Automobile parts mistake-proof assembly system and method

Abstract

The application relates to the technical field of automobile manufacturing, in particular to an automobile part mistake-proof assembly system and method, which comprises a conveying line; a plurality of assembly trays are arranged on the conveying line; a plurality of assembly stations are linearly arranged along the conveying line in sequence, each assembly station is provided with a station controller, a card reader for reading wireless radio frequency identification tag information, a bar code scanner for scanning part identity bar codes, an audible and light alarm for providing operation feedback, and a confirmation button for manually confirming operation completion, the station controller is electrically connected with the card reader, the bar code scanner, the audible and light alarm, and the confirmation button; and the controller is in communication connection with the station controllers of all the assembly stations through a network. The application realizes the assembly of automobile parts in a full-process, closed-loop control and data traceable mode.

Description

Technical Field

[0001] This invention relates to the field of automobile manufacturing technology, and in particular to a system and method for preventing errors in the assembly of automobile parts. Background Technology

[0002] The automotive industry strives for near-zero defects in the assembly quality of its parts. Traditional assembly lines rely heavily on operator skills, focus, and paper-based work instructions, lacking effective, hard-line error-proofing mechanisms. Common quality issues include: incorrect assembly of similar-model parts, omission of standard parts, skipping steps in the assembly sequence, and insufficient or excessive bolt tightening torque. These problems often only surface during final inspection or even at the customer's location, leading to significant rework, repairs, and reputational damage.

[0003] Existing improvement solutions are mostly limited to single-point error prevention, such as adding sensors to the material box to detect parts removal or using a fixed torque wrench. These solutions have significant drawbacks: 1) Each error prevention point is isolated, making it impossible to achieve precise binding and traceability at the component and product level; 2) It is impossible to enforce control over assembly sequence and process discipline; 3) The error prevention logic is simple and difficult to deal with complex scenarios such as "correct parts, wrong batch"; 4) Process data is not digitized, making it difficult to achieve lean analysis and accurate traceability. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide an error-proof assembly system and method for automotive parts, so as to realize the assembly of automotive parts with full-process, closed-loop control and data traceability.

[0005] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: A system for preventing incorrect assembly of automotive parts, comprising... Conveyor line; Assembly trays, several of the assembly trays are arranged on the conveyor line, each of the assembly trays is provided with a clamp for fixing the product to be assembled and a radio frequency identification tag storing identification information; The assembly station is arranged linearly along the conveyor line. Each assembly station is equipped with a station controller, a card reader for reading the information of the radio frequency identification tag, a barcode scanner for scanning the identification barcode of the component, an audible and visual alarm for providing operation feedback, and a confirmation button for manual confirmation of operation completion. The station controller is electrically connected to the card reader, barcode scanner, audible and visual alarm, and confirmation button respectively. The controller communicates with the station controllers of all the assembly stations via a network. The controller has a pre-stored product assembly process database. The controller defines a complete assembly sequence for each product model at each station through the product assembly process database. The controller specifies the correct model and batch information of the parts to be assembled for each station in the assembly sequence. The workstation controller is configured to execute the following error prevention process: when the assembly pallet arrives at the workstation, the product identification information is obtained through the card reader and uploaded to the controller; the controller receives and displays the current workstation assembly instruction based on the identification information; the barcode scanner is controlled to scan the barcode of the component to be assembled to obtain the scan information, and the scan information is compared in real time with the correct model and batch information in the assembly instruction; if the comparison is consistent, the audible and visual alarm is controlled to issue a pass prompt, and a release instruction is generated after receiving the confirmation button press signal; if the comparison is inconsistent, the audible and visual alarm is controlled to issue an error alarm, and a lock instruction is generated to prevent the assembly pallet from leaving the current workstation.

[0006] Based on the above technical solution, the present invention can be further improved as follows.

[0007] Furthermore, the assembly station is also equipped with a vision detection module that is communicatively connected to the station controller. The vision detection module is used to acquire images of the assembly status after the assembly action is completed, obtain feature data, compare the processed feature data with pre-stored standard feature data, obtain the comparison result, and feed the comparison result back to the station controller to determine whether to allow release.

[0008] Furthermore, the assembly station is also equipped with an intelligent tightening tool that communicates with the station controller. The assembly process database of the controller also stores the standard torque range of each fastening point. The station controller is further configured to receive the real-time torque value uploaded by the intelligent tightening tool and determine whether it falls within the standard torque range. If not, it controls the audible and visual alarm to sound and prevents the process from continuing.

[0009] The standard torque is determined by clarifying the function of the components connected at the fastening point (such as sealing, load-bearing, positioning, torque transmission, etc.) and analyzing the various static and dynamic loads (vibration, thermal cycling, impact, etc.) they will experience throughout their life cycle. Based on the analysis results, the fasteners (bolt material, strength grade) and the materials of the connected parts are selected, and the minimum required preload is calculated. This preload must be sufficient to resist the separation force that would cause connection failure and ensure connection stiffness. Using classical formulas (such as torque T = K * d * F, where K is the torque coefficient, d is the bolt diameter, and F is the target preload), the target preload is converted into a theoretical assembly torque. The above theoretical assembly torque data is input into the assembly process database of the controller to set the standard torque.

[0010] Furthermore, the assembly pallet is a programmable adaptive pallet, and the fixtures on the assembly pallet include movable positioning pins and clamping arms driven by servo motors; the assembly pallet integrates a slave controller, which can receive instructions from the controller or the workstation controller and automatically adjust the position and posture of the positioning pins and clamping arms according to the product model of the product to be assembled currently being carried.

[0011] Furthermore, it also includes a material error prevention rack connected to the controller, which is equipped with multiple sets of material boxes with indicator lights and part retrieval sensors; the controller controls the indicator lights of the corresponding material boxes to light up according to the product assembly instructions currently being delivered to the corresponding workstation; the workstation controller only allows the barcode scanner to perform scanning and comparison operations after receiving the control signal from the part retrieval sensor.

[0012] Furthermore, the controller also includes a data traceability and analysis module, which is used to collect and store the full-process assembly data of each product in real time. The full-process assembly data includes: the time spent at each workstation, the operator's employee number, the batch barcode of the parts used, the visual inspection result image, and the key tightening torque curve. The data traceability and analysis module can generate a unique quality traceability file according to the product serial number, and can also count the output efficiency, first pass rate, and the frequency and location of various errors.

[0013] Furthermore, it also includes a production status display screen connected to the controller, used to visually display real-time production indicators, status of each workstation, daily output, and fault alarm information generated by the data traceability and analysis module.

[0014] Furthermore, the assembly station is equipped with a human-machine interface connected to the station controller, which is used to display the assembly instructions, the schematic diagram of the part to be scanned, and the comparison result details of the current station in the form of graphics and animation.

[0015] Furthermore, the conveyor line is equipped with a stopper at the entrance of the assembly station, which is controlled by the station controller. The station controller controls the raising and lowering of the stopper to prevent and release the assembly pallet.

[0016] This invention addresses the aforementioned technical problems by providing a method for preventing incorrect assembly of automotive parts based on the aforementioned automotive parts error-proofing assembly system, comprising the following steps: S1: Initialization and binding. At the product launch station, the operator selects or scans the product model through the terminal. The controller retrieves the correct model and batch information according to the model and binds the correct model and batch information with the radio frequency identification tag information of the assembly tray where the product is located. S2: Pallet conveying and identification: The assembly pallet is conveyed to a certain assembly station along the conveyor line, and the card reader at the assembly station automatically reads the product identification information; S3: Command issuance and display. The workstation controller sends the product identity information read by the card reader to the controller, and the controller returns the specific assembly command for the current workstation corresponding to the product identity information. S4: Component Retrieval and Verification. The operator retrieves components from the material rack according to the assembly instructions, scans the barcode of the component to be assembled using the barcode scanner to obtain the scan information, and the workstation controller compares the scan information with the correct model and batch information in the assembly instructions in real time. S5: Assembly execution and confirmation. If the comparison passes, the workstation controller controls the audible and visual alarm to issue a pass prompt, and the operator performs physical assembly. After completion, the operator presses the confirmation button. If the comparison fails, the workstation controller controls the audible and visual alarm to issue an error alarm and generates a locking command to prevent the assembly tray from leaving the current workstation. S6: Result feedback and process control, uploading all result data of this operation to the controller; S7: Cycle and traceability. Repeat steps S2 to S6 until the product completes all assembly stations. The controller integrates the data from the entire process to form a traceable electronic assembly record.

[0017] The beneficial effects of this invention are as follows: Through a mandatory verification process combining hardware and software, the possibility of incorrect or missing parts due to human error is fundamentally eliminated; from part retrieval to final confirmation, every step is monitored and verified by the system, ensuring absolute adherence to process discipline; "one part, one file" is implemented, with each part's supplier batch, assembly time, operator, and process parameters all recorded, supporting second-level accurate recall and root cause analysis; rapid process switching via controller, combined with adaptive trays, seamlessly supports mixed-line production modes with multiple varieties and small batches; real-time production data dashboards provide managers with a transparent view of the workshop, helping to continuously optimize efficiency and quality. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the present invention; The attached diagram lists the components represented by each number as follows: 1. Conveyor line; 2. Assembly pallet; 3. Assembly station; 4. Station controller; 5. RFID reader; 6. Barcode scanner; 7. Audible and visual alarm; 8. Confirmation button; 9. Controller; 10. Vision inspection module; 11. Intelligent tightening tool; 12. Material misalignment prevention rack; 13. Production status dashboard; 14. Human-machine interface; 15. Stopper. Detailed Implementation

[0019] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0020] Example 1 like Figure 1 As shown, this embodiment discloses a fault-proof assembly system for automotive parts, including a conveyor line 1; Assembly tray 2, several of the assembly trays 2 are arranged on the conveyor line 1, each assembly tray 2 is provided with a clamp for fixing the product to be assembled and a radio frequency identification tag storing identification information; Assembly station 3, multiple assembly stations 3 are arranged linearly along the conveyor line 1, each assembly station 3 is equipped with a station controller 4, a card reader 5 for reading the information of the radio frequency identification tag, a barcode scanner 6 for scanning the identification barcode of the component, an audible and visual alarm 7 for providing operation feedback, and a confirmation button 8 for manual confirmation of operation completion. The station controller 4 is electrically connected to the card reader 5, the barcode scanner 6, the audible and visual alarm 7 and the confirmation button 8 respectively. The controller 9 is connected to the station controllers 4 of all the assembly stations 3 via a network. The controller 9 has a pre-stored product assembly process database. The controller 9 defines a complete assembly sequence for each product model at each station through the product assembly process database. The controller 9 specifies the correct model and batch information of the parts to be assembled for each station in the assembly sequence. The workstation controller 4 is configured to execute the following error prevention process: when the assembly tray 2 arrives at the workstation, it obtains product identity information through the card reader 5 and uploads it to the controller 9; it receives and displays the current workstation assembly instruction fed back by the controller 9 based on the identity information; it controls the barcode scanner 6 to scan the barcode of the component to be assembled to obtain scanning information, and compares the scanning information with the correct model and batch information in the assembly instruction in real time; if the comparison is consistent, it controls the audible and visual alarm 7 to issue a pass prompt, and generates a release instruction after receiving the pressed signal of the confirmation button 8; if the comparison is inconsistent, it controls the audible and visual alarm 7 to issue an error alarm and generates a lock instruction to prevent the assembly tray 2 from leaving the current workstation.

[0021] In this embodiment, the conveyor line 1 adopts a double-chain roller conveyor, driven by an AC motor, with a speed that can be steplessly adjusted between 0.5-2 m / min. Standard Omron E3Z photoelectric through-beam sensor arrays are installed on both sides of the conveyor line 1 frame to detect the precise position of the assembly pallet 2. 500mm before the entrance of each assembly station 3, a stopper 15 driven by an SMC cylinder and controlled by the station controller 4 is installed. The stopper 15 has a lifting height of 50mm, sufficient to prevent the pallet rollers from passing. Its "lifting" and "lowering" states are directly controlled by the digital output signal of the station controller 4, forming the hardware basis for process locking.

[0022] In this embodiment, the assembly tray 2 is made of a high-strength aluminum alloy frame, and its core features are identification and adaptive clamping functions. Specifically, a passive UHF RFID tag (such as ImpinjMonzaR6) conforming to ISO15693 standard is embedded in the center of the bottom of each tray as its unique identification information. This tag stores a globally unique tray ID code (such as Tray_001). The clamping area on the upper surface of the tray is equipped with four sets of movable positioning pins driven by servo motors (such as Yaskawa SGM7J) and two sets of pneumatic clamping arms. A Siemens ET200SP series slave controller is integrated inside the tray. This controller receives instructions from controller 9 via the Profinet bus. For example, when it is necessary to assemble the "Model A" gearbox housing, the server sends an instruction, and the slave controller drives the servo motor to move the positioning pin to the preset coordinate P1, and controls the solenoid valve to make the clamping arm execute the clamping action sequence C1, thereby realizing the automatic adjustment of the position and posture of the positioning pin and clamping arm according to the product model of the product to be assembled, supporting multi-model mixed production.

[0023] In this embodiment, each assembly station 3 is a functionally independent error-proofing unit, built around a Siemens S7-1500 series PLC as the station controller 4. The card reader 5 can be a Feig IDISC.LRU2002 UHF RFID fixed reader / writer, installed directly above the station entrance, facing the pallet path, to automatically read the RFID tag information after the pallet stops. The barcode scanner 6 can be a Honeywell 1900 series handheld 2D image scanner, connected to the industrial computer (as part of the human-machine interface) via a USB interface, with scan data transmitted to the station controller 4 in real time. A vision inspection module 10 can be added to stations involving sealing ring installation and snap ring positioning detection. This module includes a Baslerace series 5-megapixel industrial camera and an industrial computer with built-in image processing algorithms as the image processing unit. The camera is fixed above the assembly station to photograph the area after assembly. The image processing unit runs a pre-trained template matching algorithm, comparing the acquired image with standard feature data (such as a standard assembly state template image) stored in the controller 9, and outputs an "OK" or "NG" result to the station controller 4. The intelligent tightening tool 11 is installed at the bolt tightening station and is equipped with Atlas Copco's SysTork series intelligent tightening tools. This tool has built-in sensors and a communication module, which can transmit the real-time torque value and angle curve of each bolt to the station controller 4 in real time via the IO-Link interface.

[0024] In this embodiment, the assembly station 3 is equipped with a human-machine interface 14 connected to the station controller 4. This interface displays the assembly instructions, a schematic diagram of the part to be scanned, and comparison result details in a graphical and animated format. Specifically, the human-machine interface 14 uses a 15-inch Weintek industrial touchscreen and communicates with the station controller 4 via Ethernet. It displays the assembly instructions (e.g., including a 3D exploded view animation), an enlarged schematic diagram of the part to be scanned, and operating steps in a graphical and animated format. The audible and visual alarm 7 uses Banner AG4 series tri-color tower lights (red, yellow, green) with an integrated buzzer. A solid green light indicates "pass," a flashing red light accompanied by a rapid buzzer indicates "error," and a solid yellow light indicates "waiting" or "equipment preparing." The confirmation button 8 is a Schneider self-resetting emergency stop button with a green indicator light, installed on a tooling plate easily accessible to the operator. When pressed, its signal is input to the digital input module of the station controller 4.

[0025] In this embodiment, a material error prevention rack 12 is provided next to each workstation. The material error prevention rack 12 is a customized material rack, and multiple parts boxes are set on the material error prevention rack 12. A red / green LED indicator and a diffuse reflection photoelectric part retrieval sensor are installed in front of each parts box. The controller 9 illuminates the indicator light of the corresponding parts box through the digital output module of the workstation controller 4 according to the current workstation assembly instruction. When the operator picks up a part, their hand covers the part retrieval sensor, triggering the part retrieval sensor. This signal is recorded by the workstation controller 4. The logic of the workstation controller 4 is set so that subsequent barcode scanning and comparison operations are allowed and effective only after a correct part retrieval signal is detected; otherwise, the scan is invalid and a message "Please pick up the indicated part first" is displayed.

[0026] In this embodiment, controller 9 is an industrial server deployed in the workshop information center, running customized MES (Manufacturing Execution System) software based on SQL Server database.

[0027] Product Assembly Process Database: The database defines a tree-structured assembly sequence for each product model (e.g., "6AT_ModelX"). Each node in the sequence (corresponding to a workstation) details the correct model (part number) of the required parts and the acceptable batch information (configurable to a specific batch or batch range), as well as the corresponding tightening process parameters, visual inspection standard file path, etc.

[0028] Data Traceability and Analysis Module: This module collects and stores assembly data from each workstation controller in real time. Each data record includes a timestamp, product / pallet ID, workstation number, operator login ID, batch barcode of the parts used, link to the visual inspection result image file, and key tightening torque curve data. The system can generate a unique quality traceability file (PDF or electronic report) with one click based on the product serial number, and has built-in analysis tools to statistically analyze production efficiency, first-pass yield, and the frequency and location of various errors in chart form.

[0029] Production Status Dashboard 13: A 55-inch LED screen set in a prominent position in the workshop, connected to controller 9 via HDMI interface, visually displays real-time information driven by the data traceability and analysis module, including: the status of each workstation (running / stopping / alarm), the current product model in production, the planned / actual output for the day, OEE (Overall Equipment Efficiency), FPY (First Pass Rate), and a scrolling list of the latest fault alarm information.

[0030] Example 2 This embodiment discloses a method for preventing errors in the assembly of automotive parts based on the aforementioned automotive parts error-proofing assembly system, including the following steps: S1: Initialization and Binding At the product assembly station (usually the first station), the operator selects or scans the serial number barcode of the gearbox housing to be assembled through the human-machine interface 14. Based on this serial number, the controller 9 retrieves the corresponding correct model and batch information (e.g., "6AT_ModelX_Process") from its process database. The server then controls the fixture of the assembly pallet 2 to adjust to the appropriate state for "6AT_ModelX" via the station controller 4 and the pallet slave controller. Finally, the server binds the process document with the read pallet RFID tag information (e.g., Tray_001) in its internal data table, establishing a digital association between the product and the carrier.

[0031] S2: Pallet Delivery and Identification The assembled pallet 2, once bound, is transported by conveyor line 1 to the second station (let's call it the "input shaft assembly installation station"). When the pallet triggers the photoelectric sensor at the station entrance, the conveyor line pauses (or slows down), and reader 5 automatically reads the pallet's RFID tag information (Tray_001).

[0032] S3: Command Issuance and Display Workstation controller 4 sends the read ID to controller 9 via industrial Ethernet. The server queries the binding relationship, confirms that the current product is "6AT_ModelX", and determines that its next assembly step is "Install input shaft assembly (part number: INS-005, batch requirement: LOT24A01-24A03)". The server returns this specific assembly instruction to workstation controller 4. The instruction is immediately displayed on the human-machine interface 14: the installation animation of the input shaft assembly plays in the center of the screen, the sidebar text prompts the part number and batch requirement, and at the same time, the indicator light of the material box containing part "INS-005" on the material error prevention rack 12 lights up.

[0033] S4: Component Acquisition and Verification Guided by indicator lights, the operator retrieves the input shaft assembly from the correct hopper, triggering a sensor. Subsequently, the operator must use barcode scanner 6 to scan the QR code on the assembly packaging or body. The workstation controller 4 executes real-time comparison logic: parsing the scanned data (e.g., "INS-005;LOT24A02") and comparing it with server commands ("INS-005;LOT24A01-24A03"). The comparison logic includes: 1) the part numbers match perfectly; 2) the scanned batch number falls within the required batch range.

[0034] S5: Assembly Execution and Verification If the comparison passes: the workstation controller 4 activates the audible and visual alarm 7, which illuminates a green light and emits a warning sound. The operator then performs physical assembly. Assuming the workstation integrates a vision inspection system 10, the camera automatically takes a picture after assembly, and the image processing unit determines that the retaining clip is installed correctly, returning an "OK" signal to the controller 4. The operator then presses the confirmation button 8.

[0035] If the comparison fails (e.g., an incorrect part "INS-006" is scanned): the station controller 4 immediately controls the audible and visual alarm 7 to flash red and sound a buzzer, while simultaneously displaying error details on the human-machine interface 14 (e.g., "Error: Expected part INS-005, INS-006 scanned"). The stopper 15 remains raised, locking the tray.

[0036] S6: Results Feedback and Process Control If the process passes, after receiving the confirmation button 8 signal and all additional inspections (visual and torque) are OK, the workstation controller 4 first controls the stopper 15 to lower via the DO module to release the pallet. Then, it uploads all the result data of this step (including: time, operator ID, scanned part batch "LOT24A02", visual inspection OK signal) to the controller 9, and the server updates the assembly progress status of the product.

[0037] S7: Loops and Tracing The product repeats steps S2 to S6, flowing sequentially through all assembly stations (such as valve body installation, sensor installation, and assembly testing). When it finally rolls off the production line, the controller 9's database has integrated all the data from the entire transmission assembly process. Through its data traceability module, a traceable electronic assembly record can be generated, containing the tightening curve of every important bolt, the batch number of every key component, and the assembly time, achieving a complete information loop from part to assembly.

[0038] Those skilled in the art will understand that the specific equipment selections (such as PLC brand, RFID model, etc.) in the above embodiments are merely examples. For instance, the RFID system can be replaced with a QR code-based visual recognition system; the component retrieval sensor of the material error-proof rack 12 can also be replaced with a weight sensor; and the data communication of the intelligent tightening tool 11 can be via Bluetooth or Wi-Fi. These alternative solutions based on the same error-proofing principle and system architecture all fall within the protection scope of this invention.

[0039] In the description of this invention, it should be understood that the terms "center," "length," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "inner," "outer," "circumferential," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the system or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0040] In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0041] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0042] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0043] 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 spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A system for preventing errors in the assembly of automotive parts, characterized in that, include Conveyor line (1); Assembly tray (2), several assembly trays (2) are set on the conveyor line (1), each assembly tray (2) is provided with a clamp for fixing the product to be assembled and a radio frequency identification tag storing identification information; Assembly station (3), multiple assembly stations (3) are arranged linearly along the conveyor line (1). Each assembly station (3) is equipped with a station controller (4), a card reader (5) for reading the information of the radio frequency identification tag, a barcode scanner (6) for scanning the barcode of the component identification, an audible and visual alarm (7) for providing operation feedback, and a confirmation button (8) for manual confirmation of operation completion. The station controller (4) is electrically connected to the card reader (5), the barcode scanner (6), the audible and visual alarm (7), and the confirmation button (8), respectively. The controller (9) communicates with the station controllers (4) of all the assembly stations (3) via a network. The controller (9) has a product assembly process database stored in it. The controller (9) defines a complete assembly sequence for each product model at each station through the product assembly process database. The controller (9) specifies the correct model and batch information of the parts to be assembled for each station in the assembly sequence. The workstation controller (4) is configured to perform the following error prevention process: when the assembly tray (2) arrives at the workstation, the product identity information is obtained through the card reader (5) and uploaded to the controller (9); the current workstation assembly instruction fed back by the controller (9) based on the identity information is received and displayed; the barcode scanner (6) is controlled to scan the barcode of the parts to be assembled to obtain the scanning information, and the scanning information is compared with the correct model and batch information in the assembly instruction in real time; if the comparison is consistent, the sound and light alarm (7) is controlled to issue a pass prompt, and after receiving the press signal of the confirmation button (8), a release instruction is generated; if the comparison is inconsistent, the sound and light alarm (7) is controlled to issue an error alarm and a lock instruction is generated to prevent the assembly tray (2) from leaving the current workstation.

2. The automotive parts error-proofing assembly system according to claim 1, characterized in that, The assembly station (3) is also equipped with a vision detection module (10) that is connected to the station controller (4). The vision detection module (10) is used to collect images of the assembly status after the assembly action is completed, obtain feature data, compare the processed feature data with the pre-stored standard feature data, obtain the comparison result, and feed the comparison result back to the station controller (4) to decide whether to allow release.

3. The automotive parts error-proofing assembly system according to claim 1, characterized in that, The assembly station (3) is also equipped with an intelligent tightening tool (11) that is connected to the station controller (4). The product assembly process database of the controller (9) also stores the standard torque range of each fastening point. The station controller (4) is further configured to receive the real-time torque value uploaded by the intelligent tightening tool (11) and determine whether it falls within the standard torque range. If not, the controller will control the sound and light alarm (7) to sound an alarm and prevent the process from continuing.

4. The automotive parts error-proofing assembly system according to claim 1, characterized in that, The assembly tray (2) is a programmable adaptive tray. The fixtures on the assembly tray (2) include movable positioning pins and clamping arms driven by servo motors. The assembly tray (2) has an integrated slave controller. The slave controller can receive instructions from the controller (9) or the workstation controller (4) and automatically adjust the position and posture of the positioning pins and clamping arms according to the product model of the product to be assembled currently being carried.

5. The automotive parts error-proofing assembly system according to claim 1, characterized in that, It also includes a material error prevention rack (12) connected to the controller (9), which is equipped with multiple sets of material boxes with indicator lights and pick-up sensors. The controller (9) controls the indicator lights of the corresponding material boxes to light up according to the product assembly instructions currently delivered to the corresponding workstation. The workstation controller (4) only allows the barcode scanner (6) to perform scanning and comparison operations after receiving the trigger signal from the pick-up sensor.

6. A mis-assembly prevention system for automotive parts according to any one of claims 1 to 5, characterized in that, The controller (9) also includes a data traceability and analysis module, which is used to collect and store the full-process assembly data of each product in real time. The full-process assembly data includes: the time of passing through each workstation, the operator's employee number, the batch barcode of the parts used, the visual inspection result image, and the key tightening torque curve. The data traceability and analysis module can generate a unique quality traceability file according to the product serial number, and can statistically analyze the output efficiency, first pass rate, and the frequency and location of various errors.

7. The automotive parts error-proofing assembly system according to claim 6, characterized in that, It also includes a production status display screen (13) connected to the controller (9) for visually displaying the real-time production indicators, status of each workstation, daily output and fault alarm information generated by the data traceability and analysis module.

8. A mis-assembly prevention system for automotive parts according to any one of claims 1 to 5, characterized in that, The assembly station (3) is equipped with a human-machine interface (14) connected to the station controller (4), which is used to display the assembly instructions, the schematic diagram of the part to be scanned and the comparison result details of the current station in the form of graphic animation.

9. A mis-assembly prevention system for automotive parts according to any one of claims 1 to 5, characterized in that, The conveyor line (1) is equipped with a stopper (15) controlled by the station controller (4) at the entrance of the assembly station (3). The station controller (4) controls the raising and lowering of the stopper (15) to prevent and release the assembly tray (2).

10. A method for preventing errors in the assembly of automotive parts based on the error-proofing assembly system of any one of claims 1 to 9, characterized in that, Includes the following steps: S1: Initialization and binding. At the product launch station, the operator selects or scans the product model through the terminal. The controller (9) retrieves the correct model and batch information according to the model and binds the correct model and batch information with the radio frequency identification tag information of the assembly tray (2) where the product is located. S2: Pallet conveying and identification, the assembly pallet (2) is conveyed to a certain assembly station (3) along the conveyor line (1), and the card reader (5) on the assembly station (3) automatically reads the product identification information; S3: Instruction issuance and display: The workstation controller (4) sends the product identity information read by the card reader (5) to the controller (9), and the controller (9) returns the specific assembly instruction for the current workstation corresponding to the product identity information; S4: Component Retrieval and Verification. The operator retrieves components from the material rack according to the assembly instructions and uses the barcode scanner (6) to scan the barcode of the component to be assembled to obtain the scan information. The workstation controller (4) compares the scan information with the correct model and batch information in the assembly instructions in real time. S5: Assembly execution and confirmation. If the comparison is successful, the workstation controller (4) controls the audible and visual alarm (7) to issue a pass prompt. The operator performs physical assembly and presses the confirmation button (8) after completion. If the comparison is inconsistent, the workstation controller (4) controls the audible and visual alarm (7) to issue an error alarm and generates a locking command to prevent the assembly tray (2) from leaving the current workstation. S6: Result feedback and process control, upload all result data of this operation to the controller (9). S7: Cycle and traceability, repeat steps S2 to S6 until the product completes all assembly stations. The controller (9) integrates the data of the entire process to form a traceable electronic assembly record.

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