Device capable of preventing support stacking errors in car door anti-collision beam assembly production

Abstract

A device capable of preventing support overlapping errors in car door anti-collision beam assembly production comprises a machine frame, a left half part and a right half part, and the left half part and the right half part are the same in structure. The right half part comprises a clamping mechanism, a transmission detection mechanism and an anti-overlapping alarm mechanism, the clamping mechanism is used for clamping a component, and the transmission detection mechanism comprises a special-shaped rotating arm, a reset spring and a first position sensor; the first position sensor sends a measured distance signal between the end part of the right support arm and the first position sensor to the alarm part, and when the distance between the end part of the right support arm and the first position sensor exceeds a preset threshold value, the anti-overlapping alarm mechanism gives an alarm. According to the utility model, the lever principle of the special-shaped rotating arm is ingeniously utilized to amplify the tiny thickness difference of the bracket, so that a detection signal is more easily captured, and then the bracket detection mechanism is triggered to give out a sound-light alarm signal, thereby effectively avoiding the occurrence of bracket overlapping errors and solving the difficult problem that omissions are easily caused by manual inspection.

Description

Technical Field

[0001] This utility model relates to the field of welding technology, and in particular to a device for preventing incorrect welding during the welding of a car door anti-collision beam assembly. Background Technology

[0002] A door anti-collision beam assembly is a safety mechanism installed inside a vehicle door, primarily used to protect occupants in the event of a side collision. Its structure mainly involves welding the door anti-collision beam together with the front, rear, and central supports using a welding workstation.

[0003] During the welding process of the door anti-collision beam assembly, two main defects often occur in the welding of the central bracket. The first is incomplete welding of the central bracket, which can be solved by adding a sensor switch at the bottom of the bracket to implement electronic error prevention. The second defect is that during welding, the two brackets are mistakenly stacked together, resulting in double-material overlay welding. Because the central bracket is only 0.7mm thick, it is considered a thin-material, thick-product welding. When operators wearing gloves handle the parts, the thin material makes it easy to mistakenly pick up two pieces for welding, leading to overlay welding errors. If such defective products reach downstream OEMs, it will cause quality disputes and affect subsequent production.

[0004] To prevent overlapping welding errors, Chinese patent application No. 201821456923.8, entitled "Anti-overlapping Device for Stamping Die," provides a technical solution. This device includes a forming die, a starting device, and an alarm device. The starting device is installed inside the forming die, and the alarm device is fixedly installed on the left side of the starting device. When the die is stamping, when the die is pressed onto the forming module, the metal film 2 deforms inward after being impacted, squeezing the push rod 3. The push rod 3, under pressure, squeezes the first spring 4 downward. When the formed die is successfully ejected, the first spring 4 releases its elastic force, pushing the push rod 3 upward, allowing the push rod 3 to move upward and restore the metal film 2 to its original shape. If the formed die is not successfully ejected, the first spring 4 cannot push the push rod 3 upward to release its elastic force, thus pushing the push plate 5 downward. When the push plate 5 moves downward, it causes the locking block 8 to compress the second spring 7, causing the locking block 8 to disengage from the push plate 5. Without the restraint of the locking block 8, the push plate 5 continues to move downward and pushes... The actuator pusher 10 drives the drive gear 9 to rotate. Through the meshing of the drive gear 9 and the driven gear 11, the driven gear 11 rotates, causing the trigger block 12 to rotate. As the trigger block 12 rotates, it contacts the moving block 13. The moving block 13 moves inward, compressing the third spring 14. The third spring 14 releases its elasticity, pushing the trigger pusher 15 to move. This causes the connecting metal strip 16 to move with the trigger pusher 15 and contact the contact metal strip 17, creating a path between the battery 19 and the horn 20. The horn 20 then continuously emits an audible alarm to remind the operator to stop operation and prevent the mold cavity from bursting due to material stacking. Although this device can prevent material stacking, it relies on component transmission to detect stacking errors, which has a large margin of error, and by the time it is detected, the components have already been affected.

[0005] Regarding the issue of double-material mis-soldering that is prone to occur during the welding process of thin-film products, although effective error prevention methods have been continuously sought, an ideal solution has not yet been found. Relying on manual inspection before shipment to detect such defects is not only extremely labor-intensive but also prone to missed detections. Therefore, the industry urgently needs a device that can prevent double-material mis-soldering in thin-film products to improve production efficiency and product quality. Utility Model Content

[0006] This utility model addresses the shortcomings of existing technologies by providing a device that prevents incorrect bracket stacking during the production of a car door anti-collision beam assembly. The device can firmly clamp and accurately position the components to be welded. Once stacking is detected, an alarm is immediately triggered before welding, effectively solving the problem of easy oversight during manual inspection. It has the advantages of simple structure, easy operation, and accurate detection.

[0007] The technical problem described in this utility model is solved by the following technical solution:

[0008] A device for preventing incorrect bracket stacking during the production of a car door anti-collision beam assembly is disclosed. The device includes a frame, a left half, and a right half, with the left and right halves having identical structures. The right half includes a clamping mechanism, a transmission detection mechanism, and an anti-stacking alarm mechanism. The clamping mechanism is used to hold the components in place. The transmission detection mechanism includes a shaped rotating arm, a return spring, and a first position sensor. The shaped rotating arm is rotatably supported on a rotating shaft and has two arms at an angle. The end of the left arm is connected to a contact shaft, which presses against a clamping head. The end of the right arm corresponds to the first position sensor, which is fixed to the frame via a connecting plate. The first position sensor transmits the measured distance signal between the end of the right arm and the first position sensor to an alarm unit. When the distance between the two exceeds a preset threshold, the anti-stacking alarm mechanism issues an alarm.

[0009] The aforementioned door anti-collision beam assembly includes a device to prevent incorrect bracket stacking during production. The clamping mechanism comprises a hydraulic cylinder, a connecting block, and a pressing head. The piston rod of the hydraulic cylinder is connected to the right end of the connecting block. The middle part of the connecting block is hinged to the frame. The left end of the connecting block is connected to the pressing head via a drive connection. The end of the pressing head presses the bracket tightly.

[0010] The aforementioned door anti-collision beam assembly includes a device to prevent incorrect bracket stacking during production. An anti-load detection mechanism is added, consisting of a second position sensor and a sensing metal plate. The sensing metal plate is installed on the connecting block near the pressing head, and the spatial positions of the sensing metal plate and the second position sensor correspond. The distance signal emitted by the anti-load detection mechanism is sent to the alarm circuit.

[0011] The above-mentioned door anti-collision beam assembly is a device that can prevent the bracket from stacking incorrectly during production. The anti-stacking alarm mechanism includes a first position sensor, a CPU, a transistor amplifier circuit, a first relay J1, and an alarm circuit. The output signal of the first position sensor is connected to the CPU, the output of the CPU is connected to the transistor T1, the first relay J1 is connected to the emitter of the transistor T1, and the normally open contact of the first relay J1 is connected to the alarm circuit.

[0012] The circuit structure and connection method of the anti-air load alarm circuit are the same as those of the anti-overlapping alarm mechanism, and its normally open contacts are also connected to the alarm circuit.

[0013] The device that prevents incorrect bracket stacking during the production of the aforementioned door anti-collision beam assembly uses Omron E2E series proximity switches for the first and second position sensors. Beneficial effects

[0014] This utility model has the following beneficial effects:

[0015] 1. This utility model ingeniously utilizes the lever principle of the irregular rotating arm to amplify the minute difference in the thickness of the support. When there is a minute difference of 0.7mm in the material thickness, the difference is amplified to a deviation distance of 2.7mm at the sensor end through the amplification effect of the lever. The measured spacing difference is nearly 4 times, making it easier to detect. This triggers the support stacking measurement mechanism to issue an audible and visual alarm notification, effectively realizing the electronic error prevention function.

[0016] 2. This utility model also includes a bracket no-load alarm function to prevent the bracket from flowing into the next process without welding support, thereby avoiding another type of welding quality issue.

[0017] 3. This utility model has a simple structure and is easy to operate. It does not require manual intervention throughout the process, and the detection function can be performed automatically, which lays the foundation for the automated production of the central anti-collision bar assembly. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of this utility model;

[0019] Figure 2 This is a schematic diagram of the structure for preventing unloaded loads.

[0020] Figure 3 This is a schematic diagram illustrating the detection principle.

[0021] Figure 4 The circuit diagram for the alarm section.

[0022] The labels in the diagram represent: 1. Frame, 2. Hydraulic cylinder, 3. Connecting block, 4. Pressing head, 5. Tension spring, 6. Irregular rotating arm, 8. Connecting plate, 9. Limiting rod, 10. Pressing rod, 11. Rotating shaft, 12. Central anti-collision bar, 13. Pressing platform, 14. Metal sensing plate, 15. Bracket, S1. First position sensor, S2. Second position sensor, BJ. Alarm circuit. Detailed Implementation

[0023] This utility model includes a clamping mechanism, a transmission detection mechanism, and an alarm part. The clamping mechanism is used to clamp the component. The transmission detection mechanism includes a special-shaped rotating arm 6, a return spring 5, and a first position sensor S1. The special-shaped rotating arm 6 has two arms at an angle. The end of the left arm presses against the upper clamping head 11 of the middle support through a rotating shaft A. The end of the right arm corresponds to the first position sensor S1. The first position sensor S1 sends the measured distance signal between the end and the first position sensor S1 to the alarm part. When the distance between the two exceeds a preset threshold, the alarm part issues an alarm signal.

[0024] This invention also includes an anti-no-load detection mechanism, where no-load refers to the welded bracket failing to appear properly on the welding device. To address this, the anti-no-load detection mechanism includes a second position sensor S2 and a sensing metal plate 15. The sensing metal plate 15 moves with the connecting block 3 and corresponds spatially to the second position sensor S2. If no-load occurs, when the clamping head 4 presses down to clamp, the metal sensing plate 14 mounted on the connecting block 3 falls directly above the second position sensor S2 (maintaining a distance of approximately 2mm), thus sending a signal to initiate the detection process.

[0025] The bracket 15 used for the central anti-collision bar 12 has a material thickness of 0.7mm. By reasonably setting the length ratio of the two arms of the irregular rotating arm 6, the included angle of the arms, the contact rod 11 and the center distance of the rotating shaft, a larger signal amplitude (2 times the material thickness is 0.7*2=1.4mm) can be obtained on the first position sensor so that the alarm circuit can distinguish and process the signal.

[0026] If one bracket is properly placed, the right sensing end of the irregular rotating arm 6 and the first position sensor S1 maintain a normal sensing distance of about 3.5mm (the limit sensing distance of the first position sensor is set to 4mm; no electrical signal can be sensed above 4mm). If the first position sensor S1 can receive a normal electrical signal and will not issue an alarm, it indicates that the number of brackets clamped is normal and subsequent welding can be carried out.

[0027] If two middle supports are placed repeatedly, the clamping head on the support will rise by 0.7mm, the pressure rod 10 will rise, the irregular rotating arm 6 will move clockwise with the rotating shaft 11, the right sensing end will move down, and the sensing end distance will become 3.5 + 2.7 = 6.2mm, which exceeds the limit distance value (4mm) that the first position sensor can sense. The first position sensor S1 will not receive a normal electrical signal, and the alarm circuit will immediately sound an alarm, indicating that the number of supports clamped is abnormal. This reminds the operator to check and confirm. After correct installation, the alarm will be cleared, and subsequent welding can begin, thus successfully achieving the error prevention function.

[0028] After each welding operation is completed, the clamping head 4 is released and lifted, and the metal sensing plate 14 attached to the connecting block moves away from the second position sensor S2. At this time, the error prevention function is turned off, forming a complete error prevention detection.

[0029] This invention addresses a 0.7mm material thickness difference by using the lever swing of the irregularly shaped rotating arm 6 to convert the 0.7mm signal into a distance signal of up to 2.7mm sensed by the sensor. The ratio of the initial signal strength to the terminal signal strength is nearly four times, resulting in high signal sensitivity and 100% false alarm-free operation. This effectively solves the problem of easy oversight during manual inspection.

[0030] The first and second position sensors used in this invention are both from the Omron E2B series, M12 mm, and have a detection distance of about 5 mm.

[0031] The CPU in this invention uses the C8051F340 series chip, which includes two full-duplex serial UART ports with extended baud rate configurations and up to 40 I / O pins, fully meeting the needs for communication and control with other components. Any DC relay can be used, as long as the contact capacity is sufficient. The audible and visual alarm circuit uses the WT588D series voice chip.

Claims

1. A device for preventing incorrect bracket stacking during the production of a vehicle door anti-collision beam assembly, characterized in that, The device includes a frame (1), a left half and a right half, the left half and the right half have the same structure; the right half includes a clamping mechanism, a transmission detection mechanism and an anti-overlapping alarm mechanism, the clamping mechanism is used to clamp the component, the transmission detection mechanism includes a special-shaped rotating arm (6), a return spring (5) and a first position sensor (S1), the special-shaped rotating arm (6) is rotatably supported on a rotating shaft (11), the special-shaped rotating arm (6) is provided with two arms at an angle, wherein the end of the left arm is connected to a contact shaft (10), the contact shaft presses against the clamping head (4); the end of the right arm corresponds to the first position sensor (S1), the first position sensor is fixed on the frame via a connecting plate (8); the first position sensor (S1) sends the measured distance signal between the end of the right arm and the first position sensor to the alarm part, when the distance between the two exceeds a preset threshold, the anti-overlapping alarm mechanism issues an alarm.

2. The device for preventing incorrect bracket stacking during the production of the door anti-collision beam assembly according to claim 1, characterized in that, The clamping mechanism includes a hydraulic cylinder (2), a connecting block (3) and a pressing head (4). The piston rod of the hydraulic cylinder (2) is connected to the right end of the connecting block (3). The middle part of the connecting block (3) is hinged to the frame (1). The left end of the connecting block (3) and the pressing head (4) are connected in a transmission manner. The end of the pressing head (4) presses the bracket (15) tightly.

3. The device for preventing incorrect bracket stacking during the production of the door anti-collision beam assembly according to claim 1, characterized in that, An air defense detection mechanism is added. The air defense detection mechanism consists of a second position sensor (S2) and a sensing metal plate (14). The sensing metal plate (14) is installed on the side of the connecting block (3) near the pressing head (4). The spatial positions of the sensing metal plate (14) and the second position sensor (S2) correspond. The distance signal emitted by the air defense detection mechanism is sent to the alarm circuit (BJ).

4. The device for preventing incorrect bracket stacking during the production of the door anti-collision beam assembly according to claim 1, characterized in that, The anti-overlapping alarm mechanism includes a first position sensor (S1), a CPU, a transistor amplifier circuit, a first relay J1, and an alarm circuit (BJ). The output signal of the first position sensor is connected to the CPU, the output of the CPU is connected to the transistor T1, the first relay J1 is connected to the emitter of the transistor T1, and the normally open contact of the first relay J1 is connected to the alarm circuit (BJ). The circuit structure and connection method of the anti-air load alarm circuit are the same as those of the anti-overlapping alarm mechanism, and its normally open contacts are also connected to the alarm circuit (BJ).

5. The device for preventing incorrect bracket stacking during the production of the door anti-collision beam assembly according to claim 1, characterized in that, The first position sensor (S1) and the second position sensor (S2) are Omron proximity switches of the E2E series.

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