A production system and a production method of a new energy vehicle fastener

Abstract

The application provides a production system and a production method of a new energy vehicle fastener, comprising a manufacturing unit and a data monitoring unit, wherein the manufacturing unit is provided with a tapping sleeve rod, a tap and a sensing module arranged between the tapping sleeve rod and the tap, the data monitoring unit comprises an acquisition unit for acquiring feedback data of the sensing module and a calculation unit for calculating the acquired data and forming an acquisition data set, the data monitoring unit further has a storage unit for storing a standard data set, the calculation unit further compares the acquisition data set with the standard data set, the standard data set comprises standard parameters corresponding to a current product being manufactured and standard deviations of the standard parameters, and when a difference between a single data in the current acquisition data set calculated by the calculation unit and the standard parameter data is greater than a predetermined multiple of the standard deviation, an abnormal information is sent. The application performs quality inspection while manufacturing the new energy vehicle fastener, so that the product quality is improved.

Description

Technical Field

[0001] This invention relates to a production system for fasteners for new energy vehicles, and also to a method for producing fasteners for new energy vehicles, belonging to the field of intelligent manufacturing. Background Technology

[0002] New energy vehicles currently account for half of all new car sales, but due to the greater weight of their battery packs, their overall weight is about 30% higher than that of gasoline vehicles. This increased weight places higher demands on the fasteners used in new energy vehicles. Current quality control systems for these fasteners still rely heavily on manual or visual inspections. These methods are ineffective at detecting problems with the fastener materials themselves, are prone to errors and omissions, and are inefficient, failing to meet the demands of new energy vehicles for fastener quality. Summary of the Invention

[0003] The purpose of this invention is to provide a production system and method for fasteners in new energy vehicles, which can perform quality monitoring during production to detect fastener quality problems at an earlier stage.

[0004] The present invention adopts the following technical solution:

[0005] A production system for fasteners in new energy vehicles, characterized in that it includes: a manufacturing unit and a data monitoring unit, wherein the manufacturing unit comprises: a tapping sleeve, a tap, and a sensing module disposed between the two; the data monitoring unit includes a data acquisition unit for acquiring feedback data from the sensing module, and a calculation unit for calculating the acquired data and forming a data acquisition dataset; the data monitoring unit also has a storage unit for storing a standard dataset; the calculation unit also compares the data acquisition dataset with the standard dataset; the standard dataset contains standard parameters and their standard deviations corresponding to the currently manufactured product; when the difference between a single data point in the current data acquisition dataset calculated by the calculation unit and the standard parameter data is greater than a predetermined multiple of the standard deviation, an abnormal information is sent.

[0006] Furthermore, the production system for fasteners for new energy vehicles of the present invention also has the following feature: wherein the standard parameter is the torque value of the tap.

[0007] Furthermore, the production system for fasteners for new energy vehicles of the present invention also has the following feature: wherein the predetermined multiple is 3 times.

[0008] Furthermore, the production system for fasteners for new energy vehicles of the present invention also has the following feature: wherein the sensing module is a torque sensor.

[0009] Furthermore, the production system for fasteners for new energy vehicles of the present invention also has the following feature: wherein the sensing module is a current sensor.

[0010] Furthermore, the new energy vehicle fastener production system of the present invention also has the following feature: when the data in the newly entered dataset changes, the recording time t1 is used as the time node for the start of processing, and...

[0011] When the newly added data in the collected dataset changes again, the time t2 is recorded as the time node indicating the end of processing.

[0012] Furthermore, the production system for fasteners for new energy vehicles of the present invention also has the following features: the standard dataset contains the value of the standard processing time Δt, the calculation unit calculates t2-t1 and compares the difference with Δt, and when the difference is greater than or equal to three times Δt, the data monitoring unit sends an abnormal information.

[0013] This invention also provides a method for producing fasteners for new energy vehicles, characterized by comprising the following steps:

[0014] Step 1: Clamp the fastener blank and align it with the tap axis;

[0015] Step two: The data monitoring unit starts up and collects data from the sensors connected to the tap.

[0016] Step 3: When the sensor data changes, record the value and the corresponding time t1.

[0017] Step 4: Continuously record sensor data until it changes again, and record the corresponding time t2.

[0018] Step 5: During the process of recording sensor data in Step 4, a data acquisition dataset is formed. Individual data in the data acquisition dataset are continuously compared with standard parameter data. When the difference between the two is greater than a predetermined multiple of the standard deviation, an abnormality message is sent.

[0019] Furthermore, the method for producing fasteners for new energy vehicles according to the present invention also has the following characteristics:

[0020] The collected data mainly consists of torque data or current data.

[0021] Furthermore, the method for producing fasteners for new energy vehicles according to the present invention also has the following feature: in step five, when the difference is greater than three times the standard deviation, an abnormality message is sent.

[0022] Beneficial effects of the invention: The production system and method for fasteners in new energy vehicles of the present invention employ a data monitoring unit to collect fastener manufacturing data from the sensing module in real time and compare it with a standard dataset. When the difference between a single data point in the currently collected dataset calculated by the calculation unit and the standard parameter data exceeds a predetermined multiple of the standard deviation, an anomaly information is sent. This allows for quality inspection of fasteners in new energy vehicles during manufacturing, enabling timely detection of fastener quality problems. Attached Figure Description

[0023] Figure 1 This is a part of the structure of the fastener manufacturing apparatus of the present invention.

[0024] Figure 2 This is a block diagram of the fastener manufacturing system of the present invention.

[0025] Figure 3 This is a flowchart of the fastener manufacturing process. Detailed Implementation

[0026] The specific embodiments of the present invention will be described below with reference to the accompanying drawings. It should be noted that the embodiments provided below are preferred embodiments and are not intended to limit the entire scope of protection of the present invention.

[0027] like Figure 1 , Figure 2 As shown, the structure of the fastener production system for new energy vehicles at the tapping device includes: tapping sleeve 11, tap 12, torque sensor 13, spindle 14, and base 15. Their connection method and positional relationship are as follows: Figure 1 As shown, the torque sensor 13 is positioned between the tap 12 and the spindle 14, the tapping sleeve 11 is fitted behind the tap 12, and the base is mounted on the subsequent support structure of the device. In addition, the production system for fasteners in new energy vehicles also includes conventional frames, motors, etc., which will not be described in detail here. Figure 1 The parts shown, along with the racks and motors that provide basic support and power functions, all belong to the manufacturing unit.

[0028] Establish a statistical benchmark using the first N qualified samples:

[0029] M k Standard torque value

[0030] σM k Torque standard deviation.

[0031] μT: The average tapping time, or standard machining time.

[0032] σT: Standard deviation of tapping time, or standard deviation of machining time.

[0033] μA: Average value of motor acceleration time.

[0034] σA: Standard deviation of motor acceleration time.

[0035] The process of establishing a baseline should be performed using brand new taps, and outliers should be removed. Standard values ​​and standard deviations are stored in the data monitoring unit's storage unit for later retrieval by the calculation unit.

[0036] In addition, the CNC operating system also includes a data monitoring unit 20. The data connection point between the data monitoring unit 20 and the manufacturing unit is the torque data or current data collected by the torque sensor 13. Both torque and current data can be used to reflect or measure the interaction force between the tap and the fastener during operation. The logic of using the tap's torque as a measure of fastener quality is that when the fastener material itself is uneven or the tap is worn, the cutting force will increase, resulting in a significant increase in torque.

[0037] Whether it's tap wear or problems with the fastener material itself, the manufactured fastener threads are prone to defects, deterioration of thread tolerances, and drift in tightening force.

[0038] like Figure 2 The data monitoring unit 20, equipped with a data acquisition unit 21 and a calculation unit 23, monitors the real-time torque value of the sensor during the tap's operation and compares it with a standard torque value. If the difference between the two is greater than three times the standard deviation of the torque, it indicates a potential problem with the tap or the fastener material itself. An alarm is then issued, prompting an inspection of the tap and the current fastener to promptly resolve the issue.

[0039] Sometimes, a single torque anomaly may not be a typical manifestation of a quality problem. Throughout the entire part manufacturing process, there might be a more continuous anomaly in the tap or material, in which case the torque change may not be a sudden, abrupt value. To include this situation in the inspection scope, as a preferred implementation, a detection method is also provided to identify and measure such anomalies.

[0040] The data acquisition unit 21 in the data monitoring unit 20 extracts the start time t1 and end time t2 of the torque change, and the calculation unit 23 calculates the difference t2-t1 as the duration of the tapping operation.

[0041] While abnormalities in the tap or the fastener material itself may not be enough to cause a sudden change in torque, when these abnormalities accumulate, they will continuously manifest as increased resistance, forcing a reduction in feed rate. This results in a longer cycle time for a single workpiece, or a longer tapping operation. When this change exceeds three times the standard deviation, an abnormality alert will be issued, allowing for timely inspection and troubleshooting.

[0042] Of course, the operating time may also be affected by factors related to the motor. When the initial acceleration provided by the motor is greater, the tapping time may indeed become shorter, and vice versa. To eliminate the influence of motor acceleration, in a preferred implementation, the acceleration and deceleration time t3 of the motor can also be extracted. If the change in t3 exceeds three times the normal standard deviation, it indicates that the difference between t2 and t1 is caused by the change in motor acceleration, which is normal and no alarm is issued.

[0043] The data monitoring unit 20 also has a storage unit 24 that stores a standard dataset 22; the calculation unit also compares the collected dataset with the standard dataset; the standard dataset 22 contains standard parameters and their standard deviations corresponding to the currently manufactured product; when the difference between a single data point in the currently collected dataset calculated by the calculation unit 23 and the standard parameter data is greater than a predetermined multiple of the standard deviation, an abnormal information is sent.

[0044] Based on the time difference and motor acceleration, the alarm logic is as follows:

[0045] For the i-th sample, calculate its deviation from the benchmark:

[0046] Tapping time deviation: ΔT i =T cut,i - μT

[0047] Acceleration time deviation: ΔA i =T acc,i - μA

[0048] Alarm triggering conditions:

[0049] IF∣ΔT i |>3σTAND|ΔA i |≤3σATHEN ALARM: "Tap wear / passivation"

[0050] Conditions for not triggering an alarm:

[0051] IF∣ΔA i |>3σATHEN NO ALARM: "The change is caused by the motor's operating condition; ignore this ΔT." i "

[0052] like Figure 3 Manufacturing method of fasteners for new energy vehicles:

[0053] The bolt blank is obtained by cold heading. The bolt blank is placed on the tapping drill table, the drill table is started, and the motor starts to accelerate to the predetermined speed. The acceleration of the motor at this time is recorded.

[0054] Lower the tap to begin tapping, and record the point at which the torque begins to change, denoted as t1.

[0055] During the process, torque values ​​are collected at a fixed frequency, such as 100Hz, and compared with the standard torque value M in real time. k Divide the values ​​and then compare them with the standard deviation of the torque ΔM. k If the result of the division is a multiple, and the multiple exceeds 3, an abnormal alarm will be issued.

[0056] If there are no abnormalities, continue recording the torque until the point at which it suddenly decreases, denoted as t2.

[0057] The calculation unit calculates t2-t1, i.e., ΔT. i .

[0058] Compare the result with the average tapping time and calculate the difference. Compare the difference with the standard deviation; if the result is greater than or equal to three times the standard deviation, issue a warning.

[0059] If the deviation is less than 3 times the standard deviation, remove the bolt and continue tapping the next bolt.

[0060] When the torque suddenly increases above the normal value, it indicates a tapping problem. This could be due to damaged threads, poor thread routing, or uneven fastener material. This allows for timely detection of nut quality issues during the production process.

[0061] In the above embodiments, the manufacturing and manufacturing method of fasteners for new energy vehicles can monitor sudden problems in taps and fasteners by real-time monitoring of torque changes during the fastener manufacturing process. Furthermore, by combining this with monitoring of tapping time, it can further monitor slow-onset problems during the fastener manufacturing process. Moreover, by monitoring deviations in motor acceleration, it can eliminate interference from the motor's own operating conditions on the aforementioned problems. This allows for timely alerts to quality issues while eliminating some special interference situations, thereby jointly improving the quality monitoring effect during the fastener manufacturing process and providing faster fasteners with more consistent quality for subsequent new energy vehicle manufacturing.

Claims

1. A production system for fasteners for new energy vehicles, characterized in that, include: Manufacturing unit and data monitoring unit, The manufacturing unit comprises: Tapping sleeve, tap, and sensing module positioned between the two. The data monitoring unit includes a data acquisition unit that collects data fed back from the sensing module, and... The computational unit that performs calculations on the collected data and forms the collected dataset; The data monitoring unit also has a storage unit that stores a standard dataset; The computing unit compares the collected dataset with the standard dataset; The standard dataset contains standard parameters and their standard deviations corresponding to the currently manufactured product. When the difference between a single data point in the currently collected dataset calculated by the computing unit and the standard parameter data is greater than a predetermined multiple of the standard deviation, an abnormality message is sent.

2. The production system for fasteners for new energy vehicles as described in claim 1, characterized in that: in, The standard parameter is the torque value of the tap.

3. The production system for fasteners for new energy vehicles as described in claim 1, characterized in that: in, The predetermined multiple is 3 times.

4. The production system for fasteners for new energy vehicles as described in claim 1, characterized in that: in, The sensing module is a torque sensor.

5. The production system for fasteners for new energy vehicles as described in claim 1, characterized in that: in, The sensing module is a current sensor.

6. The production system for fasteners for new energy vehicles as described in claim 1, characterized in that: in, When the data in the newly acquired dataset changes, time t1 is recorded as the starting point of processing. When the newly added data in the collected dataset changes again, the time t2 is recorded as the time node indicating the end of processing.

7. The production system for fasteners for new energy vehicles as described in claim 6, characterized in that: in, The standard dataset contains the value of the standard processing time μT. The calculation unit calculates t2-t1 and compares the difference with μT. When the difference is greater than or equal to the standard deviation σT of three times the tapping time, the data monitoring unit sends an abnormality message.

8. A method for producing fasteners for new energy vehicles, characterized in that, Including the following steps: Step 1: Clamp the fastener blank and align it with the tap axis; Step 2: The data monitoring unit is activated to collect sensor data connected to the tap; Step 3: When the sensor data changes, record the value and the corresponding time t1. Step 4: Continuously record sensor data until it changes again, and record the corresponding time t2. Step 5: During the process of recording sensor data in Step 4, a data set is formed. Individual data in the data set are continuously compared with standard parameter data. When the difference between the two is greater than a predetermined multiple of the standard deviation, an abnormality message is sent.

9. The method for producing fasteners for new energy vehicles as described in claim 8, characterized in that: in, The collected data mainly consists of torque data or current data.

10. The method for producing fasteners for new energy vehicles as described in claim 8, Its features are: in, In step five, when the difference is greater than three times the standard deviation, an error message is sent. and The calculation unit calculates the difference t2-t1 and compares it with the duration of the standard tapping operation. When the difference is greater than three times the standard deviation of the tapping operation duration, an abnormal message is also sent.

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