A steering wheel switch roller automatic assembly device and method

Abstract

The application discloses a kind of steering wheel switch roller automatic assembly equipment and method, equipment includes spring feeding device, steel ball feeding device, material transfer device and assembly execution device.Spring feeding device is screened by vibration disc and visual identification component posture compliance and length qualified spring;Steel ball feeding device is accepted single steel ball by the positioning groove of the top end of material placement pipe, cooperates vacuum airway adsorption and jacking drive and sends out steel ball;Material transfer device places spring and two steel balls in the feeding position of assembly track with the axis arrangement mode of spring centering, steel ball is arranged in two ends;Push rod is pushed into the passage hole of roller body along assembly track with spring and steel ball.The application realizes the full-process automation of spring and steel ball from bulk material feeding to push assembly, double-station alternate operation efficiency is high, multi-link detection guarantees assembly quality consistency is good, and visual guidance scheme change production flexibility is high.

Description

Technical Field

[0001] This invention relates to the field of automated assembly equipment for automotive parts, specifically to an assembly device and method for automatically assembling springs and steel balls into the body of a steering wheel switch roller. Background Technology

[0002] In the manufacturing process of automotive steering wheel switches (such as volume control switches, cruise control switches, etc.), the assembly of the roller assembly is one of the key processes. The roller assembly typically consists of a roller body, a spring, and steel balls. After the spring and steel balls are installed into the internal channel holes of the roller body, the steel balls, under the elastic force of the spring, cooperate with the external structure to provide the roller with a clear gear shift feel and reliable rebound force. The assembly precision and consistency of the roller assembly directly affect the operating feel and lifespan of the steering wheel switch.

[0003] Traditional assembly methods rely primarily on manual operation. Workers manually, or with the aid of simple tools such as tweezers and pins, place the spring and one or more steel balls in a specific position at the entrance of the roller's channel hole, and then use tools to press the spring and steel balls into the channel hole. This method has the following significant drawbacks: First, the assembly efficiency is low, the manual operation rhythm is limited, and the springs and steel balls are both micro parts at the millimeter level. The material picking, alignment and pressing process takes a long time, which is difficult to adapt to the production needs of large batch and fast pace, and often becomes the production capacity bottleneck of the production line.

[0004] Secondly, the quality consistency is poor. The accuracy of manual assembly is highly dependent on the operator's skill and condition, which easily leads to defects such as missing springs, incorrect number of steel balls, or improper assembly, resulting in large fluctuations in the product qualification rate. At the same time, it is difficult to check the free length of each spring individually during manual operation. Deviations in the free length of the springs will cause inconsistencies in the feel of the roller's shifting position and the rebound force after assembly, affecting the stability of product quality.

[0005] Third, the labor costs are high. This process requires high eyesight, hand stability and proficiency from the operators. The training cycle is long and the repetitive and delicate work can easily lead to fatigue and occupational injuries, resulting in heavy long-term labor costs and management burden.

[0006] Fourth, there is a lack of flexibility. When product models change (such as changes in roller size or switch structure), manual assembly lines need to be retrained and adjusted, resulting in long changeover cycles and an inability to quickly respond to the trend of flexible production with multiple varieties and small batches.

[0007] With the increasing electronic and intelligent development of automotive interiors, steering wheel switches are becoming more functional and complex in structure, placing stringent demands on the precision, tactile consistency, and reliability of the roller assembly. Therefore, the industry urgently needs an automated steering wheel switch roller assembly system that can achieve full automation, high precision, high stability, and a certain degree of flexibility to solve the problems of low efficiency, poor consistency, and high cost associated with existing manual assembly methods. Summary of the Invention

[0008] In view of the technical problems in the existing technology where the assembly of steering wheel switch roller components relies on manual operation, resulting in low assembly efficiency, poor quality consistency, high labor costs, and insufficient flexibility in production changeover, the present invention aims to provide an automated steering wheel switch roller assembly equipment and method that can achieve full automation, high precision, and high stability.

[0009] To achieve the above objectives, the present invention provides the following technical solution: An automatic assembly device for a steering wheel switch roller is used to assemble a spring and steel balls located at both ends of the spring axially into a roller body. The roller body has a channel hole and includes: A spring feeding device is used to provide individual springs with the correct posture. A steel ball feeding device is used to provide individual steel balls. The steel ball feeding device includes a receiving bin, a lifting drive, a feeding tube, and a vacuum circuit assembly. The top end of the feeding tube is provided with a positioning groove for receiving individual steel balls. The feeding tube moves up and down in the receiving bin under the drive of the lifting drive. After the positioning groove receives the steel ball, the vacuum circuit assembly draws air to adsorb the steel ball into the positioning groove. The feeding tube is then lifted to send the steel ball out for the material transfer device to pick up. The material transfer device is used to grab the springs provided by the spring feeding device and the steel balls provided by the steel ball feeding device, and place the springs and steel balls in the assembly execution device with the spring in the center and the two steel balls on both ends of the spring axis. An assembly actuator is used to assemble springs and steel balls into a roller body. The assembly actuator includes an assembly track and an assembly base located at the end of the assembly track. The assembly track has a loading position for receiving springs and steel balls. The assembly base has a positioning clamp, a lifting mechanism, and a clamping mechanism for fixing the roller body to the positioning clamp. The assembly actuator also includes a pushing mechanism, which includes a push rod that slides along the assembly track. The push rod is used to push the springs and steel balls, which are arranged axially at the loading position, into the channel hole along the assembly track.

[0010] By adopting the above technical solution, and through the coordinated operation of the spring feeding device, steel ball feeding device, material transfer device, and assembly execution device, a fully automated operation from bulk material feeding to finished product output is achieved. The steel ball feeding device uses a positioning groove at the top of the feeding tube to receive a single steel ball, which is then fixed by vacuum circuit components. A lifting drive component then lifts the feeding tube to deliver the steel ball, achieving precise separation and reliable feeding of individual steel balls, solving the problem of multiple or empty balls caused by steel ball stacking and adhesion in traditional vibration feeding methods. The material transfer device places the spring and two steel balls on the assembly track with the spring in the center and the steel balls at opposite ends along the axial direction. A push rod pushes the axially arranged spring and steel balls along the assembly track into the channel hole of the roller body. During the pushing process, the spring and steel balls maintain axial alignment within the track groove, ensuring uniform force and preventing spring bending or steel ball misalignment. Positioning clamps and clamping mechanisms on the assembly base reliably fix the roller body, ensuring accurate pushing position. After assembly, the lifting mechanism applies a lifting force to the roller body to lock it in place, thus completing the final assembly.

[0011] Preferably, the spring feeding device includes a vibratory feeder and a spring vision recognition component located above the vibratory feeder. The spring vision recognition component is used to screen springs with compliant posture and qualified length, and guide the material transfer device to accurately grasp them.

[0012] By adopting the above technical solution, the spring feeding device uses a vibratory feeder in conjunction with a spring vision recognition component. The vibratory feeder outputs the scattered springs one by one, and the vision recognition component automatically detects and filters the posture and free length of each spring, selecting springs with compliant posture and qualified length, and guiding the material transfer device to accurately grasp them. This design avoids the omissions and misjudgments caused by traditional manual visual screening, which relies on experience and condition. It ensures that the springs grasped each time have a uniform posture and meet the length requirements, eliminating the quality problems of assembly jamming due to incorrect spring posture and inconsistent roller operation feel due to spring length deviation from the source.

[0013] Preferably, the containing chamber has at least two hoppers, each hopper having a corresponding set of lifting drive components, a material placement pipe, and a vacuum circuit assembly; the material placement pipe has an air hole communicating with the positioning groove, the diameter of the air hole being smaller than the diameter of the positioning groove and smaller than the diameter of the steel ball; a steel ball visual recognition component is provided above the containing chamber to guide the material transfer device to accurately pick up the steel ball.

[0014] By adopting the above technical solution, the receiving chamber is equipped with at least two hoppers, each corresponding to an independent set of lifting drive components, feeding pipes, and vacuum circuit components, forming a multi-module backup material supply. When a single hopper is empty or malfunctions, the material transfer device can switch to another hopper to continue picking up material without stopping the equipment, significantly improving the continuity of material supply and operational reliability. The diameter of the air vents inside the feeding pipe is smaller than the diameter of the positioning groove and smaller than the diameter of the steel ball, ensuring that the steel ball is reliably adsorbed in the positioning groove and will not fall into the air vents, guaranteeing the effectiveness of vacuum adsorption and the stability of steel ball positioning. A steel ball visual recognition component is installed above the receiving chamber to guide the material transfer device to accurately pick up the steel ball, resulting in a high success rate of material retrieval.

[0015] Preferably, the assembly execution device further includes a blocking mechanism located on the side of the assembly track. The blocking mechanism includes a blocking drive and a blocking block connected to the blocking drive. The blocking block can extend into or out of the assembly track under the drive of the blocking drive. When the spring and steel ball are pushed to the position of the blocking block by the push rod, the blocking block axially limits them.

[0016] By adopting the above technical solution, a blocking mechanism is set on the side of the assembly track. When the push rod pushes the spring and steel ball, the blocking block extends into the track groove under the drive of the blocking drive component, axially limiting the spring and steel ball and stopping them at a predetermined position. This design provides a segmented pause node for material inspection and spring deformation detection during the assembly process. Compared with the assembly method of pushing the push rod directly in one go, it can effectively check the material status during the push, avoiding the inclusion of products with missing springs or steel balls in the finished product.

[0017] Preferably, a material detection vision component is provided at the corresponding blocking block position to detect whether the spring and steel ball are missing; a pressure sensing component is provided on the push rod or the drive path of the push rod to detect the deformation pressure data when the push rod pushes the spring.

[0018] By adopting the above technical solution, a material detection vision component is installed at the pause position corresponding to the blocking block to check the integrity of the springs and steel balls, detecting whether there are missing springs or insufficient steel balls, thus realizing material confirmation during assembly. A pressure sensing component is installed on the push rod or the push rod drive path. When the push rod continues to advance and compresses the spring, the pressure sensing component detects the pressure on the push rod in real time to determine whether the spring deformation meets the standard. This pressure detection can effectively identify abnormalities such as excessive deviation of the spring's free length or missing springs, ensuring that each product has passed the deformation force verification before being pushed into the channel hole, guaranteeing the consistency of the roller's shift feel and rebound force after assembly.

[0019] Preferably, the clamping mechanism includes a clamping drive and a pressure plate driven by the clamping drive, the pressure plate being used to clamp the roller body onto the positioning fixture; the lifting mechanism is used to apply an upward lifting force to the roller body after the spring and steel ball are pushed into the channel hole, so that the spring and steel ball are assembled in the roller body.

[0020] By adopting the above technical solution, the clamping mechanism drives the pressure plate through the clamping drive component to press the roller body onto the positioning fixture, ensuring that the roller body does not shift or loosen during the process of the push rod pushing the spring and steel ball, thus guaranteeing the precise alignment of the channel hole and the track groove. After the spring and steel ball are pushed into the channel hole, the lifting mechanism applies an upward lifting force to the roller body, causing the roller body to be locked internally, and the spring and steel ball are limited and fixed in the channel hole, completing the final assembly and locking. The sequential actions of clamping and lifting ensure stability during the pushing process and achieve reliable locking after assembly.

[0021] Preferably, there are two sets of assembly actuators, which are arranged symmetrically or side by side; the material transfer device alternately supplies springs and steel balls to the two sets of assembly actuators.

[0022] By adopting the above technical solution, two sets of assembly actuators are set up, arranged symmetrically or side by side. The material transfer device alternately supplies springs and steel balls to the two sets of assembly actuators. When one set of assembly actuators is performing push assembly, the material transfer device places the next set of materials to the other set. The two assembly stations work alternately, effectively eliminating assembly waiting time and significantly improving the overall production cycle and capacity of the equipment.

[0023] Preferably, the material transfer device is a multi-axis robot, and the end of the multi-axis robot is equipped with a gripper for grasping springs and a suction nozzle for picking up steel balls.

[0024] By adopting the above technical solution, the material transfer device uses a multi-axis robot with a spring gripper and a steel ball suction nozzle at the end. It can sequentially or simultaneously complete the gripping of springs and the suction of steel balls in a single cycle, resulting in high material transfer efficiency. The multi-axis robot is highly mobile, capable of quickly switching and positioning between the spring feeding device, the steel ball feeding device, and two sets of matching actuators, adapting to the material scheduling needs of multiple workstations. Furthermore, when product models change, only the robot program needs to be adjusted, improving production flexibility.

[0025] The present invention also provides an automatic assembly method for a steering wheel switch roller, using the aforementioned automatic assembly equipment for a steering wheel switch roller, comprising the following steps: The feeding process is as follows: the spring feeding device outputs a single spring with a qualified posture, and the steel ball feeding device outputs a single steel ball through the lifting of the feeding pipe and the vacuum air path adsorption. The material transfer device grabs one spring and two steel balls in sequence or simultaneously, and places them on the loading position of the assembly track with the spring in the center and the steel balls at both ends of the spring in an axial arrangement. Push-and-assemble steps: Place the roller body in the positioning fixture, and the clamping mechanism clamps the roller body; the push rod slides along the assembly track, pushing the spring and steel ball to the end of the assembly track and pushing the spring and steel ball into the channel hole of the roller body; the lifting mechanism applies an upward lifting force to the roller body, so that the roller body is locked and the assembly is completed. Finished product removal steps: Loosen the clamping mechanism and remove the assembled roller components.

[0026] By adopting the above technical solution, this method divides the entire assembly process into three steps: material feeding, push-press assembly, and finished product removal. The process is clear and the actions are closely linked. In the material feeding step, the springs and steel balls are arranged axially with the springs in the center and the steel balls at both ends, providing precise material arrangement for the subsequent push-press assembly. In the push-press assembly step, the push rod pushes the springs and steel balls along the track into the channel hole, and the lifting mechanism locks them in place. In the finished product removal step, the clamping mechanism releases, and the finished product can be removed. The entire method achieves a fully automated closed loop from material supply to assembly completion, with strong operational consistency.

[0027] Preferably, the push assembly step also includes a detection sub-step: the push rod first pushes the spring and steel ball to the stop block and pauses, and the material detection vision component detects whether the spring and steel ball are missing; after the detection is passed, the push rod continues to advance to compress and deform the spring, and the pressure sensing component detects the pressure on the push rod at this time to determine whether the spring deformation meets the standard; after meeting the standard, the stop block is removed, and the push rod continues to push the material completely into the channel hole.

[0028] By adopting the above technical solution, a detection sub-step is added to the push-assembly process. The push rod first pushes the spring and steel ball to the stop block and pauses. The material detection vision component performs an integrity check. After confirming that there are no missing parts, the push rod continues to push and compress the spring. The pressure sensing component detects the deformation pressure data in real time. This segmented assembly method of "push-pause detection-continue pushing" integrates material missing detection and spring deformation force detection into the same pushing process. Two key quality inspections are completed before the spring and steel ball enter the channel hole, ensuring that only qualified products can be pushed in to complete the assembly. This effectively prevents unqualified products from flowing out due to missing springs or abnormal spring force values, providing a reliable closed-loop guarantee for product quality.

[0029] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. Significantly improves assembly efficiency and capacity. The equipment achieves fully automated operation from bulk material loading to finished product output, meeting the needs of continuous high-intensity production with a stable production cycle that is far superior to manual operation. Through the parallel operation of the dual-station assembly actuator and the efficient scheduling of robots, while performing push assembly at one station, the robot places the next set of springs and steel balls at the other station, further optimizing the cycle time and completely breaking through the capacity bottleneck of manual assembly.

[0030] 2. Effectively ensures consistent assembly precision and quality. Through the integrated application of a multi-stage vision system, the spring posture and free length are automatically screened during the spring feeding stage to ensure that the grasped springs have compliant postures and qualified lengths. During the steel ball feeding stage, the positioning groove of the material placement tube, combined with vacuum adsorption, achieves precise separation of individual steel balls, avoiding multiple balls or empty balls. During the assembly stage, the integrity of the springs and steel balls is checked by the material inspection vision component, and the spring compression deformation force is detected in real time by the pressure sensing component, ensuring that the spring deformation and roller feel of each product are consistent, eliminating quality fluctuations caused by human factors, and significantly improving the product qualification rate and reliability.

[0031] 3. The equipment boasts high operational reliability and ease of maintenance. The steel ball feeding device employs a multi-hopper backup design, allowing multiple hoppers to feed alternately. Even if a single hopper is empty or malfunctions, continuous operation remains unaffected. Each process is equipped with independent detection components, enabling real-time monitoring and timely handling of abnormalities in spring feeding, steel ball feeding, material placement, and push-assembly. This results in a low equipment failure rate and convenient maintenance.

[0032] 4. High production flexibility and convenient changeover. Based on vision-guided robot grasping and inspection solutions, when product models change, only the visual recognition parameters, robot grasping programs, and corresponding parameters of the assembly track need to be adjusted. No large-scale mechanical modifications are required, the changeover and debugging cycle is short, and it can quickly adapt to the flexible production needs of multiple varieties and small batches.

[0033] 5. High level of intelligence and support for data traceability. The equipment integrates multiple sensors and vision systems, enabling it to collect and monitor multi-dimensional data such as spring posture, spring length, number of steel balls, material loss, and spring deformation pressure. This provides reliable data support for production management and product quality traceability, aligning with the development direction of intelligent manufacturing. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of a specific embodiment of the present invention; Figure 2 This is a schematic diagram illustrating the structure of the material transfer device according to a specific embodiment of the present invention; Figure 3 This is a schematic diagram illustrating the structure of the steel ball feeding device according to a specific embodiment of the present invention; Figure 4 This is a partial structural schematic diagram of a steel ball feeding device according to a specific embodiment of the present invention; Figure 5 This is a schematic diagram illustrating the structure of the storage compartment according to a specific embodiment of the present invention; Figure 6 This is a cross-sectional view of the material feeding tube according to a specific embodiment of the present invention; Figure 7 This is a schematic diagram illustrating the structure of the assembly execution device according to a specific embodiment of the present invention; Figure 8 This is a partial structural diagram of the assembly execution device according to a specific embodiment of the present invention; Figure 9 This is a schematic diagram illustrating a partial structure of the pushing mechanism according to a specific embodiment of the present invention; Figure 10 This is a schematic diagram illustrating the structure of the blocking mechanism in a specific embodiment of the present invention; Figure 11 This is a schematic diagram illustrating the structure of the assembly track and assembly base according to a specific embodiment of the present invention; Figure 12 for Figure 11 Enlarged view of point A in the middle; Figure 13 for Figure 11 Enlarged view of point B in the middle.

[0035] In the diagram: 100, Spring; 200, Steel Ball; 300, Roller Body; 301, Channel Hole; 1, Spring Feeding Device; 11, Vibratory Feeder; 12, Spring Vision Recognition Component; 2, Steel Ball Feeding Device; 21, Storage Bin; 211, Material Bin; 2111, Insertion Hole; 22, Lifting Drive Component; 23, Material Placement Pipe; 231, Air Hole; 24, Vacuum Circuit Component; 25, Steel Ball Vision Recognition Component; 3, Material Transfer Device; 31, Gripper; 32, Suction Nozzle; 4, Assembly Execution Component. Device; 41. Assembly track; 411. Track groove; 412. Guide rail; 42. Assembly base; 421. Positioning fixture; 422. Lifting mechanism; 423. Clamping mechanism; 4231. Clamping drive; 4232. Pressure plate; 43. Loading position; 44. Pushing mechanism; 441. Push rod; 442. Linear motor; 443. Slider seat; 45. Blocking mechanism; 451. Blocking drive; 452. Blocking block; 46. Material detection vision component; 47. Pressure sensing component. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of this invention clearer, the embodiments of this invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0037] It should be noted that in the description of this invention, the terms "front," "rear," "upper," "lower," "left," and "right," etc., indicate the orientation or positional relationship based on the orientation of the equipment in normal use. The extension direction of the assembly track 41 is the front-to-back direction, with the end of the assembly track 41 near the initial position of the push rod 441 designated as "rear" and the end near the roller body 300 as "front." These terms are merely for ease of description and should not be construed as limiting the scope of protection of this invention.

[0038] The following is combined Figures 1 to 13 The technical solution of the present invention will be described in further detail below. Example

[0039] This embodiment provides an automatic assembly device for a steering wheel switch roller, used to assemble a spring 100 and two steel balls 200 located at both ends of the spring 100 axially into the channel hole 301 of the roller body 300.

[0040] The automated assembly equipment in this embodiment includes a spring feeding device 1, a steel ball feeding device 2, a material transfer device 3, and an assembly execution device 4. Each device is mounted on the equipment frame and works collaboratively under the unified scheduling of the control system.

[0041] The spring feeding device 1 is used to provide individual springs 100 with acceptable posture. The spring feeding device 1 includes a spring vibratory feeder 11 and a spring vision recognition component 12 positioned above the spring vibratory feeder 11. The spring vibratory feeder 11 is a flexible vibratory feeder 11, which outputs and disperses the scattered springs 100 one by one onto the surface of the vibratory feeder 11 through vibration. The spring vision recognition component 12 includes an industrial camera and an image processing unit. The industrial camera takes real-time pictures of the springs 100 on the surface of the vibratory feeder 11. The image processing unit analyzes the captured images, identifies the posture and free length of each spring 100, filters out springs 100 with acceptable posture and length within a preset tolerance range, and sends the coordinate information of the acceptable springs 100 to the material transfer device 3 to guide it to accurately grasp them. After the material transfer device 3 grasps a spring 100, the vision recognition component continues to take pictures of the surface of the vibratory feeder 11 to confirm that there are still graspable springs 100 in the feeder, thereby maximizing feeding efficiency.

[0042] The steel ball feeding device 2 is used to provide individual steel balls 200. The steel ball feeding device 2 includes a receiving bin 21, a lifting drive 22, a feeding pipe 23, and a vacuum passage assembly 24. In this embodiment, the receiving bin 21 is a receiving block, on which four bins 211 are arranged in a straight line. Each bin 211 is equipped with an independently operating lifting drive 22, feeding pipe 23, and vacuum passage assembly 24. A steel ball 200 vision recognition component is located above the receiving block to identify the position of the steel balls 200 in each bin 211, guiding the material transfer device 3 to accurately pick up the steel balls 200.

[0043] Each hopper 211 has a vertically penetrating insertion hole 2111 in its center. A material placement tube 23 is positioned corresponding to the insertion hole 2111 and can move up and down within it. The outer diameter of the material placement tube 23 matches the inner diameter of the insertion hole 2111 with a clearance fit. This clearance ensures that the material placement tube 23 can slide freely up and down while preventing the steel balls 200 from leaking out through the gap between the outer wall of the material placement tube 23 and the inner wall of the insertion hole 2111. In its initial position, the top of the material placement tube 23 is located within the insertion hole 2111, preventing the steel balls 200 in the hopper 211 from falling freely out of the insertion hole 2111, thus providing a self-sealing function.

[0044] The top of the feeding tube 23 is provided with a positioning groove for receiving a single steel ball 200. The positioning groove is a semi-circular or arc-shaped groove adapted to the curvature of the steel ball 200 surface. Its depth is such that after the steel ball 200 falls in, its top is higher than the top surface of the feeding tube 23, facilitating the material transfer device 3 to pick it up. The inside of the feeding tube 23 is provided with an axially penetrating air hole 231. The upper end of the air hole 231 communicates with the positioning groove, and the lower end is connected to the vacuum air passage assembly 24. The diameter of the air hole 231 is smaller than the diameter of the positioning groove and smaller than the diameter of the steel ball 200, ensuring that the steel ball 200 is adsorbed in the positioning groove and does not fall into the air hole 231.

[0045] The lifting drive component 22 is a cylinder, and the piston rod of the cylinder is connected to the bottom end of the material placement tube 23, driving the material placement tube 23 to move up and down in the insertion hole 2111. The material placement tube 23 switches between a low picking position and a high feeding position. When it is in the low picking position, the top of the material placement tube 23 moves down to below the stacking height of the steel balls 200 in the hopper 211, and the steel balls 200 fall into the positioning groove under the action of gravity; at this time, the vacuum circuit component 24 draws air through the air hole 231, stably adsorbing the steel balls 200 in the positioning groove. After the vacuum adsorption is completed and maintained for a predetermined time, the cylinder drives the material placement tube 23 to rise to the high feeding position, and the top of the material placement tube 23 and the adsorbed steel balls 200 extend out of the top surface of the hopper 211 for the material transfer device 3 to pick up. The purpose of maintaining vacuum adsorption for a predetermined time is to detect the vacuum feedback signal and confirm that steel balls 200 are indeed adsorbed in the positioning groove. If the vacuum degree does not reach the set value, it is judged that the material picking has failed, and the cylinder drives the material placement tube 23 to re-execute the material picking action.

[0046] The material transfer device 3 is a multi-axis robot, fixedly installed in the middle area of ​​the equipment frame. The end of the multi-axis robot is equipped with a gripper 31 and two suction nozzles 32. The gripper 31 is a pneumatic gripper used to grasp a single spring 100 provided by the spring feeding device 1. The two suction nozzles 32 are connected to a vacuum generator, used to simultaneously or sequentially pick up two steel balls 200 provided by the steel ball feeding device 2. The multi-axis robot moves between the spring feeding device 1, the steel ball feeding device 2, and the assembly execution device 4, sequentially completing the actions of grasping the spring 100, picking up the steel balls 200, and placing the material. The robot places the spring 100 and the two steel balls 200 along an axial arrangement with the spring 100 centered and the two steel balls 200 positioned at opposite ends of the spring 100's axis at the loading position 43 of the assembly execution device 4.

[0047] The assembly execution device 4 is used to assemble the spring 100 and steel ball 200 into the roller body 300. In this embodiment, two sets of assembly execution devices 4 are provided, symmetrically arranged on both sides of the multi-axis robot. The multi-axis robot alternately supplies the spring 100 and steel ball 200 to the two sets of assembly execution devices 4. When one set of assembly execution devices 4 is performing push assembly, the robot places the next set of materials to the other set of assembly execution devices 4 to eliminate assembly waiting time and improve production efficiency.

[0048] Each assembly execution device 4 includes an assembly track 41, an assembly base 42, a positioning fixture 421, a clamping mechanism 423, a lifting mechanism 422, a blocking mechanism 45, and a pushing mechanism 44.

[0049] The assembly track 41 is a long strip of metal with a straight track groove 411 extending in the front-to-back direction. The width of the track groove 411 is adapted to the diameter of the spring 100 and the steel ball 200, allowing the spring 100 and the steel ball 200, which are arranged axially, to slide smoothly axially within the track groove 411 without radial deviation. The track groove 411 has a loading position 43 where the robot places the spring 100 and the steel ball 200 in an axial arrangement. The end of the track groove 411 is an assembly position, where an assembly base 42 is located.

[0050] The assembly base 42 is fixed to the equipment frame. The positioning fixture 421 is installed on the assembly base 42 and is used to position the roller body 300. The end of the track groove 411 is aligned with the channel hole 301 of the roller body 300, so that the spring 100 and steel ball 200 pushed by the push rod 441 can enter the channel hole 301.

[0051] The clamping mechanism 423 is located above the positioning fixture 421 and includes a clamping cylinder and a pressure plate 4232 connected to the output end of the clamping cylinder. Before assembly begins, the operator or robot places the roller body 300 on the positioning fixture 421, and the clamping cylinder drives the pressure plate 4232 to move downward, pressing the roller body 300 onto the positioning fixture 421, so that the channel hole 301 is aligned with the track groove 411.

[0052] The pushing mechanism 44 is located on one side of the assembly track 41 and includes a push rod 441 and a linear drive assembly. The linear drive assembly includes a linear motor 442 and a slider seat 443. A guide rail 412 is provided on the side of the assembly track 41, and the guide rail 412 extends along the track groove 411. The slider seat 443 is slidably fitted on the guide rail 412 and is driven by the linear motor 442 to reciprocate along the guide rail 412. The push rod 441 is fixedly connected to the slider seat 443 and can slide back and forth along the track groove 411 under the drive of the linear motor 442. The initial position of the push rod 441 is located behind the loading position 43. After the robot places the spring 100 and the steel ball 200 in the loading position 43, the push rod 441 moves forward under the drive of the linear motor 442, contacts the rear end of the spring 100 and the steel ball 200, and pushes the spring 100 and the steel ball 200, which are arranged axially, to move along the track groove 411 towards the assembly position.

[0053] A blocking mechanism 45 is located on the side of the track groove 411, between the loading position 43 and the assembly position. The blocking mechanism 45 includes a blocking cylinder and a blocking block 452 connected to the output end of the blocking cylinder. The blocking block 452 can extend into or out of the track groove 411 under the drive of the blocking cylinder. When the push rod 441 pushes the spring 100 and the steel ball 200 to move along the track groove 411 to the position of the blocking block 452, the blocking block 452 extends into the track groove 411 and axially limits the steel ball 200 at the front end of the spring 100, so that the spring 100 and the steel ball 200 stop at the blocking block 452. A material detection vision component 46 is provided above the position corresponding to the blocking block 452. The material detection vision component 46 includes an industrial camera, which takes pictures of the track groove 411 when the spring 100 and the steel ball 200 stop at the blocking block 452 to detect whether the spring 100 and the two steel balls 200 are all in place and whether there are any missing parts.

[0054] A pressure sensing component 47 is provided on the push rod 441 or the slider seat 443. After the material detection vision component 46 confirms that there is no missing material, the push rod 441 continues to move forward under the drive of the linear motor 442, pushing the spring 100 to compress and deform. During this process, the pressure sensing component 47 detects the pressure value on the push rod 441 in real time, which reflects the reaction force of the spring 100's compression deformation. The control system compares the detected pressure value with a preset qualified threshold range to determine whether the deformation of the spring 100 meets the standard. If the pressure value is within the qualified range, the spring 100 is deemed qualified; if the pressure value is too low, the spring 100 may be missing or its free length may be too short; if the pressure value is too high, the free length of the spring 100 may be too long or there may be foreign objects in the track.

[0055] After the inspection is passed, the blocking cylinder drives the blocking block 452 to exit the track groove 411, no longer interfering with the movement of the material. The push rod 441 continues to push the spring 100 and the steel ball 200 forward along the track groove 411, and the spring 100 and the steel ball 200 are pushed into the channel hole 301 of the roller body 300.

[0056] The lifting mechanism 422 is located below the positioning fixture 421 and includes a lifting cylinder. When the spring 100 and the steel ball 200 are fully pushed into the channel hole 301, the piston rod of the lifting cylinder extends upward, applying an upward lifting force to the roller body 300, causing the internal structure of the roller body 300 to be locked, and the spring 100 and the steel ball 200 to be limited and fixed in the channel hole 301, completing the final assembly and locking.

[0057] After assembly, the clamping cylinder drives the pressure plate 4232 to release upwards, the lifting cylinder resets, and the operator or unloading mechanism removes the assembled roller component from the positioning fixture 421, completing a full assembly cycle. Example

[0058] This embodiment provides an automatic assembly method for a steering wheel switch roller, using the automatic assembly equipment for steering wheel switch rollers described in Embodiment 1. The method includes a feeding step, a pressing assembly step, and a finished product removal step. The pressing assembly step further includes a detection sub-step.

[0059] The specific process of the feeding step is as follows: the spring vibratory feeder 11 outputs the scattered springs 100 one by one, the spring vision recognition component 12 selects the springs 100 with compliant posture and qualified length, and sends the coordinate information to the multi-axis robot. In the steel ball feeding device 2, the corresponding material placement pipe 23 of each material bin 211 moves down to the low position of material picking under the drive of the cylinder, the steel ball 200 falls into the positioning groove, the vacuum circuit component 24 draws air to adsorb and detects vacuum feedback, and after confirming that there are balls, the material placement pipe 23 is lifted to the high position of feeding. The multi-axis robot first moves to the spring feeding device 1, where the gripper 31 picks up a qualified spring 100. Then it moves to the steel ball feeding device 2, where two suction nozzles 32 pick up two steel balls 200 each. Finally, the robot moves to the loading position 43 of one of the assembly execution devices 4, placing the spring 100 and two steel balls 200 along an axis with the spring 100 centered and the steel balls 200 at both ends of the spring 100 in the loading position 43 of the track groove 411. After placement, the robot returns to the spring feeding device 1 and the steel ball feeding device 2 to pick up the next set of materials, alternately placing them in the loading position 43 of another assembly execution device 4.

[0060] The specific process of the push-fit assembly step is as follows: The roller body 300 is placed on the positioning fixture 421 by an operator or robot, and the clamping cylinder drives the pressure plate 4232 to clamp the roller body 300. The linear motor 442 drives the push rod 441 to move forward along the track groove 411. The push rod 441 contacts the steel ball 200 at the rear end of the spring 100, pushing the spring 100 and the steel ball 200 to move forward along the track groove 411.

[0061] The specific process of the detection sub-step is as follows: Push rod 441 pushes spring 100 and steel ball 200 to blocking block 452. Block 452, driven by blocking cylinder, extends into track groove 411 to axially limit the front end of steel ball 200, and push rod 441 pauses. Material detection vision component 46 takes a picture of track groove 411 to check whether spring 100 and steel ball 200 are fully in place. If the detection is qualified, push rod 441 continues to advance forward, compressing spring 100. Pressure sensing component 47 detects the pressure value in real time and determines whether the deformation of spring 100 meets the standard. If the material detection fails or the pressure value is unqualified, the equipment alarms and pauses, requiring operator inspection and handling.

[0062] After the inspection is passed, the blocking cylinder drives the blocking block 452 to exit the track groove 411, and the push rod 441 continues to push the spring 100 and steel ball 200 forward along the track groove 411, pushing the spring 100 and steel ball 200 into the channel hole 301 of the roller body 300. The lifting cylinder pushes upward, applying a lifting force to the roller body 300, so that the internal structure is locked, and the assembly is completed.

[0063] The specific process of removing the finished product is as follows: the clamping cylinder drives the pressure plate 4232 to release upwards, the lifting cylinder resets, and the assembled roller component is removed from the positioning fixture 421, completing a complete assembly cycle.

[0064] In the parallel operation mode of the two sets of assembly actuators 4, when the first set of assembly actuators 4 is performing the pushing assembly step, the robot has already placed the next set of springs 100 and steel balls 200 to the loading position 43 of the second set of assembly actuators 4; after the first set of assembly actuators 4 finishes taking out the finished product, the second set of assembly actuators 4 immediately begins the pushing assembly, and the robot continues to replenish materials to the first set of assembly actuators 4. The two sets of assembly actuators 4 advance alternately, effectively eliminating assembly waiting time and greatly improving production efficiency.

[0065] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An automatic assembly device for a steering wheel switch roller, used to assemble a spring (100) and steel balls (200) located at both axial ends of the spring (100) into a roller body (300), the roller body (300) having a channel hole (301), characterized in that, include: A spring feeding device (1) is used to provide a single spring (100) with a qualified posture; A steel ball feeding device (2) is used to provide a single steel ball (200). The steel ball feeding device (2) includes a receiving bin (21), a lifting drive (22), a feeding pipe (23), and a vacuum circuit assembly (24). The top end of the feeding pipe (23) is provided with a positioning groove for receiving a single steel ball (200). The feeding pipe (23) moves up and down in the receiving bin (21) under the drive of the lifting drive (22). After the positioning groove receives the steel ball (200), the vacuum circuit assembly (24) draws air to adsorb the steel ball (200) into the positioning groove. The feeding pipe (23) is then lifted to send the steel ball (200) out for the material transfer device (3) to pick up. The material transfer device (3) is used to grab the spring (100) provided by the spring feeding device (1) and the steel ball (200) provided by the steel ball feeding device (2), and place the spring (100) and the steel ball (200) in the assembly execution device (4) with the spring (100) in the center and the two steel balls (200) on opposite ends of the spring (100) in an arrangement. An assembly actuator (4) is used to assemble the spring (100) and the steel ball (200) into the roller body (300). The assembly actuator (4) includes an assembly track (41) and an assembly base (42) located at the end of the assembly track (41). The assembly track (41) is provided with a loading position (43) for receiving the spring (100) and the steel ball (200). The assembly base (42) is provided with a positioning clamp (421) and a lifting mechanism (422). 2) and a clamping mechanism (423) for fixing the roller body (300) to the positioning fixture (421); the assembly execution device (4) also includes a pushing mechanism (44), which includes a push rod (441) that slides along the assembly track (41), the push rod (441) being used to push the spring (100) and steel ball (200) arranged axially at the loading position (43) along the assembly track (41) into the channel hole (301).

2. The automatic assembly equipment for steering wheel switch rollers according to claim 1, characterized in that, The spring feeding device (1) includes a vibratory plate (11) and a spring vision recognition component (12) located above the vibratory plate (11). The spring vision recognition component (12) is used to screen springs (100) with compliant posture and qualified length, and guide the material transfer device (3) to accurately grasp them.

3. The automatic assembly equipment for steering wheel switch rollers according to claim 1, characterized in that, The storage bin (21) is provided with at least two hoppers (211), each hopper (211) is provided with a set of lifting drive (22), material placement pipe (23) and vacuum air passage assembly (24); the material placement pipe (23) is provided with an air hole (231) communicating with the positioning groove, the diameter of the air hole (231) is smaller than the diameter of the positioning groove and smaller than the diameter of the steel ball (200); a steel ball visual recognition assembly (25) is provided above the storage bin (21) to guide the material transfer device (3) to accurately pick up the steel ball (200).

4. The automatic assembly equipment for steering wheel switch rollers according to claim 1, characterized in that, The assembly execution device (4) also includes a blocking mechanism (45) located on the side of the assembly track (41). The blocking mechanism (45) includes a blocking drive (451) and a blocking block (452) connected to the blocking drive (451). The blocking block (452) can extend into or out of the assembly track (41) under the drive of the blocking drive (451). When the spring (100) and the steel ball (200) are pushed to the position of the blocking block (452) by the push rod (441), the blocking block (452) axially limits them.

5. The automatic assembly equipment for steering wheel switch rollers according to claim 4, characterized in that, A material detection vision component (46) is provided at the position of the corresponding blocking block (452) to detect whether the spring (100) and steel ball (200) are missing; a pressure sensing component (47) is provided on the push rod (441) or the drive path of the push rod (441) to detect the deformation pressure data when the push rod (441) pushes the spring (100).

6. The automatic assembly equipment for steering wheel switch rollers according to claim 1, characterized in that, The clamping mechanism (423) includes a clamping drive (4231) and a pressure plate (4232) driven by the clamping drive (4231). The pressure plate (4232) is used to clamp the roller body (300) onto the positioning fixture (421). The lifting mechanism (422) is used to apply an upward lifting force to the roller body (300) after the spring (100) and the steel ball (200) are pushed into the channel hole (301), so that the spring (100) and the steel ball (200) are assembled in the roller body (300).

7. The automatic assembly equipment for steering wheel switch rollers according to claim 1, characterized in that, Two sets of assembly actuators (4) are provided, and the two sets of assembly actuators (4) are arranged symmetrically or side by side; the material transfer device (3) alternately supplies springs (100) and steel balls (200) to the two sets of assembly actuators (4).

8. The automatic assembly equipment for steering wheel switch rollers according to claim 1, characterized in that, The material transfer device (3) is a multi-axis robot. The end of the multi-axis robot is equipped with a gripper (31) for gripping the spring (100) and a suction nozzle (32) for sucking up the steel ball (200).

9. An automatic assembly method for a steering wheel switch roller, characterized in that, The automatic assembly equipment for steering wheel switch rollers as described in any one of claims 1 to 8 includes the following steps: Feeding steps: The spring feeding device (1) outputs a single qualified spring (100), and the steel ball feeding device (2) outputs a single steel ball (200) by lifting through the material placement pipe (23) and adsorbing through the vacuum path; the material transfer device (3) sequentially or simultaneously grabs a spring (100) and two steel balls (200), and places them in the loading position (43) of the assembly track (41) with the spring (100) in the center and the steel balls (200) at both ends of the spring (100) in an axial arrangement. Push-and-assemble step: Place the roller body (300) in the positioning fixture (421), and the clamping mechanism (423) clamps the roller body (300); the push rod (441) slides along the assembly track (41), pushing the spring (100) and the steel ball (200) to move towards the end of the assembly track (41), and pushing the spring (100) and the steel ball (200) into the channel hole (301) of the roller body (300); the lifting mechanism (422) applies an upward lifting force to the roller body (300), so that the roller body (300) is clamped, and the assembly is completed; Finished product removal steps: Loosen the clamping mechanism (423) and remove the assembled roller component.

10. The automatic assembly method for a steering wheel switch roller according to claim 9, characterized in that, The push assembly step also includes a detection sub-step: the push rod (441) first pushes the spring (100) and steel ball (200) to the stop block (452) and pauses. The material detection vision component (46) detects whether the spring (100) and steel ball (200) are missing. After the detection is passed, the push rod (441) continues to push forward to compress and deform the spring (100). The pressure sensing component (47) detects the pressure on the push rod (441) at this time and judges whether the deformation of the spring (100) meets the standard. After meeting the standard, the stop block (452) exits and the push rod (441) continues to push the material completely into the channel hole (301).

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