An automated pneumatic hemming system method for automotive interior coverings

Abstract

The present application relates to the technical fields of automobile interior production, and specifically relates to an automatic pneumatic edge covering system method for automobile interior covering parts, which comprises: a placing step, in which a framework is placed on an upper die and fixed, and a skin is laid on a lower die and positioned by a needle; a heating step, in which a heating lamp box is moved to preheat the framework and / or the skin; a die closing and edge covering step, in which the upper die is driven to close with the lower die, and an edge covering mechanism is driven to perform multi-stage flattening actions in a preset order, so that the skin edge is attached to the framework; a pressure maintaining and curing step, in which the die closing state is maintained to bond and cure the skin and the framework; and a die opening and taking step, in which the completed interior covering part is taken out after the die is opened. The present application preheats and secondarily warms up before and after the die closing respectively through accurate timing control, ensures that the adhesive is at the best activation temperature, and gets rid of the dependence of the edge covering operation on the environmental temperature and humidity. At the same time, the multi-stage flattening actions imitate the manual operation, effectively avoid wrinkles, and improve the edge covering quality and consistency.

Description

Technical Field

[0001] This invention relates to the technical field of automotive interior parts production, specifically an automated pneumatic edge-wrapping system method for automotive interior trim parts. Background Technology

[0002] In the manufacturing process of automotive interior parts, the application of the wrapping process is extremely common. It involves bonding the surface of the automotive interior parts to the frame together, and edge wrapping is one of the processes, and also the most difficult to control.

[0003] In the past, the overlay process used a hot air gun to heat the surfaces of the leather and interior trim, controlling the surface temperature of the trim at 50-60°C. After the resin adhesive on the leather surface became sticky, the leather was pasted onto the shape of the trim, and the edges were trimmed according to the condition of the trim. The optimal ambient temperature for leather overlay is 15-20°C. When the temperature is above 50°C and the humidity is above 70%, the adhesive layer is not easy to dry, and the trim and leather can easily stick together unintentionally during overlay, causing inconvenience. When the temperature is too low, the preheating time of the leather is long and the cooling rate is fast, affecting the overlay speed and reducing work efficiency. There is a need to design an automatic edge-wrapping system that mimics the movements of a human hand to overlay the product skin onto the workpiece frame. Each edge-wrapping action is completed by a combination of multiple cylinders, including pushing, pressing, and backfeeding actions, but it is difficult to solve the above problems.

[0004] To address the problems mentioned above, those skilled in the art have proposed an automated pneumatic edge-wrapping system method for automotive interior trim components. Summary of the Invention

[0005] The purpose of this invention is to provide an automated pneumatic edge-wrapping system method for automotive interior trim parts, in order to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] An automated pneumatic edge-wrapping system method for automotive interior trim components includes the following steps:

[0008] Placement steps: Place the skeleton on the upper mold and fix it, lay the skin on the lower mold and position it using hanging pins;

[0009] Heating step: Move the heating lamp box to the mold station to preheat the skeleton and / or skin;

[0010] Mold closing and edge wrapping steps: Drive the upper mold and lower mold to close, and drive the edge wrapping mechanism to perform multi-stage flattening actions in a preset sequence, so that the skin edge fits into the skeleton;

[0011] Pressure holding and curing step: Keep the mold closed to allow the skin and skeleton to bond and cure.

[0012] Mold opening and part removal steps: After the mold is opened, the wrapped interior parts are removed.

[0013] As a further aspect of the present invention, the placement step specifically includes: fixing the skeleton by vacuum adsorption or cylinder gripper of the upper mold, and driving the hanging pin to extend through the hanging pin cylinder of the lower mold to penetrate and position the skin.

[0014] As a further aspect of the present invention, the heating step specifically includes: after the transfer cylinder drives the lamp box to move into place, the heating cylinder drives the heating lamp tube to descend to the preset heating position to radiate heat the area to be wrapped on the skin and / or the frame.

[0015] As a further aspect of the present invention, the heating step further includes: after heating is completed, the heating cylinder drives the heating lamp tube to rise and reset, and the transfer cylinder moves the lamp box back to its original position and locks it with a pin.

[0016] As a further embodiment of the present invention: the mold closing and edge wrapping step includes: after the upper and lower molds are closed in place, driving all hanging pin cylinders to retract, so that the hanging pins are withdrawn from the skin, and driving the heating lamp tube to perform secondary heating on the edge wrapping area before resetting.

[0017] As a further aspect of the present invention: in the mold closing and edge wrapping step, the multi-stage pushing action includes: firstly driving the first set of pushing cylinders to perform the first-level pushing action in a first order, and then driving the second set of pushing cylinders to perform the second-level pressing action in a second order, so as to imitate the human hand to gradually push and press the skin edge.

[0018] As a further aspect of the present invention: after performing the multi-stage pushing action, a pressing and resetting step is also included: first, control the partial pressing cylinder to retract, and at the same time drive the corner-specific pressing cylinder to extend, so as to finally shape and press the corner of the part.

[0019] As a further aspect of the present invention: at the same time as or after the mold closing and edge wrapping step, a slider support step is also included: driving the slider cylinder set inside the mold to extend, providing inner support for the edge wrapping area, and driving the slider cylinder to retract back to its original position after the edge wrapping action is completed.

[0020] As a further aspect of the present invention: before the mold opening and part removal step, a vacuum release step is also included: disconnecting the vacuum adsorption of the upper mold to the skeleton and releasing the cylinder gripper.

[0021] As a further aspect of the present invention: the method adjusts the number of cylinders involved in the edge-wrapping action and the execution order according to the different shapes of the parts to be processed, so as to adapt to different specifications of automotive interior parts.

[0022] The present invention has the following advantages:

[0023] 1. This invention effectively solves the problems of severe environmental constraints and poor operational consistency in traditional edge-wrapping processes. Traditional wrapping processes heavily rely on ambient temperature (optimal 15-20℃) and humidity (requires less than 70%). Excessive temperature can lead to incomplete adhesive drying and unintentional bonding, while insufficient temperature necessitates prolonged preheating and rapid cooling, significantly impacting production efficiency and yield. This invention, through precise process control, independently and controllably preheats the skeleton and / or skin before mold closing during the heating step. Furthermore, a secondary heating action after mold closing ensures the adhesive remains within its optimal activation temperature range during the edge-wrapping step. This method completely eliminates the stringent dependence of edge-wrapping operations on workshop temperature and humidity, transforming edge-wrapping quality control from uncontrollable environmental factors to controllable equipment parameters, thus significantly improving process stability.

[0024] 2. This invention significantly improves the automation and biomimetic effect of edge-binding operations, overcoming the shortcomings of low efficiency and unstable yield rates associated with manual operations. Traditional processes rely on manual operation, making it difficult to guarantee consistency. In the mold-closing edge-binding step, this invention designs a "multi-stage flattening action" that mimics human hand movements. By controlling multiple sets of cylinders to execute first-stage flattening and second-stage pressing in a preset sequence, it achieves a gradual, non-pulling bonding of the skin edge. Compared to traditional manual or simple mechanical pressing, this graded and sequential control logic effectively removes air from the bonding surface, avoiding wrinkles or loose adhesion. It is particularly suitable for complex curved automotive interior parts, producing a smooth and tight edge-binding effect, significantly improving the product's appearance quality and service life.

[0025] 3. This invention solves the technical problems of inaccurate positioning and springback deformation that easily occur when edge-wrapping complex structural parts through intelligent timing control. For the process requirement that leather needs to be pasted according to the shape of the interior parts, this invention integrates multiple protection mechanisms into the process. For example, in the mold closing and edge-wrapping step, the sliding block cylinder is first driven to extend and provide inner rigid support for the edge-wrapping area, followed by the withdrawal of the hanging pins and multi-stage flattening, ensuring that the skeleton does not deform under the flattening force, thus guaranteeing the product's dimensional accuracy. Simultaneously, in the part placement step, a dual method of upper mold adsorption or clamp fixation and lower mold hanging pin positioning is used to ensure precise alignment of the skeleton and the outer skin before heating and mold closing, avoiding defects such as uneven edge wrapping or exposed base caused by outer skin displacement in traditional processes.

[0026] 4. This invention possesses extremely high process adaptability, solving the problem that traditional edge-wrapping equipment cannot be compatible with multiple products. While traditional automatic edge-wrapping systems mimic human hand movements, their equipment versatility is poor. The method described in this invention, with its core control logic, allows for preset increases, decreases, or adjustments to the number and execution sequence of cylinders involved in the edge-wrapping action based on the different shapes of the parts to be processed. This means that without replacing the entire set of molds or equipment, only by modifying the control program of the pneumatic system, it is possible to compatiblely produce automotive interior parts of different specifications and contours on the same system, greatly reducing equipment investment costs and production changeover time, and meeting the modern production needs of small-batch, multi-variety automotive interior parts. Attached Figure Description

[0027] Figure 1 This is the overall flowchart of the automated pneumatic edge-sealing system method of the present invention.

[0028] Figure 2 for Figure 1 A detailed flowchart of the middleware placement process.

[0029] Figure 3 for Figure 1 A detailed flowchart of the heating step.

[0030] Figure 4 for Figure 1 Detailed flowchart of the edge-wrapping process in the middle mold.

[0031] Figure 5 This is a flowchart illustrating the associated auxiliary actions in the edge-sealing system method of the present invention. Detailed Implementation

[0032] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0033] The technical solution of the present invention will be further described in detail below with reference to specific embodiments.

[0034] Example: Please refer to Figures 1 to 5 An automated pneumatic edge-wrapping system method for automotive interior trim components includes the following steps:

[0035] Placement steps: Place the skeleton on the upper mold and fix it, lay the skin on the lower mold and position it using hanging pins;

[0036] Heating step: Move the heating lamp box to the mold station to preheat the skeleton and / or skin;

[0037] Mold closing and edge wrapping steps: Drive the upper mold and lower mold to close, and drive the edge wrapping mechanism to perform multi-stage flattening actions in a preset sequence, so that the skin edge fits into the skeleton;

[0038] Pressure holding and curing step: Keep the mold closed to allow the skin and skeleton to bond and cure.

[0039] Mold opening and part removal steps: After the mold is opened, the wrapped interior parts are removed.

[0040] The placement step specifically includes: fixing the skeleton by vacuum adsorption or cylinder grippers of the upper mold, and extending the hanging pin by the hanging pin cylinder of the lower mold to penetrate and position the skin. To ensure the accuracy of skeleton positioning, the upper mold is equipped with positioning contour blocks that match the shape of the skeleton, and work in conjunction with vacuum adsorption and / or cylinder grippers.

[0041] The heating step specifically includes: after the transfer cylinder drives the lamp box to its position, the heating cylinder drives the heating lamp tube to descend to a preset heating position to radiate heat to the area to be edged on the skin and / or frame. The height of the heating position can be adjusted according to the softening temperature of different materials.

[0042] The heating step further includes: after heating is completed, the heating cylinder drives the heating lamp tube to rise and reset, and the transfer cylinder moves the lamp box back to its original position and locks it with a pin to prevent interference during the mold closing process.

[0043] The mold closing and edge-wrapping step includes: after the upper and lower molds are closed in place, driving all hanging pin cylinders to retract, causing the hanging pins to withdraw from the surface, and driving the heating lamps to perform secondary heating on the edge-wrapping area before resetting. To improve the heating efficiency and uniformity, the heating lamps used for this secondary heating can be independently controlled in power, separate from the preheating lamps.

[0044] In the mold-closing and edge-sealing step, the multi-stage flattening action includes: firstly, driving the first set of flattening cylinders to perform a first-level flattening action in a first sequence; then driving the second set of flattening cylinders to perform a second-level pressing action in a second sequence, to mimic the gradual flattening and pressing of the skin edge by hand. Both the first and second sequences follow a path extending from the middle to both ends, or from a gently curving area to a complex curvature area, to orderly expel interlayer air.

[0045] After performing the multi-stage flattening action, a pressing and resetting step is also included: first, the partial pressing cylinder is controlled to retract, while the corner-specific pressing cylinder is driven to extend, to finally shape and press the corner of the part. In order to avoid displacement of the already fitted area during the pressing process, the retraction of the partial pressing cylinder and the extension of the corner-specific pressing cylinder overlap in timing, that is, the pressing cylinder of the main body area is fully released before the corner pressing cylinder contacts the surface.

[0046] Simultaneously or after the mold closing and edge-wrapping step, a slider support step is also included: driving a slider cylinder located inside the mold to extend, providing inner rigid support for the edge-wrapping area, and driving the slider cylinder to retract back to its original position after the edge-wrapping action is completed. The extension and retraction of the slider cylinder is detected by a limit switch installed on the mold, and its front end is equipped with a contour-following support block that matches the inner wall contour of the skeleton to prevent deformation of the skeleton due to edge-wrapping pressure.

[0047] Before the mold opening and part removal step, a vacuum release step is also included: disconnecting the vacuum adsorption of the upper mold to the skeleton and releasing the cylinder gripper.

[0048] The method involves pre-setting, reducing, or adjusting the number and execution sequence of cylinders involved in the edging action based on the different shapes of the parts to be processed, in order to adapt to different specifications of automotive interior parts. This adjustment is achieved by calling pre-stored process formulas for different products in the control system, without the need for mechanical replacement.

[0049] Working principle:

[0050] I. Component Placement and Initialization Phase

[0051] During operation, the operator or automatic feeding mechanism first performs the part placement step. For the upper mold, the interior part skeleton is placed in the predetermined position, and four fiber optic sensors installed on the upper mold monitor the product's position in real time. When the sensors detect the skeleton, the control system triggers the vacuum adsorption device of the upper mold to generate negative pressure, firmly adsorbing the skeleton through suction cups. Simultaneously, or alternatively, a gripper cylinder extends to clamp the skeleton, ensuring that the skeleton does not shift during subsequent processing. To further improve positioning accuracy, the positioning contour block of the upper mold serves as an initial guide and limiter when placing the skeleton. For the lower mold, the operator lays the skin material flat on the surface of the lower mold. At this time, the hanging pin cylinder of the lower mold is in the extended state, driving the hanging pin to penetrate the skin and accurately position it, preventing wrinkles or displacement of the skin during heating or mold closing. At this point, the part placement step is completed, and the equipment is ready to start.

[0052] II. Heating and Light Box Reset Stage

[0053] After the operator presses the equipment start button, the system enters the heating step. First, the pin cylinder retracts, releasing the lock on the light box. Then, the light box transfer cylinder extends forward, driving the entire heated light box to move along the linear guide rail to the mold station. Once the light box is in position, the heating cylinder mounted on the light box extends, lowering the surface-side heating lamp to the preset heating position, beginning radiant heating of the area to be edged on the surface and / or frame. Thermocouples installed near the heating lamp monitor the temperature in real time and feed the signal back to the temperature controller, keeping the surface temperature within the optimal activation range of the adhesive (e.g., 50-60℃). After heating reaches the preset time or temperature, the heating cylinder retracts, causing the heating lamp to rise and reset. Then, the light box transfer cylinder reverses its movement, moving the light box back to its original position. The pin cylinder extends again, inserting the pin into the positioning hole in the light box base to lock the light box, completing the entire heating step.

[0054] III. Mold Closing and Edge Binding Stage

[0055] After the heating step is completed, the system executes the mold closing and edge-wrapping step. First, the upper mold descends smoothly along the guide post system under the action of the main drive hydraulic cylinder or air cylinder, closing with the lower mold. After the mold is closed, the locking force is provided by the locking devices installed at the four corners of the mold. Then, the slider cylinder installed inside the lower mold immediately extends, and the contour support block at its front end tightly fits against the inner side of the skeleton, providing rigid inner support for the edge-wrapping area and preventing deformation of the skeleton due to subsequent flattening actions. Immediately afterwards, all the hanging pin cylinders retract synchronously, causing the hanging pins to withdraw from the skin and release the fixation to the skin; the heating cylinders in the edge-wrapping area extend again, driving the heating lamps to descend and perform secondary heating of the edge-wrapping area, ensuring that the adhesive maintains optimal adhesion at the moment of bonding. After the heating reaches the set time or temperature, the heating cylinders retract, and the lamps rise to reset.

[0056] Next comes the core multi-stage flattening action. Following a preset program, the control system first drives the first set of flattening cylinders to extend in a preset first sequence (e.g., from the center of the product's length towards both sides), performing a first-stage flattening action to initially push the skin to the edge of the frame. Then, it drives the second set of flattening cylinders to extend in a preset second sequence (e.g., from the straight edge towards the corner), performing a second-stage pressing action to further press the skin together. This graded, sequential control logic mimics the gradual flattening and pressing action of a human hand on the skin's edge, effectively expelling air from the bonding surface and preventing wrinkles.

[0057] After multi-stage flattening, the system executes a clamping and resetting step. First, some clamping cylinders in the main body area retract, releasing some pressure and providing space for material flow. Simultaneously, dedicated corner clamping cylinders extend to perform final shaping and clamping on complex areas such as the corners of the parts, ensuring a tight fit and clear outline in the corner areas. During this process, magnetic switches installed on all cylinders are used to detect the piston's position, ensuring the reliability of each action.

[0058] IV. Pressure Holding, Curing, and Mold Opening / Part Removal Stage

[0059] After pressing and shaping, the vacuum adsorption device of the upper mold is de-energized and ventilated by the vacuum generator, disconnecting the adsorption on the skeleton. The gripper cylinder retracts under the control of the solenoid valve, releasing the skeleton and completely releasing its fixation. The system remains in the mold-closed state for a period of time, then enters the pressure holding and curing step to fully cure the adhesive and ensure a firm bond between the skin and the skeleton. After the pressure holding time ends, the edge-wrapping mechanism resets in the reverse sequence of the multi-stage flattening action, the slider cylinder retracts and exits the inner support, and then the upper mold rises and opens under the action of the main drive mechanism. The operator or the automatic unloading mechanism removes the wrapped interior parts, thus completing one complete work cycle.

[0060] V. Process Adaptability Adjustment

[0061] It should be noted that the method described in this invention has a high degree of process adaptability. For automotive interior parts of different shapes and specifications, the control system can, according to the specific contour of the part to be processed, call different process formulas preset in the programmable logic controller to pre-set, increase, decrease or adjust the number of cylinders, grouping method and execution order involved in the edge-wrapping action, without changing the entire set of molds or equipment. This allows for the compatible production of multiple products on the same system, significantly reducing equipment investment costs and production changeover time.

[0062] All components of this invention are general standard parts or parts known to those skilled in the art. Their structure and principles are readily known to those skilled in the art through technical manuals or conventional experimental methods. It is obvious to those skilled in the art that this invention is not limited to the details of the above exemplary embodiments, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects. The scope of this invention is defined by the appended claims rather than the foregoing description, and thus all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0063] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An automated pneumatic edge-wrapping system method for automotive interior trim parts, characterized in that, Includes the following steps: Placement steps: Place the skeleton on the upper mold and fix it, lay the skin on the lower mold and position it using hanging pins; Heating step: Move the heating lamp box to the mold station to preheat the skeleton and / or skin; Mold closing and edge wrapping steps: Drive the upper mold and lower mold to close, and drive the edge wrapping mechanism to perform multi-stage flattening actions in a preset sequence, so that the skin edge fits into the skeleton; Pressure holding and curing step: Keep the mold closed to allow the skin and skeleton to bond and cure; Mold opening and part removal steps: After the mold is opened, the wrapped interior parts are removed.

2. The method for an automated pneumatic edge-wrapping system for automotive interior trim parts according to claim 1, characterized in that, The placement step specifically includes: fixing the skeleton by vacuum adsorption or cylinder grippers of the upper mold, and driving the hanging pins to extend through the hanging pin cylinder of the lower mold to penetrate and position the skin.

3. The automated pneumatic edge-wrapping system method for automotive interior trim parts according to claim 1, characterized in that, The heating step specifically includes: after the transfer cylinder drives the lamp box to move into place, the heating cylinder drives the heating lamp tube to descend to the preset heating position to radiate heat the area to be wrapped on the skin and / or frame.

4. The automated pneumatic edge-wrapping system method for automotive interior trim parts according to claim 3, characterized in that, The heating step further includes: after heating is completed, the heating cylinder drives the heating lamp tube to rise and reset, and the transfer cylinder moves the lamp box back to its original position and locks it with a pin.

5. The method for an automated pneumatic edge-wrapping system for automotive interior trim parts according to claim 1, characterized in that, The mold closing and edge wrapping step includes: after the upper and lower molds are closed in place, driving all hanging pin cylinders to retract, causing the hanging pins to exit from the skin, and driving the heating lamp tube to perform secondary heating on the edge wrapping area before resetting.

6. A method for an automated pneumatic edge-wrapping system for automotive interior trim components according to claim 1 or 5, characterized in that, In the molding and edge-wrapping step, the multi-stage flattening action includes: firstly driving the first set of flattening cylinders to perform the first-level flattening action in the first order, and then driving the second set of flattening cylinders to perform the second-level pressing action in the second order, so as to imitate the human hand to gradually flatten and press the skin edge.

7. The method for an automated pneumatic edge-wrapping system for automotive interior trim parts according to claim 6, characterized in that, After performing the multi-stage flattening action, a pressing and resetting step is also included: first, control the partial pressing cylinder to retract, and at the same time drive the corner-specific pressing cylinder to extend, so as to finally shape and press the corner of the part.

8. The method for an automated pneumatic edge-wrapping system for automotive interior trim parts according to claim 1, characterized in that, Simultaneously or after the mold closing and edge wrapping step, a slider support step is also included: driving the slider cylinder located inside the mold to extend, providing inner support for the edge wrapping area, and driving the slider cylinder to retract back to its original position after the edge wrapping action is completed.

9. The method for an automated pneumatic edge-wrapping system for automotive interior trim parts according to claim 1, characterized in that, Before the mold opening and part removal step, a vacuum release step is also included: disconnecting the vacuum adsorption of the upper mold to the skeleton and releasing the cylinder gripper.

10. The method for an automated pneumatic edge-wrapping system for automotive interior trim parts according to claim 1, characterized in that, The method allows for the preset addition, reduction, or adjustment of the number of cylinders involved in the edge-wrapping action and their execution sequence based on the different shapes of the parts to be processed, in order to adapt to different specifications of automotive interior parts.

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