined or pasted. This Mark point 603 is precisely calibrated during the manufacturing of the mounting plate 1 and its position is absolutely fixed throughout the entire production process. It is not connected to any moving parts, thus forming a stable and reliable absolute spatial coordinate reference.

[0027] First, the tooling positioning camera 601 focuses on a feature area (such as a specific corner or additional marker point) on the first flexible tooling assembly 2 to acquire its initial image position. Then, the vision module 6 moves to make the distance positioning camera 602 focus on a fixed Mark point 603. The control system calculates the initial relative distance between the tooling feature point and the fixed Mark point 603. Subsequently, the central control system (such as a PLC or industrial computer) retrieves the corresponding target width parameter from the recipe library based on the product model of the current production order and calculates the expected target relative distance between the tooling feature point and the fixed Mark point 603. The system then drives the servo mechanism to move the first flexible tooling assembly 2 along the Y-axis to the target position. Finally, the vision module 6 performs a second image measurement to acquire the current relative distance between the tooling feature point and the fixed Mark point 603 after the movement. If the deviation is within the allowable accuracy tolerance, the adjustment is considered complete.

[0028] To achieve automatic unlocking and locking of the clamp 10 at the workstation, this invention designs a unique mobile air supply system. This mobile air supply system includes a mobile unlocking air supply source 15, a mobile unlocking air supply head 14, and an air source pressing cylinder 16. The air source pressing cylinder 16 and the mobile unlocking air supply source 15 are mounted on the mobile platform of the vision module 6, moving along the Y-axis with the vision module 6. The mobile unlocking air supply source 15 is mounted at the output end of the air source pressing cylinder 16, while the mobile unlocking air supply head 14 is fixed on the first flexible tooling assembly 2, serving as a connection component between the air supply source and the clamp's air circuit interface.

[0029] Once the mounting plate 1 enters the spacing adjustment station 12 and is precisely positioned by the lifting module, the air source pressing cylinder 16 actuates, driving the movable unlocking air supply source 15 to move downwards, making it tightly dock with the movable unlocking air supply head 14 on the first flexible tooling assembly 2. After docking, the movable unlocking air supply source 15 delivers compressed air through the air path and distributes it to each clamp 10, driving them to unlock and restoring the tooling assembly to a movable state. When the movable air supply system cuts off the air supply, the spring reset mechanism inside the clamp 10 automatically locks it, fixing the tooling assembly in its current position.

[0030] The flexible fixture itself is reconfigurable, but the lifting mechanism of its internal ejector pin array is usually fixed in a certain state by a mechanical locking device (such as a locking screw). To achieve automated changeover, this production line integrates a dedicated ejector pin unlocking module 5. The ejector pin unlocking module 5 is located at the spacing adjustment station 12 and includes two electric screwdrivers 501 that can move independently along the X-axis. Each electric screwdriver 501 is mounted on an X-axis guide rail 502 and can be precisely moved to a specific locking screw on the corresponding flexible fixture by being driven by a servo or stepper motor. The two electric screwdrivers 501 serve the flexible fixtures of the first flexible tooling group 2 and the second flexible tooling group 3, respectively.

[0031] To accommodate variations in the position of the locking screws under different Y-axis widths, at least one X-axis guide rail 502 is designed to be movable as a whole along the Y-axis. In this embodiment, the X-axis guide rail 502 is mounted on a transfer module driven by a linear motor 7. The linear motor 7 can drive the entire X-axis guide rail 502 and the electric screwdriver 501 on it to be positioned quickly and accurately in the Y-axis direction.

[0032] The workflow is as follows: When the mounting plate 1 enters the spacing adjustment station 12 and the Y-axis spacing is adjusted, the control system, based on the current product model, controls the linear motor 7 to move the electric screwdriver 501 to the corresponding Y coordinate, and then controls the electric screwdriver 501 to move along the X-axis to the screw hole position. The electric screwdriver 501 descends and rotates, loosening the locking screws on the flexible fixture, releasing all the ejector pins inside the fixture from constraint, restoring them to a "free" or initial state, preparing for subsequent molding. After molding is completed, the electric screwdriver 501 performs a tightening action again to lock the new fixture shape.

[0033] The molding module 4 is positioned above the molding station 13. Its basic structure includes a lifting cylinder 401 mounted on a frame. The output shaft of the lifting cylinder 401 points vertically downwards, and a pressure plate 402 is fixed to its end. At the bottom of the pressure plate 402, a molding die 403 corresponding to the current target product is fixed via a quick-change interface or bolts. The lower surface of the molding die 403 is machined with a specific three-dimensional profile that matches the product's support surface.

[0034] A position detection device 18 is typically installed on the frame of the molding module 4, above the pressure plate 402. This position detection device 18 can be a laser displacement sensor, a proximity switch, or a mechanical limit switch, used to detect the pressing distance and positioning status of the pressure plate 402 in real time.

[0035] Once the mounting plate 1 (with its flexible fixture already unlocked) is precisely positioned at the molding station 13 by the lifting module, the control system issues a command, and the lifting cylinder 401 drives the pressure plate 402 and the mold 403 to descend as a whole. The position detection device 18 monitors the downward position of the pressure plate 402 in real time and feeds the signal back to the control system. When the position detection device 18 detects that the pressure plate 402 has been pressed down to the preset precise position, it indicates that the mold 403 has been fully pressed into the ejector pin matrix area of ​​the flexible fixture, and the imprinting depth has met the process requirements. At this time, the control system issues a confirmation signal, suspends the further pressing of the lifting cylinder 401 (or keeps it in its current position), and allows subsequent locking operations to continue. This detection mechanism ensures the consistency of the imprinting depth each time, avoiding molding defects caused by insufficient imprinting or fixture damage caused by excessive imprinting.

[0036] During the imprinting process, the mold 403's surface forces the movable ejector pins below to shift to varying degrees, thus "imprinting" a support surface on the fixture that perfectly matches the contour of the product's back side. After imprinting is complete, the lifting cylinder 401 retracts, and the mold 403 leaves. At this point, the ejector pin matrix of the flexible fixture has been shaped into the form required for the new product. This shape can be fixed simply by tightening the locking screws using the electric screwdriver 501 of the ejector pin unlocking module 5, completing a complete reconstruction of the tooling from its physical form to its functional state.

[0037] To ensure the long-term reliable operation of the ejector pin mechanism inside the flexible fixture and prevent the accumulation of dust, debris, and other foreign objects that could cause pin jamming, this invention also integrates a clean air supply system. The clean air supply source 17 is fixed to the mounting plate and connected to a clean air interface on each flexible fixture via pipelines. The clean air supply source 17 delivers compressed air to the ejector pin base area of ​​the flexible fixture, blowing air upwards through the ejector pin gaps to dislodge accumulated small foreign objects from the fixture surface. Simultaneously, workers use an industrial vacuum cleaner above the flexible fixture to effectively remove the blown-up foreign objects, ensuring the flexibility and positioning accuracy of the ejector pin movement and significantly extending the service life of the flexible fixture.

[0038] In summary, the flexible intelligent production line of the present invention integrates a flexible tooling assembly with adjustable spacing, a closed-loop measurement system based on a fixed visual reference, an automatic unlocking / locking mechanism, and a forming module 4 to construct a "software-defined hardware" intelligent manufacturing platform. Its core benefits are reflected in the following aspects: First, it achieves extreme flexibility and rapid reconfiguration capabilities for the production line. By simply changing the digital formula, the hardware can automatically adapt to automotive trim parts of different sizes and shapes, reducing the changeover time of several hours in traditional production lines to minutes, perfectly responding to the customized needs of multiple varieties and small batches. Second, it innovatively adopts visual closed-loop control with the fixed Mark point 603 on the mounting plate 1 as the absolute reference, measuring and correcting deviations in real time, ensuring extremely high precision and repeatability of tooling reconfiguration and positioning, eliminating manual debugging errors, and ensuring product assembly quality. Finally, through the full-process automated collaboration of conveyor line 11, lifting and positioning, and various functional modules, it achieves flexible small-batch production while maintaining the continuity and high efficiency of large-scale operations, significantly reducing the cost of special tooling and production line transformation, and providing key technical support for the agile and intelligent transformation of the automotive parts manufacturing industry.

[0039] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the design concept of the present invention should be included within the protection scope of the present invention.

[0040] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

Claims

1. A flexible intelligent production line, characterized in that: The device includes at least one mounting plate and a molding module located above the mounting plate. The mounting plate is provided with a first flexible tooling group and a second flexible tooling group. At least one of the first flexible tooling group and the second flexible tooling group can move along the Y-axis, so that the distance between them can be adjusted. Both the first flexible tooling group and the second flexible tooling group include at least one flexible fixture arranged along the X-axis. The bottom of the molding module is connected to a mold. The molding module drives the mold to move in the vertical direction and press out a shape corresponding to the target product on the flexible fixture.

2. The flexible intelligent production line according to claim 1, characterized in that: It also includes a pin unlocking module, which includes two electric screwdrivers that can move along the X-axis. The two electric screwdrivers are located outside the first flexible tooling group and the second flexible tooling group, respectively. When the electric screwdrivers move to the position corresponding to the flexible fixture, they can unlock or lock the shape of the flexible fixture.

3. The flexible intelligent production line according to claim 1, characterized in that: It also includes a vision module disposed above the mounting plate, the vision module being movable along the Y-axis, a mark point being disposed on the mounting plate, and the vision module determining the distance it moves by the change in the distance between the first flexible tooling group and / or the second flexible tooling and the mark point.

4. The flexible intelligent production line according to claim 2, characterized in that: The ejector pin unlocking module includes two X-axis guide rails, and the two electric screwdrivers are respectively mounted on the X-axis guide rails. At least one of the X-axis guide rails can move along the Y-axis.

5. The flexible intelligent production line according to claim 4, characterized in that: At least one of the X-axis guide rails is mounted on the transplanting module, the transplanting module including a linear motor arranged along the Y-axis direction, the linear motor driving the X-axis guide rail to move along the Y-axis direction.

6. The flexible intelligent production line according to claim 1, characterized in that: The mounting plate is provided with a Y-axis tooling guide rail. The first flexible tooling group and / or the second flexible tooling group are slidably connected to the Y-axis tooling guide rail and locked to the Y-axis tooling guide rail by a clamp. A movable air supply system is provided to control the locking and unlocking of the clamp.

7. The flexible intelligent production line according to claim 1, characterized in that: The molding module includes a lifting cylinder located above the mounting plate. The output shaft of the lifting cylinder is vertically downward and fixed with a pressure plate. The mold is fixed to the bottom of the pressure plate.

8. The flexible intelligent production line according to claim 3, characterized in that: It also includes a workbench, on which a conveyor line flowing along the Y-axis is provided, and several mounting plates are provided on the conveyor line. Above the conveyor line, the workbench is provided with a spacing adjustment station and a forming station in sequence. The vision module is located at the spacing adjustment station, and the forming module is located at the forming station.

9. The flexible intelligent production line according to claim 8, characterized in that: The workbench is equipped with a lifting module located below the conveyor line. When the mounting plate enters the spacing adjustment station or the forming station, the lifting module will lift the mounting plate and separate it from the conveyor line.

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