A double-station flexible piercing and welding station for automobile bumpers

Abstract

The present application relates to the technical field of automobile bumper processing, and particularly relates to a double-station flexible puncture welding station for automobile bumpers, comprising a rack, a mechanical hand symmetrically installed on the rack, a puncture welding head installed at the output end of the mechanical hand, a jig mounting frame installed on the rack, and a bumper jig detachably mounted on the top of the jig mounting frame; the bumper jig comprises a bottom plate, a profiling support seat, and a clamping air cylinder; an air valve box is installed on the rack, a pneumatic electromagnetic valve is installed in the air valve box, a plug-in air cylinder is fixed on the rack, and a gas path connector male head is fixed at the output end of the plug-in air cylinder. Through the double-station design, the quick replacement of the jig, and the automatic gas path connection, the present application realizes the high-efficiency and high-flexibility puncture welding of the bumper, and greatly improves the production efficiency and equipment utilization.

Description

Technical Field

[0001] This invention relates to the field of automotive parts processing equipment, specifically to a dual-station flexible piercing welding workstation for automotive bumpers. Background Technology

[0002] With the rapid development of the automotive industry, the performance and appearance requirements for car bumpers are increasing. Plastic bumpers are widely used due to their lightweight, high design flexibility, and good cushioning performance. During the bumper production process, various brackets, clips, or reinforcing ribs are often welded onto them for mounting headlights, radar, sensors, or connecting other body parts. Penetration welding is a highly efficient and clean plastic joining technology that uses a heating element to penetrate two plastic parts and fuse them together.

[0003] Currently, most common bumper piercing welding equipment is designed for single-station operation. The typical workflow is as follows: the operator installs and clamps the bumper workpiece onto a dedicated welding fixture, and then a robotic arm or welding head performs the welding operation. After welding is complete, the equipment stops, the operator removes the finished product, and then a new workpiece to be welded is installed. This method of operation has a significant efficiency bottleneck: welding and loading / unloading cannot be performed concurrently, the equipment spends most of its time waiting, resulting in low equipment utilization and a slow overall production cycle.

[0004] Furthermore, with the rapid pace of vehicle model updates and the widespread adoption of multi-variety, small-batch production, the requirements for production line flexibility are becoming increasingly stringent. Different bumper models (such as different styles of sedans and SUVs) require different contour supports and clamping fixtures. Traditional equipment requires replacing the entire welding fixture when changing product models, and manually reconnecting the air and electrical lines used to drive the clamping cylinders. This process is cumbersome and time-consuming, requiring professional operation and debugging, which not only increases production preparation time but also severely impacts the flexibility and responsiveness of the production line. Frequent pipe insertion and removal can also easily lead to joint wear, leaks, or incorrect connections, affecting equipment stability and safety.

[0005] Therefore, it is necessary to provide a flexible dual-station piercing welding workstation for automotive bumpers to solve the above-mentioned technical problems. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention provides a flexible dual-station piercing welding workstation for automotive bumpers, comprising a frame, bumper fixtures, fixture mounting brackets, and a transport trolley for conveying the bumper fixtures. Robotic arms are symmetrically mounted on the frame, and each robotic arm's output end is equipped with a piercing welding head. By symmetrically arranging two robotic arms on the frame, simultaneous or alternating welding of different positions on the bumper can be achieved, significantly improving welding efficiency. More importantly, the dual-station layout enables "online mold changing": while one bumper fixture is being welded at its working position on the frame, the operator can load and unload another bumper fixture from the transport trolley or a preparatory station on the other side, thus achieving parallel welding and loading / unloading and significantly reducing equipment downtime.

[0007] A fixture mounting bracket is installed on the frame, and a bumper fixture is detachably mounted on the top of the fixture mounting bracket. This detachable design is the basis for flexible production, allowing for quick replacement of the appropriate fixture for different bumper models.

[0008] The bumper fixture includes a base plate, a contour support fixed to the top of the base plate for supporting and positioning the bumper, and a clamping cylinder for holding the bumper. The contour support is designed according to the contour of the bumper to provide precise positioning; the clamping cylinder is used to firmly fix the bumper to the fixture, ensuring stability during the welding process.

[0009] A valve box is installed on the frame, and a pneumatic solenoid valve is installed inside the valve box. The pneumatic solenoid valve is connected to an external air source. A plug-in cylinder is fixed on the frame, and a male air connector is fixed to the output end of the plug-in cylinder. The interface of the male air connector is connected to the corresponding interface of the pneumatic solenoid valve through a pipeline. A female air connector is fixed on the base plate, which is plugged into and connected to the male air connector. The female air connector is connected to the corresponding interface of the clamping cylinder through a pipeline.

[0010] This is one of the key technical points of this invention. By setting a male pneumatic connector driven by a plug-in cylinder, which mates with a female pneumatic connector fixed on the fixture base plate, automatic and rapid connection and disconnection of the pneumatic circuit is achieved. When the bumper fixture is pushed into place in the fixture mounting frame, the plug-in cylinder automatically pushes the male and female connectors to engage, and the pneumatic solenoid valve on the frame can control the clamping cylinder on the fixture through this pneumatic circuit. When changing fixtures, the plug-in cylinder pulls out the male connector, and the pneumatic circuit is automatically disconnected, eliminating the need for manual disassembly of any pipelines. This completely solves the drawback of manually plugging and unplugging pipelines during model changes in traditional solutions, greatly shortening changeover time and improving the reliability and safety of the connection.

[0011] Preferably, the conveying trolley includes a frame and omnidirectional self-locking wheels mounted at the four corners of the frame bottom. The frame is equipped with a plurality of roller sets for supporting and guiding the movement of the bumper fixture. The conveying trolley is used to smoothly and accurately transport the bumper fixture (along with the bumper workpiece attached to it) from the preparation area to the fixture mounting frame on the frame. The roller sets reduce friction during pushing.

[0012] Preferably, the top of the base plate is provided with first positioning holes near the left and right sides. A mounting plate is fixed on the frame, and the mounting plate is provided with second positioning holes. When the bumper fixture is installed on the transport trolley, the second positioning hole and the first positioning hole are limited by a first positioning pin. This solution achieves precise and detachable positioning of the bumper fixture on the transport trolley, ensuring the consistency of the fixture's position on the trolley and facilitating subsequent docking with the positioning mechanism on the frame.

[0013] Preferably, a first fixing plate for limiting the base plate is symmetrically fixed on the fixture mounting bracket, and a second fixing plate for limiting the base plate is symmetrically fixed on the frame. The first fixing plate and the second fixing plate limit the movement of the base plate from above and the side, respectively, to ensure the straightness and stability of the fixture during the pushing-in and pulling-out process, and to prevent displacement during operation.

[0014] Preferably, a plurality of guide wheels are installed on both the left and right sides of the base plate, and the guide wheels cooperate with the first fixed plate and the second fixed plate. The guide wheels change sliding friction into rolling friction, making the transfer of the fixture between the frame and the trolley smoother and less labor-intensive, and reducing wear.

[0015] Preferably, a positioning cylinder is fixed on the fixture mounting frame, and a second positioning pin is fixed to the output end of the positioning cylinder, with the second positioning pin engaging with the first positioning hole for limiting. When the bumper fixture is pushed into the precise working position of the fixture mounting frame, the positioning cylinder drives the second positioning pin to insert into the first positioning hole on the base plate, thereby achieving precise positioning and locking of the fixture on the frame and ensuring high repeatability of the welding position.

[0016] Preferably, the inner side of the base plate is symmetrically provided with positioning grooves, and the fixture mounting bracket is symmetrically fixed with limiting rods, which cooperate with the positioning grooves. This solution provides coarse guidance and final positioning functions. When the operator pushes the fixture, when they feel the limiting rods engage with the positioning grooves, it indicates that the fixture has reached the predetermined position, making the operation simple and intuitive.

[0017] Preferably, both the left and right sides of the frame are fixed with limiting plates for contacting the sides of the fixture mounting frame, and the inner sides of the limiting plates are chamfered. The limiting plates contact the sides of the fixture mounting frame when the transport trolley approaches the frame, thereby limiting the trolley's insertion position, ensuring accurate relative positioning between the trolley and the frame, and facilitating smooth fixture transfer. The chamfered design serves a guiding function.

[0018] Compared with related technologies, the present invention provides the following beneficial effects: This invention employs a symmetrical dual-robot layout, enabling simultaneous welding operations on both sides or different areas of the bumper, significantly shortening the welding cycle time for a single workpiece. More importantly, the use of quickly interchangeable bumper fixtures and a transport trolley allows for completely parallel "welding" and "loading / unloading": while welding is being performed on one bumper fixture on the frame, the operator can load / unload and prepare workpieces for another bumper fixture on a different transport trolley. The equipment does not need to be stopped for loading / unloading, greatly improving equipment utilization and overall production efficiency.

[0019] The bumper fixture in this invention features a fully detachable design and achieves rapid and precise positioning via a first positioning pin connected to the transport trolley, and a second positioning pin connected to the fixture mounting frame. When switching between different bumper models, only one bumper fixture (including the contour support, clamping cylinder, and pneumatic connector on the base plate) needs to be replaced, requiring no tools. Changeover time can be reduced from several hours to just minutes. This allows the production line to flexibly meet the needs of multi-variety, small-batch production, significantly enhancing the adaptability and flexibility of the equipment.

[0020] This invention innovatively features a male pneumatic connector driven by a plug-in cylinder, which mates with a female pneumatic connector fixed to the fixture base plate. When the bumper fixture is pushed into its working position and locked, the plug-in cylinder automatically pushes the male connector to engage with the female connector. The pneumatic solenoid valve on the frame then controls the clamping cylinder on the fixture via this pneumatic circuit. When changing fixtures, the plug-in cylinder automatically pulls the male connector out, instantly disconnecting the pneumatic circuit. The entire process requires no manual disassembly or assembly of any air pipes or connectors, completely avoiding problems such as incorrect pipe connections, air leaks, and connector wear caused by manual plugging and unplugging, significantly improving the reliability and safety of the equipment.

[0021] Through the rolling engagement of the guide wheel and the fixed plate, the coarse guidance of the limit rod and the positioning groove, and the precision locking of the second positioning pin driven by the positioning cylinder and the first positioning hole, multi-stage positioning of the bumper fixture on the frame is achieved, ensuring the repeatability accuracy of the fixture's position each time it is in place. Combined with the contour support and the automatic clamping cylinder for stable fixation of the bumper workpiece, a highly consistent working benchmark is provided for the robot arm and the piercing welding head, thereby ensuring the stability and consistency of welding quality in mass production.

[0022] The conveyor trolley uses omnidirectional self-locking wheels for easy manual pushing and locking. The transfer of the fixture between the frame and the trolley relies on guide wheels rolling between fixed plates, making pushing effortless and smooth. Pneumatic circuitry and positioning are automated; operators only need to perform simple actions such as pushing in and pulling out, greatly reducing operational difficulty and labor intensity, while also minimizing reliance on skilled workers. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall top structure of the present invention; Figure 2 This is a schematic diagram of the vehicle structure of the present invention; Figure 3 This is a schematic diagram of the fixture mounting bracket and bumper fixture structure of the present invention; Figure 4 This is a schematic diagram of the fixture mounting frame structure of the present invention; Figure 5 This is a schematic diagram of the bumper fixture structure of the present invention.

[0024] Labels in the diagram: 1. Frame; 2. Bumper jig; 3. Jig mounting bracket; 4. Conveyor trolley; 5. Robotic arm; 6. Piercing welding head; 7. Base plate; 8. Contouring support seat; 9. Clamping cylinder; 10. Valve box; 11. Pneumatic solenoid valve; 12. Insertion / removal cylinder; 13. Male pneumatic connector; 15. Female pneumatic connector; 16. Frame; 17. Universal self-locking wheel; 18. Roller assembly; 20. First positioning hole; 21. Mounting plate; 22. Second positioning hole; 23. First positioning pin; 24. First fixing plate; 25. Second fixing plate; 26. Guide wheel; 27. Positioning cylinder; 28. Second positioning pin; 29. ​​Positioning groove; 30. Limiting rod; 31. Limiting plate. Detailed Implementation

[0025] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0026] Please refer to the following: Figures 1-5 A flexible piercing welding workstation for automotive bumpers with dual workstations, the core components of which include a frame 1, a bumper fixture 2, a fixture mounting frame 3, and a transport trolley 4 for transferring the bumper fixture 2.

[0027] The frame 1, serving as the main support structure of the entire workstation, is welded from high-strength steel, ensuring overall rigidity and stability. Two industrial robotic arms 5 are symmetrically mounted on the left and right sides of the top of the frame 1. Each robotic arm 5 has a piercing welding head 6 installed at its output end, i.e., the wrist end. The piercing welding head 6 is a mature existing technology in this field, containing a heating element and a retractable welding needle, capable of penetrating the bumper and the accessory to be welded and fusing them. This symmetrical dual-robotic arm layout allows the workstation to simultaneously perform welding operations on the left and right sides or different feature areas of the bumper workpiece, or for one robotic arm to perform welding while the other prepares for repositioning, greatly improving welding efficiency.

[0028] A fixture mounting frame 3 is fixedly installed at the center of the frame 1. The top of the fixture mounting frame 3 is a flat support platform for detachably mounting the bumper fixture 2. The bumper fixture 2 is a special tooling for supporting and positioning the bumper to be welded. It mainly includes a base plate 7, multiple contoured support seats 8 fixed to the upper surface of the base plate 7, and several clamping cylinders 9. The top contour of the contoured support seat 8 matches the inner surface contour of a specific model of bumper, enabling precise support and positioning of the bumper. The clamping cylinders 9 are installed around the perimeter of the base plate 7, and their piston rod ends are connected to pressure blocks for clamping and fixing the bumper workpiece placed on the contoured support seats 8 from the outside.

[0029] To achieve rapid and smooth transfer of the bumper fixture 2 between the frame 1 and the preparation area, this invention employs a conveyor trolley 4. The conveyor trolley 4 has a frame 16, with universal self-locking wheels 17 installed at the four corners of its bottom for easy manual pushing and locking. Multiple guide wheels 26 are installed on the left and right edges of the base plate 7. A mounting plate 21 is fixed to the top of the frame 16, and a second positioning hole 22 is provided on the mounting plate 21. Correspondingly, a first positioning hole 20 is provided on the base plate 7 of the bumper fixture 2 at a corresponding position. When the bumper fixture 2 is placed on the frame 16 of the conveyor trolley 4 and limited by the second fixing plate 25, the first positioning pin 23 is simultaneously passed through the second positioning hole 22 and the first positioning hole 20, thus precisely fixing the bumper fixture 2 onto the conveyor trolley 4.

[0030] The process of transferring the bumper fixture 2 from the transport trolley 4 to the fixture mounting frame 3 is now described. First, multiple sets of rollers 18 are installed on the support platform of the fixture mounting frame 3 on the frame 1. Simultaneously, first fixing plates 24 are symmetrically fixed on the front and rear sides of the fixture mounting frame 3. Second fixing plates 25 are also symmetrically fixed on the frame 16 of the transport trolley 4. When the operator pushes the transport trolley 4 carrying the bumper fixture 2 closer to the frame 1, the limiting plates 31 on both sides of the frame 16 contact the sides of the fixture mounting frame 3, providing coarse positioning. The chamfered design at the ends of the limiting plates 31 makes the contact process smoother.

[0031] Next, the operator pushes the bumper fixture 2 from the transport trolley 4 toward the fixture mounting frame 3. At this time, the guide wheels 26 on both sides of the base plate 7 first contact the second fixing plate 25 on the frame 16, and then smoothly transition to contact the first fixing plate 24 on the fixture mounting frame 3. The inner sides of the first fixing plate 24 and the second fixing plate 25 form a guide groove, and the guide wheels 26 roll in the guide groove, guiding the bumper fixture 2 to move linearly. When the positioning groove 29 on the inner side of the base plate 7 engages with the limiting rod 30 fixed on the fixture mounting frame 3, it indicates that the bumper fixture 2 has reached the precise working position.

[0032] At this time, the control system will issue a command to activate the positioning cylinder 27. The positioning cylinder 27 is fixed on the fixture mounting bracket 3, and its output end is connected to the second positioning pin 28. The positioning cylinder 27 pushes the second positioning pin 28 downward to insert it into the first positioning hole 20 on the base plate 7, thereby precisely locking the bumper fixture 2 on the fixture mounting bracket 3 and ensuring that it will not move during the welding process.

[0033] While the bumper fixture 2 is mechanically positioned, the pneumatic system is automatically connected. A plug-in cylinder 12 is fixed on the frame 1, and a male pneumatic connector 13 is installed at the output end of the cylinder 12. The male pneumatic connector 13 connects via a hose to the corresponding interface of the pneumatic solenoid valve 11 installed in the valve box 10 on the frame 1. A female pneumatic connector 15 is fixedly installed on the corresponding side of the base plate 7 of the bumper fixture 2. This female pneumatic connector 15 connects via pipes inside or on the surface of the base plate 7 to the interfaces of each clamping cylinder 9 on the fixture.

[0034] Once the bumper fixture 2 is pushed into position and locked by the positioning cylinder 27, the insertion cylinder 12 is activated, its piston rod extends, and pushes the male connector 13 of the air circuit connector forward to precisely insert it into the female connector 15 of the air circuit connector fixed on the base plate 7. After insertion, the air circuit is opened. At this time, the pneumatic solenoid valve 11 can control the clamping cylinder 9 to operate according to the control program through the opened air circuit, firmly clamping the bumper workpiece onto the contour support 8.

[0035] After preparation, the two robotic arms 5 are activated, driving their respective piercing and welding heads 6 to weld the bumper workpieces according to preset trajectories and parameters. During the welding process, the operator can simultaneously install the next bumper workpiece to be welded on another prepared bumper fixture 2, which is placed on another conveyor trolley 4 in the preparation area.

[0036] After welding is completed, the robotic arm 5 resets. The clamping cylinder 9 releases. The insertion / removal cylinder 12 reverses its movement, pulling the male connector 13 of the air circuit connector from the female connector 15, automatically disconnecting the air circuit. The positioning cylinder 27 drives the second positioning pin 28 to be pulled out of the first positioning hole 20. Then, the operator pulls the welded bumper fixture 2 from the fixture mounting frame 3 back onto the transport trolley 4 and locks it with the first positioning pin 23. Next, the operator pushes the transport trolley 4 carrying the completed workpiece fixture away, while simultaneously pushing another transport trolley 4 carrying the unprocessed workpiece fixture to the front of the frame 1, and repeats the above steps of pushing in, positioning, connecting the air circuit, and clamping. This cycle is repeated to achieve complete parallel operation of welding and loading / unloading, i.e., "dual-station" operation. When it is necessary to change the bumper model, only the entire bumper fixture 2, along with its positioning pins and air circuit female connector, needs to be replaced. The entire process requires no tools and takes only a few minutes, achieving extremely high flexibility.

[0037] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A double-station flexible piercing welding station for automobile bumpers, characterized in that, It includes a frame (1), a bumper fixture (2), a fixture mounting frame (3), and a transport trolley (4) for transporting the bumper fixture (2). A robot arm (5) is symmetrically mounted on the frame (1), and a piercing welding head (6) is mounted on the output end of the robot arm (5). A fixture mounting bracket (3) is installed on the frame (1), and a bumper fixture (2) is detachably mounted on the top of the fixture mounting bracket (3). The bumper fixture (2) includes a base plate (7), a contour support seat (8) fixed on the top of the base plate (7) for supporting and positioning the bumper, and a clamping cylinder (9) for clamping the bumper. A valve box (10) is installed on the frame (1), and a pneumatic solenoid valve (11) is installed inside the valve box (10). A plug-in cylinder (12) is fixed on the frame (1). A male air connector (13) is fixed at the output end of the plug-in cylinder (12). The interface of the male air connector (13) is connected to the corresponding interface of the pneumatic solenoid valve (11) through a pipeline. A female air connector (15) is fixed on the base plate (7) and is connected to the male air connector (13) through a pipeline. The female air connector (15) is connected to the corresponding interface of the clamping cylinder (9) through a pipeline.

2. The automotive bumper dual station flexible piercing weld station of claim 1, wherein: The conveying trolley (4) includes a frame (16) and universal self-locking wheels (17) installed at the four corners of the bottom of the frame (16). The frame (1) is equipped with a number of roller sets (18) for supporting and guiding the movement of the bumper fixture (2).

3. The automotive bumper dual station flexible piercing weld station of claim 2, wherein: The top of the base plate (7) is provided with first positioning holes (20) near the left and right sides. The frame (16) is fixed with a mounting plate (21). The mounting plate (21) is provided with second positioning holes (22). When the bumper fixture (2) is installed on the conveyor trolley (4), the second positioning hole (22) and the first positioning hole (20) are limited by the first positioning pin (23).

4. The automotive bumper dual station flexible piercing weld station of claim 2, wherein: The fixture mounting bracket (3) is symmetrically fixed with a first fixing plate (24) for limiting the base plate (7), and the frame (16) is symmetrically fixed with a second fixing plate (25) for limiting the base plate (7).

5. The automotive bumper dual station flexible piercing weld station of claim 2, wherein: Several guide wheels (26) are installed on both the left and right sides of the base plate (7), and the guide wheels (26) cooperate with the first fixed plate (24) and the second fixed plate (25).

6. The automotive bumper dual station flexible piercing weld station of claim 1, wherein: The fixture mounting bracket (3) is fixed with a positioning cylinder (27), and the output end of the positioning cylinder (27) is fixed with a second positioning pin (28), and the positioning pin (28) is limited to cooperate with the first positioning hole (20).

7. The automotive bumper dual station flexible piercing weld station of claim 1, wherein: The bottom plate (7) has symmetrically provided positioning grooves (29) on its inner side, and the fixture mounting bracket (3) has symmetrically fixed limiting rods (30), which cooperate with the positioning grooves (29).

8. The automotive bumper dual station flexible piercing weld station of claim 1, wherein: The frame (16) is fixed with limiting plates (31) on both the left and right sides for contacting the side of the fixture mounting frame (3), and the inner side of the end of the limiting plate (31) is chamfered.

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