A high-efficiency production process for computer housings

Abstract

The application discloses a kind of computer shell efficient production process.The method includes the following steps: S1, modularization preparation: according to production instruction, corresponding type of metal plate or plastic granules is automatically selected and transported to pretreatment station;S2, intensive forming: the raw material after pretreatment is sent into composite machining center, by being integrated in the same station punching forming and laser cutting module, or injection molding and in-mold cutting gate module, once the structure forming of shell blank and excess material separation is completed;S3, closed-loop post-processing: shell blank is transferred to intelligent post-processing unit;S4, coating rapid curing;S5, online intelligent detection and stacking.The application significantly improves production efficiency and shortens cycle, improves product precision and yield, greatly reduces energy consumption and floor area, improves production flexibility and intelligent level, improves environmental friendliness, reduces VOCs emission.

Description

Technical Field

[0001] This invention relates to the field of computer manufacturing technology, specifically to an efficient manufacturing process for computer casings. Background Technology

[0002] Currently, the mainstream production process for computer casings (including metal and plastic materials) is usually divided into multiple independent processes. For example, for metal casings, discrete production is adopted, which involves "blanking, stretching, punching, trimming, cleaning, and surface treatment"; while for plastic casings, assembly line production is adopted, which involves "injection molding, cooling, part removal, manual or robotic gate cutting, grinding, and spraying".

[0003] The existing technology has the following main problems:

[0004] 1. The process relies on buffer zones and manual or AGV transfers between processes, resulting in a large amount of waiting and handling time, uncoordinated production rhythm, and a long overall manufacturing cycle;

[0005] 2. The independent equipment layout results in a large workshop footprint. Repeated heating, cooling, and transfer processes lead to redundant energy consumption, which does not meet green manufacturing requirements.

[0006] 3. Multiple clamping and positioning operations result in cumulative errors. Post-processing (such as trimming and polishing) typically employs automated or manual operations along fixed paths, which cannot compensate for the deformation caused by previous processes, leading to fluctuations in yield.

[0007] 4. Changing the production of different models of computer shells (such as the A-side and C-side of a laptop or the panel of a desktop computer case) requires a lot of manual labor to adjust molds, change fixtures and reprogram, which cannot meet the market demand for multiple varieties and small batches.

[0008] Therefore, there is an urgent need for a high-efficiency manufacturing process for computer casings that can integrate multiple processes, achieve closed-loop precision control, and possess high flexibility and energy efficiency. Summary of the Invention

[0009] The purpose of this section is to outline some aspects of the embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be construed as limiting the scope of the invention.

[0010] 1. Technical problems to be solved:

[0011] To address the problems of discrete processes, low efficiency, large footprint and energy consumption, limited precision and yield, and poor flexibility mentioned above, this invention is proposed.

[0012] Therefore, the purpose of this invention is to provide a highly efficient manufacturing process for computer casings. This invention significantly improves production efficiency and shortens cycle time, increases product precision and yield, greatly reduces energy consumption and floor space, enhances production flexibility and intelligence, improves environmental friendliness, and reduces VOC emissions.

[0013] 2. Technical Solution:

[0014] To address the aforementioned technical problems, according to one aspect of the present invention, the present invention provides the following technical solution:

[0015] Includes the following steps:

[0016] S1. Modular Material Preparation: Based on production instructions, automatically select and transport the corresponding type of metal sheet or plastic granules to the pre-processing station.

[0017] S2, Intensive Forming: The pre-treated raw materials are sent to the composite processing center, and the structural forming and residual material separation of the shell blank are completed in one go through the stamping and laser cutting modules or the injection molding and in-mold gate cutting modules integrated in the same station.

[0018] S3. Closed-loop post-processing: The shell blank is transferred to the intelligent post-processing unit, which integrates a vision inspection module and an adaptive machining module. The vision module detects the shape and position tolerances of the blank in real time and generates a compensation path, driving the adaptive machining module to complete high-precision trimming, drilling, or surface micro-processing.

[0019] S4. Rapid coating curing: The post-processed shell is sent into the multi-functional coating chamber, where electrostatic dust removal, primer spraying, and topcoat spraying are performed in sequence. The coating is cured within a preset time using a UV-assisted infrared hot air mixed drying method.

[0020] S5. Online Intelligent Inspection and Palletizing: Utilizes high-precision 3D vision sensors to perform full-size and appearance inspections on the finished product casings, and sorts qualified and unqualified products to different palletizing stations based on the inspection results.

[0021] As a preferred embodiment of the efficient manufacturing process for computer casings of the present invention, the modular material preparation in step S1 further includes: identifying raw material information through QR codes or RFID tags, and automatically matching the corresponding mold parameters and process formulas to achieve multi-variety co-line production with zero changeover time.

[0022] As a preferred embodiment of the efficient manufacturing process for computer casings according to the present invention, the composite machining center in step S2 is configured as a metal casing production line, including a continuous progressive die, which sequentially completes blanking, stretching, punching, flanging and cutting within the same die, and integrates a laser cutting module at the final station for fine trimming.

[0023] As a preferred embodiment of the efficient production process for computer casings according to the present invention, the composite processing center in step S2 is configured as a plastic casing production line, including a multi-station rotary injection molding machine, wherein the first station completes injection and pressure holding, the second station uses an in-mold cutter to cut off the gate before the mold is fully opened, and the third station performs rapid air cooling and shaping.

[0024] As a preferred embodiment of the efficient manufacturing process for computer casings according to the present invention, the visual inspection module in step S3 is based on a deep learning algorithm to identify microscopic defects such as scratches, shrinkage, and air bubbles on the surface of the casing, and to generate a three-dimensional defect map containing the location and depth of the defects.

[0025] As a preferred embodiment of the efficient manufacturing process for computer casings of the present invention, the adaptive machining module in step S3 is a six-axis industrial robot or a gantry machining center, which automatically adjusts the trajectory, pressure and dwell time of the cutting tool or sandblasting nozzle according to the three-dimensional defect map or geometric tolerance data, so as to accurately repair the defect area or remove excess material.

[0026] As a preferred embodiment of the efficient production process for computer casings according to the present invention, the multi-functional coating chamber in step S4 adopts a circulating air path design and is equipped with a dry filtration system to realize the recovery of paint mist after spraying and the standard emission of exhaust gas.

[0027] As a preferred embodiment of the efficient manufacturing process for computer casings of the present invention, the specific parameters of the ultraviolet light-assisted infrared hot air mixed drying method are as follows: First, ultraviolet light with a wavelength of 280-400nm is used to irradiate for 30-60 seconds to induce deep curing of the coating. Then, hot air at 60-80℃ is circulated and maintained for 5-8 minutes. Finally, surface cross-linking is strengthened by infrared radiation at 120-140℃ for 2-3 minutes.

[0028] As a preferred embodiment of the efficient manufacturing process for computer casings of the present invention, the online intelligent detection in step S5 further includes: analyzing the detection data in real time through a statistical process control model, and automatically adjusting the molding parameters in step S2 or the compensation path in step S3 when continuous defects or dimensional deviation trends are detected.

[0029] As a preferred embodiment of the efficient manufacturing process for computer casings according to the present invention, the entire production process is uniformly scheduled by the Manufacturing Execution System and communicates in real time with all equipment in steps S1 to S5 through the Industrial Internet of Things to achieve full-process traceability and dynamic energy efficiency management.

[0030] 3. Beneficial effects:

[0031] Compared with the prior art, the beneficial effects of the present invention are:

[0032] This type of computer casing uses a highly efficient manufacturing process:

[0033] 1. This invention achieves zero changeover time through modular material preparation; it integrates stamping / injection molding with subsequent trimming / gate cutting in the same station through intensive molding, eliminating inter-process transfer and waiting; combined with rapid curing technology, the overall production cycle is increased by more than 50% compared with existing discrete processes, and the manufacturing cycle is shortened from several hours to minutes.

[0034] 2. This invention introduces a closed-loop post-processing system, utilizing real-time data generated by a vision inspection module to drive adaptive machining. This fundamentally solves the problem that traditional fixed-path machining cannot adapt to blank deformation, improving the accuracy of processes such as trimming and drilling to ±0.02mm and increasing the overall yield to over 98%. Real-time feedback from online inspection proactively prevents batch defects, further reducing the scrap rate.

[0035] 3. The intensive molding and co-curing processes of this invention reduce repeated material handling and secondary heating between processes. The circulating air duct and dry filtration system in the coating room reduce energy and material consumption. The overall equipment footprint can be reduced by 30%-40%, and the comprehensive energy consumption per unit product is reduced by more than 25%.

[0036] 4. This invention achieves automated parameter formula management, dynamic energy efficiency optimization, and full-process quality traceability throughout the entire process through RFID information identification and unified scheduling of the MES system. The production line can quickly switch between producing different models of computer casings within 5 minutes, perfectly adapting to the market trend of personalization and customization. The dry filtration system replaces the traditional water curtain cabinet, avoiding the generation of spraying wastewater, while effectively collecting overspray paint mist, reducing VOC emissions, and meeting environmental protection regulations. Attached Figure Description

[0037] To more clearly illustrate the technical solutions of the embodiments of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and detailed embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein:

[0038] Figure 1 This is a flowchart illustrating the modular material preparation and intensive molding process for an efficient computer casing manufacturing process according to the present invention.

[0039] Figure 2 This is a closed-loop post-processing flowchart of an efficient computer casing manufacturing process according to the present invention.

[0040] Figure 3 This is a flowchart illustrating the rapid curing process of a coating in an efficient manufacturing process for computer casings according to the present invention.

[0041] Figure 4 This invention relates to an online intelligent inspection and palletizing system and a closed-loop feedback mechanism for efficient computer casing manufacturing. Detailed Implementation

[0042] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0043] This invention is described in detail with reference to the schematic diagrams. When describing the embodiments of this invention, for ease of explanation, the cross-sectional views illustrating the device structure may be partially enlarged, not according to the usual scale. Furthermore, the schematic diagrams are merely examples and should not be construed as limiting the scope of protection of this invention. In actual fabrication, the three-dimensional spatial dimensions of length, width, and depth should be included.

[0044] The orientation or positional relationship indicated in the terminology is based on the orientation or positional relationship shown in the accompanying drawings and is only for the convenience of describing the invention and simplifying the description, and is not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention.

[0045] The term "connection method" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0046] The embodiments of the present invention will now be described in further detail with reference to the accompanying drawings.

[0047] This invention provides an overall structural schematic diagram of an embodiment of an efficient computer casing manufacturing process, comprising:

[0048] Please see Figure 1-4 This embodiment of a high-efficiency manufacturing process for computer casings includes the following steps:

[0049] S1. Modular Material Preparation: Based on production instructions, automatically select and transport the corresponding type of metal sheet or plastic granules to the pre-processing station.

[0050] S2, Intensive Forming: The pre-treated raw materials are sent to the composite processing center, and the structural forming and residual material separation of the shell blank are completed in one go through the stamping and laser cutting modules or the injection molding and in-mold gate cutting modules integrated in the same station.

[0051] S3. Closed-loop post-processing: The shell blank is transferred to the intelligent post-processing unit, which integrates a vision inspection module and an adaptive machining module. The vision module detects the shape and position tolerances of the blank in real time and generates a compensation path, driving the adaptive machining module to complete high-precision trimming, drilling, or surface micro-processing.

[0052] S4. Rapid coating curing: The post-processed shell is sent into the multi-functional coating chamber, where electrostatic dust removal, primer spraying, and topcoat spraying are performed in sequence. The coating is cured within a preset time using a UV-assisted infrared hot air mixed drying method.

[0053] S5. Online Intelligent Inspection and Palletizing: Utilizes high-precision 3D vision sensors to perform full-size and appearance inspections on the finished product casings, and sorts qualified and unqualified products to different palletizing stations based on the inspection results.

[0054] Next, specifically, the modular material preparation in step S1 further includes: identifying raw material information through QR codes or RFID tags, and automatically matching the corresponding mold parameters and process formulas to achieve multi-variety co-line production with zero changeover time.

[0055] Furthermore, specifically, the composite machining center in step S2 is configured for the metal casing production line: including a continuous progressive die, which sequentially completes blanking, stretching, punching, flanging and cutting within the same die, and integrates a laser cutting module at the final station for fine trimming.

[0056] Next, specifically, the composite processing center in step S2 is configured for the plastic shell production line as follows: including a multi-station rotary injection molding machine, the first station completes injection and pressure holding, the second station uses an in-mold cutter to cut off the gate before the mold is fully opened, and the third station performs rapid air cooling and shaping.

[0057] Specifically, in step S3, the visual inspection module, based on a deep learning algorithm, is used to identify microscopic defects on the outer shell surface, such as scratches, shrinkage, and air bubbles, and to generate a three-dimensional defect map containing the location and depth of the defects.

[0058] Then, specifically, the adaptive machining module in step S3 is a six-axis industrial robot or a gantry machining center, which automatically adjusts the trajectory, pressure and dwell time of the tool or sandblasting nozzle according to the three-dimensional defect map or geometric tolerance data, so as to accurately repair the defect area or remove excess material.

[0059] Subsequently, specifically, the multi-functional painting chamber in step S4 adopts a circulating air path design and is equipped with a dry filtration system to achieve the recovery of paint mist after spraying and the emission of exhaust gas in compliance with standards.

[0060] Next, the specific parameters of the ultraviolet light-assisted infrared hot air mixed drying method are as follows: First, the coating is irradiated with ultraviolet light with a wavelength of 350nm for 60 seconds to induce deep curing. Then, it is maintained by hot air circulation at 60℃ for 8 minutes. Finally, the surface cross-linking is strengthened by infrared radiation at 140℃ for 2 minutes.

[0061] Furthermore, specifically, the online intelligent detection in step S5 further includes: analyzing the detection data in real time through a statistical process control model, and automatically adjusting the molding parameters in step S2 or the compensation path in step S3 when continuous defects or dimensional deviation trends are detected.

[0062] Finally, specifically, the entire production process is uniformly scheduled by the Manufacturing Execution System (MES) and communicates in real time with all equipment in steps S1 to S5 through the Industrial Internet of Things (IIoT) to achieve full-process traceability and dynamic energy efficiency management.

[0063] Example 1:

[0064] This process organically integrates modular material preparation, intensive molding, closed-loop post-processing, rapid coating curing, and online intelligent inspection and palletizing to form a highly automated and flexible continuous production line. It aims to solve the problems of dispersed processes, frequent material transfers, high energy consumption, and delayed quality feedback in the existing computer casing manufacturing process.

[0065] In one specific embodiment of the present invention, the efficient manufacturing process for the computer casing begins with a modular material preparation step. The manufacturing execution system, based on the received production instructions, parses the specific model, quantity, and delivery time requirements of the computer casing to be produced, and automatically selects metal sheets of the corresponding specifications from the raw material storage area accordingly.

[0066] For example, aluminum alloy sheets or magnesium alloy sheets can be selected, or corresponding grades of plastic granules can be chosen, such as polycarbonate and acrylonitrile-butadiene-styrene copolymer alloys. The selected raw materials are then precisely transported to the pre-processing station via automated guided vehicles or roller conveyor lines.

[0067] At this pretreatment station, the system automatically levels and cleans / degreases metal sheets, while dehumidifying and drying plastic granules. To further enable flexible, multi-variety, small-batch co-production, the modular material preparation process also includes automatic identification of raw material information and formula matching.

[0068] Specifically, each roll of metal sheet has a QR code label or RFID tag attached to its core or the packaging bag of each bag of plastic granules. This tag contains unique identification information for that batch of raw materials. When the raw materials enter the material preparation conveyor line, an industrial barcode reader or RFID reader / writer installed on the side of the conveyor line reads the information stored in the tag without contact. This information may include, but is not limited to, the material grade, production date, supplier code, and batch number. After obtaining this information, the Manufacturing Execution System (MES) immediately retrieves the preset mold parameters and process formula matching the raw material information from the process database.

[0069] Mold parameters can include the closing height of a stamping die, the set value of the stamping force curve, or the clamping force and ejection stroke of an injection mold; the process formula can include the temperature of each section of the injection molding machine's barrel, injection pressure and speed, holding time, etc., or the stamping speed and drawbar resistance adjustment value of the stamping equipment. Since this identification and matching process is completely automated, eliminating the need for tedious manual adjustments and parameter testing after mold changes, the production changeover time between different product models can be compressed to an extremely short level, even reaching the ideal state of zero changeover time. This significantly improves equipment utilization and the production line's ability to quickly respond to diverse market demands.

[0070] After modular material preparation is completed, the pre-treated raw materials are sent to the composite processing center to perform intensive molding steps. The core design concept of this composite processing center is to integrate the molding process and the waste material separation process, which are traditionally completed on multiple independent machines, into the same workstation or the same equipment system and complete them at once, thereby significantly shortening the material flow distance and waiting time between processes.

[0071] For the two main product types, metal casings and plastic casings, embodiments of the present invention provide two different composite machining center configuration schemes using different technical approaches. On a production line for manufacturing computer metal casings, the composite machining center is configured as a large multi-station press, with a specially designed progressive die mounted on its worktable. This progressive die has multiple stamping stations arranged sequentially along the feeding direction, each station corresponding to a different forming process.

[0072] Specifically, when the metal coil is driven by the automatic feeder to step through the mold, the blank is first unloaded at the first station; then in the subsequent stations, it goes through the stretching station to form the general concave outline of the shell, the punching station to punch the reserved holes for the keyboard area or interface area, and the flanging station to form the vertical or oblique bending structure of the shell edge; finally, at the cutting station at the end of the mold, the workpiece that has completed the main body forming is separated from the carrier strip.

[0073] Specifically, a high-precision fiber laser cutting module is integrated near the final cutting station of the progressive die or as a separate downstream station. This laser cutting module is equipped with a dynamic focusing galvanometer system, which can perform fine trimming on complex and subtle features on the shell blank that cannot be directly formed due to stamping process limitations before or after the workpiece is cut and separated. For example, it can deburr and round the edges of heat dissipation holes, perform high-precision hole enlargement on camera holes or fingerprint recognition holes, and precisely cut the gaps of antenna partition strips.

[0074] The cutting path of the laser cutting module is automatically generated and driven by the CNC system built into the composite machining center based on the 3D model data of the current production model. For production lines using computer plastic casings, the composite machining center is configured as a multi-station rotary injection molding machine. This rotary injection molding machine has a turntable that rotates around a vertical axis, on which multiple mold lower parts are evenly distributed along the circumference. In a complete work cycle, the turntable rotates sequentially through several fixed stations. At the first station, the injection station, the injection unit of the injection molding machine injects molten plastic material into the closed mold cavity at high pressure and high speed, and holds it under pressure for a period of time to compensate for the plastic's cooling and shrinkage.

[0075] Subsequently, the turntable, carrying the workpiece which has not yet fully cooled and the mold has not fully opened, rotates to the second station. At this station, an in-mold gate-cutting mechanism hidden inside the mold is activated. This mechanism, driven by a miniature hydraulic cylinder or high-pressure pneumatic cylinder, precisely cuts off the solidified but still warm gate material from the product body at the end of the mold's runner system, close to the product surface. Because the product is still constrained and supported within the mold cavity at this time, it avoids quality problems such as tearing, cracking, or excessively high residual sprue that are easily caused by traditional post-gate-cutting processes, and the cut surface is smooth and clean. After the gate is cut off, the turntable continues to rotate to the third station, the air-cooling and shaping station.

[0076] At this workstation, the upper and lower molds are opened with a tiny gap, or through specially designed air channels inside the mold, filtered and cooled compressed air is blown onto the surface and interior of the workpiece to rapidly and uniformly cool the product, thereby accelerating its shaping and reducing internal stress warping deformation caused by uneven cooling.

[0077] By integrating the three processes of injection molding and pressure holding, in-mold gate cutting, and rapid air cooling and shaping into different stations on the same equipment, the molding cycle of the plastic shell is significantly shortened, and the product dimensional accuracy and appearance quality are effectively improved.

[0078] The computer casing blanks obtained after the intensive forming process, whether made of metal or plastic, often have burrs and flash on their edges, or small machining allowances for holes and feature dimensions. Therefore, the casing blanks need to be transferred to an intelligent post-processing unit to perform closed-loop post-processing steps. This intelligent post-processing unit is an integrated workstation that combines online inspection and adaptive processing functions.

[0079] Specifically, the core components of this unit include a vision inspection module consisting of a high-resolution industrial camera system, and an adaptive machining module consisting of a six-axis industrial robot or a gantry machining center equipped with different end effectors. The shell blank is accurately placed onto a fixed fixture within the post-processing unit via a conveyor belt or robot gripper.

[0080] First, the vision inspection module begins operation. Its structured light projection device or laser contour scanner projects a specific pattern of light onto the surface of the billet, while multiple high-resolution industrial cameras at different angles simultaneously acquire images. Based on the acquired 3D point cloud data, the built-in vision algorithm software can accurately register and compare the measured data with the theoretical 3D model, thereby calculating the form and position tolerances of the billet at key feature locations, such as flatness, contour, and position, and generating a compensation path file containing specific deviation values ​​and directions in real time.

[0081] In addition, the visual inspection module also integrates defect recognition functionality based on deep learning algorithms. During the model training phase, technicians have inputted a massive number of image samples containing various common appearance defects into the deep neural network model, such as scratches, abrasions, and indentations that may occur during the stamping process of metal shells, and shrinkage marks, weld lines, air bubbles, and black spots that may occur during the injection molding process of plastic shells.

[0082] A well-trained model can analyze acquired images within milliseconds, identifying not only the type of defect but also accurately pinpointing its spatial coordinates, outline, and estimating its depth or severity, thereby generating a 3D defect map. This 3D defect map, along with the aforementioned geometric tolerance compensation path file, is transmitted to the control system of the adaptive machining module. Based on the received instruction data, the adaptive machining module automatically selects an appropriate end-effector from its tool library.

[0083] Examples include alloy milling cutters for metal trimming, miniature rotary files for plastic deburring, drill bits for drilling, and flexible sanding belts or sandblasting guns for surface micro-treatment. Six-axis industrial robots or gantry machining centers, with their multi-degree-of-freedom flexible spatial motion capabilities, precisely drive these tools along generated compensation paths to perform high-precision trimming of shell blanks, enlarging or drilling of pre-drilled holes, and precise grinding or polishing of surface scratches and other defective areas.

[0084] For example, for a shallow scratch on a metal casing, the adaptive processing module can control the end effector of a robot equipped with a micro-flexible polishing wheel to perform localized polishing along the scratch trajectory with precise pressure and a preset number of reciprocations until the visual inspection module confirms that the defect has been eliminated. This closed-loop working mode of "inspection-analysis-processing-re-inspection" ensures that every casing product achieves extremely high dimensional accuracy and appearance quality standards after post-processing, while minimizing material removal and improving processing efficiency.

[0085] After the post-processing steps are completed, the computer casing can proceed to the rapid coating curing step. In this embodiment of the invention, this step is completed in a specially designed multi-functional coating chamber. This coating chamber is a closed or semi-closed passageway structure, internally divided into several continuous functional sections.

[0086] The outer casing products first enter the electrostatic dust removal section via a suspended conveyor chain or a ground-mounted pallet. In this section, rotating electrostatic dust removal brushes, in conjunction with ionizing air bars, effectively remove fine dust and fibers adsorbed on the product surface, creating a clean base for subsequent spraying.

[0087] Subsequently, the product passes through the primer spraying station and the topcoat spraying station in sequence. At the primer spraying station, multiple reciprocating spraying robots or fixed automatic spray guns atomize and spray a uniform layer of primer coating onto the outer shell surface according to the product shape. The main function of the primer is to enhance the adhesion between the coating and the substrate and provide basic anti-corrosion performance.

[0088] After a brief settling period, the product enters the topcoat spraying station. The spraying robot, following a pre-programmed procedure, applies the pre-mixed topcoat paint with the correct color and gloss level onto the primer layer, giving the product the desired final appearance, color, and texture. After spraying, the product proceeds to the core of this process: the mixing, drying, and curing section. This section utilizes a UV-assisted infrared hot air mixing and drying method to achieve rapid and high-quality curing of the coating.

[0089] The specific working process and optimized process parameters are as follows: First, the product enters a UV pre-curing area equipped with a shielded door. Within this area, multiple sets of high-power UV LEDs arranged above, below, and on both sides of the product are illuminated. These LEDs emit UV light with wavelengths primarily between 280 and 400 nanometers, intensely irradiating the liquid coating on the product surface for 30 to 60 seconds. This UV light can penetrate the coating surface, triggering a rapid reaction of the photoinitiator within the coating. This causes a deep cross-linking reaction within seconds, forming a preliminary three-dimensional network skeleton structure, achieving a surface-dry or even touch-dry state. This effectively prevents sagging or surface particle adsorption problems that may occur during subsequent hot air drying.

[0090] Next, the product enters an insulated zone equipped with a hot air circulation system. In this zone, clean air, heated to 60 to 80 degrees Celsius by electric or gas heating devices, is circulated across the product surface at a certain speed by a fan, a process that lasts five to eight minutes. The gentle hot air environment helps the solvents or moisture inside the coating to evaporate slowly and evenly, and allows the coating to further level and solidify on the framework formed by UV pre-curing, eliminating any possible pinholes or orange peel effect.

[0091] Finally, the product enters a high-temperature strengthening zone equipped with a mid-wave infrared radiator. When energized, the infrared radiator emits mid-wave infrared radiation, which is strongly absorbed by the coating material, rapidly raising the coating temperature to 120-140 degrees Celsius within two to three minutes. Within this temperature range, the active functional groups in the coating resin undergo a vigorous thermal cross-linking strengthening reaction, making the molecular network structure of the coating denser and stronger, ultimately endowing the coating with excellent hardness, wear resistance, chemical corrosion resistance, and scratch resistance. The entire mixing, drying, and curing process is precisely controlled within a preset time. Compared to traditional single hot air drying methods, the curing time is significantly shortened, energy consumption is lower, and the final performance indicators of the coating are significantly improved.

[0092] Furthermore, this multi-functional painting booth employs an advanced circulating airflow design and a dry filtration system. Air within the painting booth is guided through the circulating airflow, carrying overspray paint mist particles generated during the spraying process into the dry filtration module. This module is filled with labyrinthine baffles or high-dust-capacity fiberglass filter felt. Paint mist particles are captured and trapped by impact and inertia, while the clean air is either recycled or treated by a subsequent activated carbon adsorption device to meet emission standards before being released into the atmosphere. This achieves effective recovery of overspray paint mist during the spraying process and environmentally compliant emission of volatile organic compounds (VOCs).

[0093] After the computer casings have undergone coating curing and cooled to room temperature, they are transported to the online intelligent inspection and palletizing station. This station is equipped with an inspection and sorting system consisting of high-precision 3D vision sensors, a high-performance image processing industrial computer, and a sorting and palletizing robot.

[0094] High-precision 3D vision sensors typically employ structured light 3D scanning technology or multi-view stereo vision technology, enabling them to rapidly acquire complete 3D topographic data of the entire computer casing surface and edges with micron-level precision. The measurement software within the industrial control computer comprehensively compares this measured 3D data with the computer-aided design theoretical model, automatically calculating and outputting the measured values ​​and deviations of all key control dimensions of the product. Simultaneously, its appearance defect detection algorithm module also analyzes the surface image to identify any potential coating defects, scratches, dents, or stains.

[0095] Based on pre-set tolerance ranges and appearance quality standards, the control system determines each inspected casing as either "qualified" or "unqualified." After inspection, the palletizing robot or Cartesian coordinate sorting robot at the end of the conveyor line performs precise sorting actions based on the received judgment signal: casings judged as qualified are picked up by the robot and neatly stacked into pallets or dedicated turnover boxes at the qualified product palletizing station, ready for warehousing or packaging.

[0096] Shells deemed defective are sorted onto a separate defective product buffer conveyor line, awaiting further manual review, rework, or scrapping. To further enhance the production line's intelligence and real-time quality control, the detection data generated by the online intelligent inspection process is not only used for immediate pass / fail determination but is also analyzed in real-time by a statistical process control model.

[0097] The model continuously monitors changes in statistical indicators of critical dimensions and defect numbers, such as mean, range, and standard deviation. When the model detects multiple consecutive defective products, or observes that the mean of a critical dimension shows a continuous trend of shifting towards the tolerance zone boundary, it means that a slow drift or anomaly may have occurred in a certain stage of the production process.

[0098] At this point, the online intelligent inspection system automatically sends feedback adjustment commands to upstream equipment on the production line via industrial Ethernet. For example, if a flatness index of the casing shows a tendency to exceed tolerances, the system will adjust the blank holder force parameter of the stamping process in the composite machining center, or adjust a specific coefficient in the compensation path algorithm of the intelligent post-processing unit. If continuous shrinkage defects are found in the injection molded parts, the system will adjust the holding pressure or mold temperature parameters of the injection molding machine. This closed-loop automatic quality feedback adjustment mechanism based on process data can correct process parameters back to the optimal state before a large number of scrap products are generated, thereby minimizing production losses.

[0099] Throughout all the steps described above—modular material preparation, intensive molding, closed-loop post-processing, rapid coating curing, and online intelligent inspection and palletizing—is a Manufacturing Execution System (MES) deployed on a central server. This MES acts as the "brain" of the entire production line, communicating in real-time, bidirectionally with all automated equipment distributed across various workstations via an Industrial Internet of Things (IIoT) platform. This includes, but is not limited to, automated guided vehicles (AGVs), conveyor line controllers, programmable logic controllers (PLCs) in composite machining centers, injection molding machine controllers, industrial robot control cabinets, PLCs in the painting room, and vision inspection industrial control computers.

[0100] The Manufacturing Execution System (MES) is responsible for the unified scheduling and production planning of production tasks, breaking down production instructions into specific action sequences and process parameters that can be executed by each workstation. Simultaneously, it collects real-time operational status data, measured process parameter values, alarm information, and unique traceability codes and inspection results for each product from each piece of equipment. Through the correlation and aggregation of this massive amount of data, the MES can establish a complete digital product file for each computer casing leaving the factory. This file records detailed data throughout the entire process, from raw material batches, molding parameters, post-processing compensation amounts, coating process curves to final inspection results, achieving full traceability of product quality.

[0101] Meanwhile, the manufacturing execution system also incorporates dynamic energy efficiency management, which can monitor the instantaneous power and cumulative energy consumption of major energy-consuming equipment such as presses, injection molding machines, and heating and drying tunnels in real time. It also analyzes the data in conjunction with production rhythm and output. When it finds that the energy utilization rate is low or there is abnormal energy waste, it will promptly issue optimization suggestions to the management personnel or automatically adjust the working mode of the equipment. For example, it can make the equipment automatically switch to a low-power sleep state during standby intervals, thereby optimizing the energy consumption of the entire production line while ensuring production efficiency and quality.

[0102] Although the present invention has been described above with reference to embodiments, various modifications can be made and components can be replaced with equivalents without departing from the scope of the invention. In particular, as long as there is no structural conflict, the features in the disclosed embodiments can be combined with each other in any manner. The lack of an exhaustive description of these combinations in this specification is merely for the sake of brevity and resource conservation. Therefore, the present invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A high-efficiency manufacturing process for computer casings, characterized in that, Includes the following steps: S1. Modular material preparation: Based on production instructions, automatically select and transport the corresponding type of metal sheet or plastic granules to the pre-processing station; S2, Intensive Forming: The pre-treated raw materials are sent to the composite processing center, and the structural forming and residual material separation of the shell blank are completed in one go through the stamping and laser cutting modules or the injection molding and in-mold gate cutting modules integrated in the same station. S3, Closed-loop post-processing: The shell blank is transferred to the intelligent post-processing unit, which integrates a vision inspection module and an adaptive processing module. The vision module detects the shape and position tolerance of the blank in real time and generates a compensation path, driving the adaptive processing module to complete high-precision trimming, drilling or surface micro-processing. S4. Rapid coating curing: The post-processed shell is sent into the multi-functional coating chamber, where electrostatic dust removal, primer spraying, and topcoat spraying are performed in sequence. The coating is cured within a preset time using a UV-assisted infrared hot air mixed drying method. S5. Online Intelligent Inspection and Palletizing: Utilizes high-precision 3D vision sensors to perform full-size and appearance inspections on the finished product casings, and sorts qualified and unqualified products to different palletizing stations based on the inspection results.

2. The efficient manufacturing process for computer casings according to claim 1, characterized in that, The modular material preparation in step S1 further includes: identifying raw material information through QR codes or RFID tags, and automatically matching the corresponding mold parameters and process formulas to achieve multi-variety co-line production with zero changeover time.

3. The efficient manufacturing process for computer casings according to claim 1, characterized in that, The composite machining center in step S2 is configured for a metal shell production line: it includes a continuous progressive die, which sequentially completes blanking, stretching, punching, flanging and cutting within the same die, and integrates a laser cutting module at the final station for fine trimming.

4. The efficient manufacturing process for computer casings according to claim 1, characterized in that, The composite processing center in step S2 is configured for the plastic shell production line, including a multi-station rotary injection molding machine. The first station completes injection and pressure holding, the second station uses an in-mold cutter to cut off the gate before the mold is fully opened, and the third station performs rapid air cooling and shaping.

5. The efficient manufacturing process for computer casings according to claim 1, characterized in that, The visual inspection module in step S3 is based on a deep learning algorithm and is used to identify microscopic defects such as scratches, shrinkage, and air bubbles on the surface of the shell, and generate a three-dimensional defect map containing the location and depth of the defects.

6. The efficient manufacturing process for computer casings according to claim 5, characterized in that, The adaptive machining module in step S3 is a six-axis industrial robot or a gantry machining center. Based on the three-dimensional defect map or geometric tolerance data, it automatically adjusts the trajectory, pressure, and dwell time of the cutting tool or sandblasting nozzle to accurately repair the defect area or remove excess material.

7. The efficient manufacturing process for computer casings according to claim 1, characterized in that, The multi-functional painting chamber in step S4 adopts a circulating air path design and is equipped with a dry filtration system to realize the recovery of paint mist after spraying and the emission of exhaust gas in compliance with standards.

8. The efficient manufacturing process for computer casings according to claim 1, characterized in that, The specific parameters of the ultraviolet light-assisted infrared hot air mixed drying method are as follows: First, ultraviolet light with a wavelength of 280-400nm is used to irradiate for 30-60 seconds to induce deep curing of the coating. Then, hot air at 60-80℃ is circulated for 5-8 minutes. Finally, surface cross-linking is strengthened by infrared radiation at 120-140℃ for 2-3 minutes.

9. The efficient manufacturing process for computer casings according to claim 1, characterized in that, The online intelligent detection in step S5 further includes: analyzing the detection data in real time through a statistical process control model, and automatically adjusting the molding parameters in step S2 or the compensation path in step S3 when continuous defects or dimensional deviation trends are detected.

10. The efficient manufacturing process for computer casings according to claim 1, characterized in that, The entire production process is uniformly scheduled by the Manufacturing Execution System (MES) and communicates in real time with all equipment in steps S1 to S5 through the Industrial Internet of Things (IIoT) to achieve full-process traceability and dynamic energy efficiency management.

Images