A flexible engine production line single-shaft electric gun tightening sequence control digital device

Abstract

This invention relates to the field of assembly line quality control technology and discloses an intelligent digital device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line. The invention acquires the relative displacement data of the single-axis electric gun through a pull-rope encoder and obtains the wire rope swing angle data and the single-axis electric gun posture data using a dual-axis tilt angle sensor. The CPU module converts the displacement and swing angle data into real-time three-dimensional spatial coordinates. When the electric gun posture is within a set range, the real-time three-dimensional spatial coordinates are compared with the target preset coordinates in a preset rule base. When the coordinate deviation is not greater than a set threshold and fully conforms to the preset tightening sequence logic, a start signal is output to the single-axis electric gun; otherwise, a lock signal is output and an alarm is triggered. This invention achieves 100% intelligent error prevention for the tightening sequence and integrates WYSIWYG drag-and-drop teaching programming and anomaly handling data traceability functions, significantly improving the changeover efficiency for multiple platform models.

Description

Technical Field

[0001] This invention relates to the field of assembly line quality control technology, specifically to a digital intelligent device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line. Background Technology

[0002] In engine manufacturing processes, for fastening applications such as flywheel housings and cylinder head covers where sealing and assembly reliability are critical, manual assembly using a single-axis electric arc gun is typically employed. This method offers high tightening accuracy and cost-effectiveness.

[0003] However, existing error-proofing methods for single-axis electric bolt gun assembly have certain limitations. Current conventional control mechanisms mostly rely on upper and lower limits for torque and angle, fixed tightening procedures, and sleeve selectors. These error-proofing methods can usually only prevent abnormal torque during a single tightening action or check for missed tightening at the end of the process. They cannot proactively identify and intercept incorrect tightening sequences among multiple bolts during operation. Furthermore, existing single-axis electric bolt gun assembly systems lack the ability to sense the spatial position of the electric bolt, and the operation process often lacks digital recording, making accurate quality traceability of the final assembly result difficult.

[0004] In actual final assembly lines, the movement path and operating sequence of single-axis electric arc guns still heavily rely on the operator's experience and judgment. Due to the lack of effective sequence-based error prevention mechanisms, manual operation frequently results in errors such as not tightening in the required sequence. These sequence errors cause uneven stress on the flange surface, affecting the sealing and reliability of engine components and incurring additional rework costs. Furthermore, as automobile manufacturing moves towards multi-platform co-production, engine model changes are becoming more frequent. Traditional error prevention solutions and equipment struggle to quickly adapt to engine model changes, failing to meet the flexible production demands of rapid switching between multi-platform engine products. Therefore, accurately identifying and strictly controlling the operating position and tightening sequence of single-axis electric arc guns in complex multi-model co-production scenarios is a pressing technical problem in the current engine assembly field. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a digital intelligent device for controlling the tightening sequence of a single-axis electric gun on a flexible engine production line. This device solves the problems of ineffective error prevention in manual electric gun tightening sequence control on flexible engine production lines, difficulty in tracing abnormal quality data, and cumbersome and inefficient programming during multi-model production changes.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution: a digital intelligent device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line, comprising a balancer, a steel wire rope below the balancer, a single-axis electric gun fixedly connected to the lower end of the steel wire rope, an tilt angle swing head device passing through the outside of the steel wire rope, a pull rope encoder installed on one side of the steel wire rope, the pull rope of the pull rope encoder being fixedly connected to the steel wire rope, and dual-axis tilt angle sensors installed on both the tilt angle swing head device and the outer shell of the single-axis electric gun;

[0007] It also includes a CPU module, which acquires the displacement data of the pull-cord encoder, the swing angle data of the dual-axis tilt angle sensor on the tilt angle swing head device, and the attitude tilt angle data of the dual-axis tilt angle sensor on the housing of the single-axis electric gun. Based on the displacement data and the swing angle data, it calculates the real-time three-dimensional spatial coordinates of the single-axis electric gun. When the attitude tilt angle data is within a set range, it compares the target preset coordinates in the preset rule base with the real-time three-dimensional spatial coordinates. When the coordinate deviation is not greater than a set threshold and meets the preset tightening sequence, it outputs a start signal to the single-axis electric gun; otherwise, it outputs a lock signal to the single-axis electric gun.

[0008] Preferably, the tilt angle swing head device includes a tilt angle swing mechanism fixing plate, a rope X-axis tilt angle swing head mechanism, a rope Y-axis tilt angle swing head mechanism, and a tilt angle swing head through shaft. The steel wire rope passes through the tilt angle swing head through shaft. The tilt angle swing head through shaft is connected to the rope X-axis tilt angle swing head mechanism and the rope Y-axis tilt angle swing head mechanism respectively. A dual-axis tilt angle sensor fixing bracket is installed on the tilt angle swing mechanism fixing plate, and the dual-axis tilt angle sensor on the tilt angle swing head device is fixed on the dual-axis tilt angle sensor fixing bracket.

[0009] Preferably, the origin of the preset spatial coordinate system in the CPU module is the position of the tilting head device. The CPU module executes spatial geometric operation logic including trigonometric functions, substitutes the displacement data into the straight line length variable in the spherical coordinate system, substitutes the swing angle data into the spatial swing angle variable, and calculates and outputs the real-time three-dimensional spatial coordinates in the Cartesian coordinate system.

[0010] Preferably, the CPU module reads the order priority parameters of all bolt points of the current model in the rule base and stores them in an array, performs a loop to traverse the array, filters out the minimum priority parameter in the array, and extracts the position corresponding to the minimum priority parameter as the current target tightening position;

[0011] After receiving the qualified tightening signal from the single-axis electric gun, the CPU module resets the priority parameter of the current target tightening position to a preset maximum value and repeatedly executes the operation of looping through the array.

[0012] Preferably, the system also includes a line PLC controller that is communicatively connected to the CPU module. After the system starts, the CPU module reads the current engine model information through the line PLC controller and calls the bolt tightening sequence parameters and target preset coordinate parameters corresponding to the engine model information in the rule base.

[0013] Preferably, it also includes an industrial control all-in-one computer and a network switch. The industrial control all-in-one computer is communicatively connected to the CPU module through the network switch. The industrial control all-in-one computer displays a digital operation interface, and the CPU module contains a teaching module.

[0014] After entering the teaching mode, the CPU module acquires the real-time three-dimensional spatial coordinates of the single-axis electric gun when it is at the target point, and stores the real-time three-dimensional spatial coordinates in the point database when it receives the teaching trigger command, and simultaneously generates the corresponding tightening point information on the digital operation interface.

[0015] Preferably, in the teaching mode, the industrial control all-in-one computer receives a cursor drag operation signal for the tightening point information on the digital operation interface, modifies the order and tightening priority of each tightening point in the point database, and the CPU module extracts the modified order and tightening priority to generate the tightening sequence logic rule for the corresponding model.

[0016] Preferably, the digital operation interface includes an anomaly handling screen;

[0017] When an unqualified tightening result is detected, the CPU module outputs a workpiece release prohibition signal;

[0018] When the CPU module receives the skip command for the bolt input on the anomaly handling screen, it marks the current bolt tightening result and position status as a skip anomaly and records it in the memory. It then releases the workpiece prohibition signal and obtains the target preset coordinates of the next bolt tightening position to enter the comparison process.

[0019] Preferably, it also includes a data storage module. After the tightening action of a single bolt is completed, the data storage module records the tightening time, the three-dimensional spatial coordinates of the location, the tightening sequence verification result, and the qualified status quality data.

[0020] The data storage module is connected to an external manufacturing execution system and sends the qualified status quality data to the manufacturing execution system.

[0021] Preferably, it also includes a power supply module and an analog quantity module. The power supply module provides operating power for the CPU module and each sensor. The CPU module includes a data processing unit. The signal output terminals of the pull rope encoder, the dual-axis tilt angle sensor on the tilt angle swing head device, and the dual-axis tilt angle sensor on the housing of the single-axis electric gun are connected to the analog quantity module through shielded signal lines. The input displacement data and angle data are converted into digital signals by the analog quantity module and sent to the data processing unit.

[0022] The above solution achieves the following beneficial technical effects:

[0023] This application combines a pull-rope encoder with a dual-axis tilt angle sensor on the tilt angle oscillating head device to acquire the displacement and swing angle of a single-axis electric gun in real time and calculate its three-dimensional spatial coordinates. Simultaneously, a dual-axis tilt angle sensor on the single-axis electric gun housing verifies the electric gun's working posture. The CPU module compares the real-time calculated coordinates and posture data with the target preset coordinates in a preset rule base. The electric gun is only allowed to start when the match is successful and conforms to the preset sequence. This accurately identifies the actual operating position of the electric gun, forcing operators to strictly follow the preset sequence for tightening operations. This solves the problem of sequence errors that easily occur in traditional manual operations and ensures the sealing and reliability of engine component assembly.

[0024] This application incorporates a teaching module within the CPU module and provides a digital operating interface in conjunction with an industrial control all-in-one computer. When the operator moves the single-axis electric gun to the actual target location, the system can directly capture and store its real-time three-dimensional spatial coordinates. Simultaneously, it allows for intuitive modification of the point order and priority via cursor dragging on the interface, thereby automatically generating the tightening sequence logic rules for the corresponding machine model. This lowers the technical threshold for operators, reduces the time required for writing and configuring error-proofing programs for new models, and effectively meets the rapid production changeover requirements under conditions of frequent co-production of engines on multiple platforms.

[0025] This application is equipped with a data storage module that can automatically record information such as tightening time, three-dimensional spatial coordinates, sequence verification results, and pass / fail status of each bolt after assembly. It also supports the synchronous storage of intervention records such as skipping the bolt in the exception handling interface into the database. The collected quality data can be directly sent to the manufacturing execution system, realizing the full digitization of the single-axis electric gun fastening process. This ensures that every node in the assembly process can be recorded and queried, providing objective data support for product quality traceability and subsequent process optimization on the production line. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the tilt angle swing head device in this invention;

[0027] Figure 2This is a schematic diagram of the single-axis electric gun and sensor mounting structure in this invention;

[0028] Figure 3 This is a schematic diagram of the overall installation structure of the present invention;

[0029] Figure 4 This is the electrical schematic diagram of the power supply module in this invention;

[0030] Figure 5 This is a schematic diagram of the power supply and Ethernet communication wiring between the industrial control all-in-one computer and the CPU module of the present invention.

[0031] Figure 6 This is a schematic diagram of the network switch topology communication wiring of the present invention;

[0032] Figure 7 This is a schematic diagram of the power supply and signal output wiring for the pull-cord encoder and the dual-axis tilt angle sensor of the present invention.

[0033] Figure 8 This is a schematic diagram of the input wiring principle for the analog quantity module of the present invention to receive analog quantity signals from various sensors;

[0034] Figure 9 This is a schematic diagram of the wiring principle for the reserved port of the Y-axis angle sensor signal input and CPU module of the pull rope in this invention;

[0035] Figure 10 This is a schematic diagram of the digital input wiring of the CPU module of the present invention;

[0036] Figure 11 This is a schematic diagram of the digital output wiring of the CPU module of the present invention.

[0037] Among them, 101, rope encoder; 102, dual-axis tilt angle sensor; 103, dual-axis tilt angle sensor mounting bracket; 104, rope X-axis tilt angle swing head mechanism; 105, rope Y-axis tilt angle swing head mechanism; 106, tilt angle swing mechanism mounting plate; 107, balancer; 108, tilt angle swing head through shaft; 201, industrial control all-in-one computer; 202, CPU module; 203, network switch; 204, power supply module; 205, analog quantity module; 4, single-axis electric gun. Detailed Implementation

[0038] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] See attached document Figure 1 - Appendix Figure 3A digital intelligent device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line includes a balancer 107, a steel wire rope below the balancer 107, a single-axis electric gun 4 fixedly connected to the lower end of the steel wire rope, an tilt angle swing head device passing through the outside of the steel wire rope, a pull rope encoder 101 installed on one side of the steel wire rope, the pull rope of the pull rope encoder 101 being fixedly connected to the steel wire rope, and a dual-axis tilt angle sensor 102 installed on both the tilt angle swing head device and the outer shell of the single-axis electric gun 4.

[0040] It also includes a CPU module 202, which acquires the displacement data of the pull rope encoder 101, the swing angle data of the dual-axis tilt angle sensor 102 on the tilt angle swing head device, and the attitude tilt angle data of the dual-axis tilt angle sensor 102 on the housing of the single-axis electric gun 4. Based on the displacement data and swing angle data, it calculates the real-time three-dimensional spatial coordinates of the single-axis electric gun 4. When the attitude tilt angle data is within the set range, it compares the target preset coordinates in the preset rule library with the real-time three-dimensional spatial coordinates. When the coordinate deviation is not greater than the set threshold and meets the preset tightening sequence, it outputs a start signal to the single-axis electric gun 4; otherwise, it outputs a lock signal to the single-axis electric gun 4.

[0041] Specifically, the draw rope encoder 101 uses the Milang MPS-S draw rope encoder with a displacement accuracy of less than 2mm; the dual-axis tilt angle sensor 102 uses the Witt intelligent dual-axis tilt angle sensor with an angle accuracy of ±0.1°. The entire control system is divided into a digital perception layer, an intelligent decision-making layer, and a digital execution layer. During coordinate comparison, the CPU module 202 sets 1mm as the coordinate deviation threshold. When the deviation between the calculated real-time three-dimensional spatial coordinates and the preset coordinates is less than or equal to 1mm, it is determined to be a match and the single-axis electric gun 4 is unlocked. If the deviation is greater than 1mm or the gun is not moved to the target bolt position in the set order, the CPU module 202 will not only cut off the enable signal to lock the single-axis electric gun 4, but also link the audible and visual alarm module to trigger an alarm and display the correct position on the operation interface, thereby achieving 100% error prevention accuracy.

[0042] The tilt angle swing head device includes a tilt angle swing mechanism fixing plate 106, a rope X-direction tilt angle swing head mechanism 104, a rope Y-direction tilt angle swing head mechanism 105, and a tilt angle swing head through shaft 108. A steel wire rope passes through the tilt angle swing head through shaft 108. The tilt angle swing head through shaft 108 is connected to the rope X-direction tilt angle swing head mechanism 104 and the rope Y-direction tilt angle swing head mechanism 105 respectively. A dual-axis tilt angle sensor fixing bracket 103 is installed on the tilt angle swing mechanism fixing plate 106. The dual-axis tilt angle sensor 102 on the tilt angle swing head device is fixed on the dual-axis tilt angle sensor fixing bracket 103.

[0043] Specifically, in actual mechanical installation, the draw rope encoder 101 is installed on the outside of the steel wire rope of the balancer 107 above the single-axis electric gun 4 via a snap-fit ​​fastener, ensuring that the direction of draw rope extension and retraction is completely consistent with the direction of lifting and lowering of the single-axis electric gun 4. Using a customized dual-axis tilt angle sensor mounting bracket 103, one of the dual-axis tilt angle sensors 102 is installed below the draw rope Y-axis tilt angle swing head mechanism 105. When the electric gun moves the steel wire rope, this sensor can accurately capture the swing angle in the X and Y directions when the tilt angle swing head through shaft 108 tilts. The other dual-axis tilt angle sensor 102 is directly fixed to the head of the single-axis electric gun 4, specifically for real-time verification of whether the vertical working posture of the electric gun is within the specified range.

[0044] The CPU module 202 presets the origin of the spatial coordinate system as the position of the tilting head device. The CPU module 202 executes spatial geometric operation logic containing trigonometric functions, substitutes the displacement data into the straight line length variable of the spherical coordinate system, substitutes the swing angle data into the spatial swing angle variable, and calculates and outputs the real-time three-dimensional spatial coordinates in the Cartesian coordinate system.

[0045] Specifically, the data sampling period of the data acquisition and conversion module is set to 10ms. The CPU module 202 uses the SCL programming language to write the core spatial algorithm. It uses spatial geometric operation rules and trigonometric functions to convert the input analog physical displacement and swing angle data into X, Y, and Z three-dimensional spatial coordinates with an actual accuracy of less than 2mm in real time. This provides a precise digital coordinate comparison basis for the error prevention and verification module.

[0046] CPU module 202 reads the order priority parameters of all bolt points of the current model in the rule base and stores them in an array. It then performs a loop to traverse the array, filters out the lowest priority parameter in the array, and extracts the position corresponding to the lowest priority parameter as the current target tightening position.

[0047] After receiving the qualified tightening signal from the single-axis electric gun 4, the CPU module 202 resets the priority parameter of the current target tightening position to the preset maximum value and repeatedly executes the operation of looping through the array.

[0048] Specifically, the CPU module 202 internally utilizes array traversal and minimum value filtering logic to automatically prevent errors in target point determination. The error prevention verification program defines a specific array to store the coordinate parameters of each bolt point. It traverses the array using a FOR loop instruction, filtering out the minimum parameter value among the current bolt points to be tightened as the highest priority target. After a single bolt is properly tightened, the CPU module 202 forcibly assigns the priority parameter of that point in the array to a preset maximum value of 32767, thus automatically excluding that point in the next loop traversal, achieving sequential progression and logical jumps between target points.

[0049] It also includes a line PLC controller that communicates with the CPU module 202. After the system starts, the CPU module 202 reads the current engine model information through the line PLC controller and calls the bolt tightening sequence parameters and target preset coordinate parameters corresponding to the model information in the rule base.

[0050] Specifically, upon daily startup, the system automatically executes an initialization procedure to complete the calibration of the reference plane data of the dual-axis tilt angle sensor and the detection of the communication link, ensuring the accuracy of the coordinate system origin parameters. The CPU module 202 establishes communication with the line PLC controller via industrial Ethernet. The line PLC controller is connected to an RFID reader / writer installed on the line. After scanning the current engine tray chip with the RFID reader / writer to obtain the engine model information, the CPU module 202 uses edge detection instructions to capture the changes in the engine model signal at the currently arriving workstation in real time. When a non-zero valid engine model signal is detected, the CPU module 202 automatically traverses and calls the corresponding bolt position, tightening sequence, and coordinate parameters in the DB200 workpiece type data block in the internal memory. After the parameter call is completed, the system automatically initializes the bolt position status display and tightening result display for that engine model. This achieves automatic identification and rapid switching of multiple platform engine models without changing the original production cycle, shortening the engine model changeover time.

[0051] See attached document Figure 5 and attached Figure 6 It also includes an industrial control all-in-one computer 201 and a network switch 203. The industrial control all-in-one computer 201 is connected to the CPU module 202 through the network switch 203. The industrial control all-in-one computer 201 displays a digital operation interface, and the CPU module 202 contains a teaching module.

[0052] After entering the teaching mode, the CPU module 202 acquires the real-time three-dimensional spatial coordinates of the single-axis electric gun 4 when it is at the target point, and stores the real-time three-dimensional spatial coordinates in the point database when it receives the teaching trigger command, and simultaneously generates the corresponding tightening point information on the digital operation interface.

[0053] Specifically, the 201 industrial control all-in-one machine uses an Advantech touchscreen device, installed next to the assembly line workstation. Accessing the calibration teaching screen within the system requires an operation permission password. Operators do not need to master professional low-level programming code. After activating the teaching mode, they only need to hold the single-axis electric gun 4 and move it to the actual physical location of the bolt to be tightened, press the teaching cursor button on the operation panel, and the system will automatically capture and permanently record the real-time three-dimensional coordinate data of that point in the point database, achieving WYSIWYG point location acquisition, which greatly reduces the usage threshold of error-proofing equipment.

[0054] In teaching mode, the industrial control all-in-one computer 201 receives the cursor drag operation signal for the tightening point information on the digital operation interface, modifies the order and tightening priority of each tightening point in the point database, and the CPU module 202 extracts the modified order and tightening priority to generate the tightening sequence logic rules for the corresponding model.

[0055] Specifically, the calibration teaching visualization interface of the 201 industrial control all-in-one computer has a built-in intuitive logic arrangement function. Operators can directly adjust the order of each captured point on the display screen by dragging the cursor with the touch screen or mouse, and set specific tightening priorities for them. After configuration confirmation, the system automatically generates a complete tightening sequence logic rule and a corresponding point database for this model.

[0056] See attached document Figure 10 and attached Figure 11 The digital user interface includes an error handling screen;

[0057] When an unqualified tightening result is detected, the CPU module 202 outputs a workpiece release prohibition signal;

[0058] When a skip command for the bolt is received from the error handling screen, the CPU module 202 marks the current bolt tightening result and position status as a skip error and records it in the memory. It then releases the workpiece release prohibition signal and obtains the target preset coordinates of the next bolt tightening position to enter the comparison process.

[0059] Specifically, the digital operation interface incorporates multiple display screens. In the daily operation guidance screen, the system uses a simplified 3D diagram of the engine as the background, with a yellow flashing effect marking the current bolt position to be tightened and a green indicator showing completed workstations. When the single-axis electric gun 4 detects that its torque or angle has not reached the set upper or lower limits and outputs an unqualified data (NOK) value, the interface automatically jumps to the anomaly handling screen, and the CPU module 202 locks the line release logic. The anomaly handling screen has virtual buttons for skipping the current bolt, re-tightening, and contacting maintenance. Upon receiving the skip command from the operator, the CPU module 202 forcibly modifies the tightening result and position status of the workstation to a specific skip anomaly state and writes it into the internal data block for long-term memory. Only then is the current anti-run restriction lifted and the process moved to the next tightening node, thus achieving foolproof control and operation traceability in case of abnormal manual intervention.

[0060] It also includes a data storage module. After a single bolt is tightened, the data storage module records the tightening time, the three-dimensional spatial coordinates of the location, the tightening sequence verification results, and the qualified status quality data.

[0061] The data storage module communicates with the external manufacturing execution system and sends qualified status quality data to the manufacturing execution system.

[0062] Specifically, the data storage module relies on the data storage function of Siemens WINCC within the system. After each bolt tightening operation is completed, the system automatically records detailed tightening time, actual three-dimensional spatial coordinates, sequence verification results, and pass / fail status, among other comprehensive quality data. This data not only supports local querying by date, production batch, or workpiece number in the historical data screen of the 201 industrial control all-in-one computer, but is also uploaded in real time to the database of an external manufacturing execution system for permanent storage, constructing a complete digital quality archive of the assembly process and providing objective evidence for subsequent product quality traceability.

[0063] See attached document Figure 4 Appendix Figure 7 To be continued Figure 9 It also includes a power supply module 204 and an analog module 205. The power supply module 204 provides working power for the CPU module 202 and each sensor. The CPU module 202 includes a data processing unit. The signal output terminals of the draw rope encoder 101, the dual-axis tilt angle sensor 102 on the tilt angle swing head device, and the dual-axis tilt angle sensor 102 on the housing of the single-axis electric gun 4 are connected to the analog module 205 through shielded signal lines. The input displacement data and angle data are converted into digital signals by the analog module 205 and sent to the data processing unit.

[0064] Specifically, in terms of hardware configuration, the power supply module 204 uses a MIWI power supply module, which connects to an external 220V AC power supply and converts it to a stable 24V DC voltage, powering the CPU module 202, the industrial control all-in-one computer 201, and various sensors. The CPU module 202 uses a Siemens S7-1200 series 1214 CPU module, and the analog input module 205 uses a Siemens SM1234 module. All analog signal output terminals of the sensors on site are strictly connected to the analog input module 205 using shielded signal cables, and all communication equipment is reliably grounded. This effectively shields against the complex industrial electromagnetic interference in the assembly workshop, ensuring that the basic sensing data input to the data processing unit of the CPU module 202 remains stable and reliable.

[0065] Working principle: After the system starts, the power module 204 first provides working power to the entire device. The CPU module 202 reads the engine model information of the current station through the line PLC controller and calls the corresponding bolt tightening sequence parameters and target preset coordinate parameters in the preset rule library.

[0066] When the operator pulls down the single-axis electric gun 4 to prepare for operation, the steel wire rope below the balancer 107 extends or shortens accordingly, pulling the rope encoder 101 to generate displacement data. At the same time, the swing of the steel wire rope causes the tilt angle swing head through shaft 108 passing through it to deflect, thereby driving the rope X-direction tilt angle swing head mechanism 104 and the rope Y-direction tilt angle swing head mechanism 105 to move. The dual-axis tilt angle sensor 102 fixed on the tilt angle swing mechanism fixing plate 106 and the dual-axis tilt angle sensor fixing bracket 103 collects the swing angle data of the steel wire rope in real time, while the dual-axis tilt angle sensor 102 on the housing of the single-axis electric gun 4 collects the attitude tilt angle data of the electric gun synchronously.

[0067] Subsequently, the aforementioned analog signals are uniformly collected to the analog module 205 through the shielded signal line, converted into digital signals, and sent to the CPU module 202. Then, the CPU module 202 performs spatial geometric calculations with the location of the tilting head device as the origin of the spatial coordinate system, substitutes the displacement data into the straight line length variable of the spherical coordinate system, substitutes the swing angle data into the spatial swing angle variable, and calculates the real-time three-dimensional spatial coordinates of the single-axis electric gun 4 in the Cartesian coordinate system in real time through trigonometric functions.

[0068] During the tightening verification, the CPU module 202 extracts the position with the lowest current priority as the target tightening position, and first judges whether the attitude data fed back by the dual-axis tilt angle sensor 102 on the electric gun housing is within the set range. If the operation attitude is compliant and the deviation between the real-time three-dimensional space coordinates and the target preset coordinates is not greater than the set threshold and conforms to the preset tightening sequence, then a start signal is output to the single-axis electric gun 4; otherwise, a lock signal is output to implement error prevention and interception.

[0069] After a single bolt is properly tightened, the CPU module 202 resets the priority of that point and searches for the next target. If an abnormal situation such as stripped thread is encountered, the operator can enter a skip command on the digital operation interface of the industrial control all-in-one computer 201, which is connected to the network switch 203. The system will then release the workpiece prohibition signal and transfer it to the next node.

[0070] Finally, after the assembly operation is completed, the data storage module automatically packages and sends the three-dimensional spatial coordinates of all nodes, tightening time, verification results and manual intervention records to the external manufacturing execution system, thereby realizing the mandatory sequential control of single-axis electric gun fastening operations and full life cycle data traceability on the flexible production line.

[0071] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A digital intelligent device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line, characterized in that, The device includes a balancer (107), a steel wire rope below the balancer (107), a single-axis electric gun (4) fixedly connected to the lower end of the steel wire rope, an tilt angle swing head device passing through the outside of the steel wire rope, a pull rope encoder (101) installed on one side of the steel wire rope, the pull rope of the pull rope encoder (101) being fixedly connected to the steel wire rope, and a dual-axis tilt angle sensor (102) installed on both the tilt angle swing head device and the outer shell of the single-axis electric gun (4). It also includes a CPU module (202), which acquires the displacement data of the pull rope encoder (101), the swing angle data of the dual-axis tilt angle sensor (102) on the tilt angle swing head device, and the attitude tilt angle data of the dual-axis tilt angle sensor (102) on the housing of the single-axis electric gun (4). Based on the displacement data and the swing angle data, it calculates the real-time three-dimensional spatial coordinates of the single-axis electric gun (4). When the attitude tilt angle data is within a set range, it compares the target preset coordinates in the preset rule library with the real-time three-dimensional spatial coordinates. When the coordinate deviation is not greater than the set threshold and meets the preset tightening sequence, it outputs a start signal to the single-axis electric gun (4); otherwise, it outputs a lock signal to the single-axis electric gun (4).

2. The intelligent digital device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line according to claim 1, characterized in that, The tilt angle swing head device includes a tilt angle swing mechanism fixing plate (106), a rope X-direction tilt angle swing head mechanism (104), a rope Y-direction tilt angle swing head mechanism (105), and a tilt angle swing head through shaft (108). The wire rope passes through the tilt angle swing head through shaft (108). The tilt angle swing head through shaft (108) is connected to the rope X-direction tilt angle swing head mechanism (104) and the rope Y-direction tilt angle swing head mechanism (105) respectively. A dual-axis tilt angle sensor fixing bracket (103) is installed on the tilt angle swing mechanism fixing plate (106). The dual-axis tilt angle sensor (102) on the tilt angle swing head device is fixed on the dual-axis tilt angle sensor fixing bracket (103).

3. The intelligent digital device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line according to claim 1, characterized in that, The CPU module (202) presets the origin of the spatial coordinate system as the position of the tilting head device. The CPU module (202) executes spatial geometric operation logic containing trigonometric functions, substitutes the displacement data into the straight line length variable of the spherical coordinate system, substitutes the swing angle data into the spatial swing angle variable, and calculates and outputs the real-time three-dimensional spatial coordinates in the Cartesian coordinate system.

4. The intelligent digital device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line according to claim 1, characterized in that, The CPU module (202) reads the order priority parameters of all bolt points of the current model in the rule base and stores them in an array. It then performs a loop to traverse the array, filters out the minimum priority parameter in the array, and extracts the position corresponding to the minimum priority parameter as the current target tightening position. After receiving the qualified tightening signal from the single-axis electric gun (4), the CPU module (202) resets the priority parameter of the current target tightening position to the preset maximum value and repeatedly performs the operation of looping through the array.

5. The intelligent digital device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line according to claim 1, characterized in that, It also includes a line PLC controller that is communicatively connected to the CPU module (202). After the system starts, the CPU module (202) reads the current engine model information through the line PLC controller and calls the bolt tightening sequence parameters and target preset coordinate parameters corresponding to the engine model information in the rule base.

6. The intelligent digital device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line according to claim 1, characterized in that, It also includes an industrial control all-in-one computer (201) and a network switch (203). The industrial control all-in-one computer (201) is connected to the CPU module (202) through the network switch (203). The industrial control all-in-one computer (201) displays a digital operation interface. The CPU module (202) contains a teaching module. After entering the teaching mode, the CPU module (202) obtains the real-time three-dimensional spatial coordinates of the single-axis electric gun (4) when it is at the target point, and stores the real-time three-dimensional spatial coordinates in the point database when it receives the teaching trigger command, and synchronously generates the corresponding tightening point information on the digital operation interface.

7. The intelligent digital device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line according to claim 6, characterized in that, In the teaching mode, the industrial control computer (201) receives the cursor drag operation signal for the tightening point information on the digital operation interface, modifies the order and tightening priority of each tightening point in the point database, and the CPU module (202) extracts the modified order and tightening priority to generate the tightening sequence logic rule for the corresponding model.

8. The intelligent digital device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line according to claim 6, characterized in that, The digital user interface includes an error handling screen; When an unqualified tightening result is detected, the CPU module (202) outputs a workpiece release prohibition signal; When the CPU module (202) receives the skip command for the bolt input on the abnormality handling screen, it marks the current bolt tightening result and position status as a skip abnormality and records it in the memory, releases the workpiece prohibition signal, and obtains the target preset coordinates of the next bolt tightening position to enter the comparison process.

9. The intelligent digital device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line according to claim 1, characterized in that, It also includes a data storage module. After the tightening action of a single bolt is completed, the data storage module records the tightening time, the three-dimensional spatial coordinates of the location, the tightening sequence verification result, and the qualified status quality data. The data storage module is connected to an external manufacturing execution system and sends the qualified status quality data to the manufacturing execution system.

10. The intelligent digital device for controlling the tightening sequence of a single-axis electric gun in a flexible engine production line according to claim 1, characterized in that, It also includes a power supply module (204) and an analog quantity module (205). The power supply module (204) provides working power for the CPU module (202) and each sensor. The CPU module (202) includes a data processing unit. The signal output terminals of the pull rope encoder (101), the dual-axis tilt angle sensor (102) on the tilt angle swing head device and the dual-axis tilt angle sensor (102) on the housing of the single-axis electric gun (4) are connected to the analog quantity module (205) through shielded signal lines. The input displacement data and angle data are converted into digital signals by the analog quantity module (205) and sent to the data processing unit.

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