Full-automatic flexible production line for aluminum veneer

Abstract

An aluminum veneer full-automatic flexible production line, including a general control system, a double-station feeding manipulator, an automatic wire drawing machine, a first automatic material turning manipulator, a first material transfer manipulator, an automatic bending center, a second material transfer manipulator, an automatic spot welding machine, a reinforcing rib placing robot, a third material transfer manipulator, a nut locking robot, an automatic laser welding robot, a second automatic material turning manipulator, a fourth material transfer manipulator, an automatic polishing robot and a double-station discharging manipulator. The aluminum veneer full-automatic flexible production line is formed by changing the traditional aluminum veneer production and manufacturing process, combining the existing production equipment with automatic selection, transformation, upgrading and configuration. After putting into production, compared with the traditional production line, the number of workers is reduced from 24 to 3-4, the annual production capacity is increased from 210,000 square meters to 310,000 square meters, and the production capacity is increased by 47.6%.

Description

Technical Field

[0001] This utility model relates to a fully automated flexible production line for aluminum single-panel panels, belonging to the field of aluminum single-panel processing technology for building materials. Background Technology

[0002] Aluminum single-layer panels are a type of building decoration material that combines numerous advantages such as good environmental friendliness, corrosion resistance, high strength, ease of cleaning, and recyclability. The production of aluminum single-layer panels involves processes such as punching and cutting raw materials, bending, assembly, welding, and polishing to process the aluminum single-layer panels into the required shapes and sizes.

[0003] Traditional aluminum panel sheet metal processing lines operate with each process independently. Aluminum panel processing and turnover rely heavily on a large workforce, and the welding and grinding processes generate significant pollution, posing a substantial threat to worker health. The automation level of each production process is low, and the production process, quality, and efficiency depend heavily on worker skills and experience. Furthermore, aluminum panels are non-standard, customized parts, making automation in aluminum panel production extremely difficult.

[0004] CN 201910774692.8 discloses a fully automated laser processing production line for uncoiling and blanking aluminum panels. The aluminum panels described only involve automated processing and production of uncoiling and blanking, and do not involve fully automated production of aluminum panels.

[0005] Improving the automation level, efficiency, and quality of aluminum panel processing is of paramount importance. Summary of the Invention

[0006] The purpose of this invention is to solve the automation problem in aluminum panel processing, improve the production efficiency and processing quality of aluminum panels, and propose a fully automated flexible production line for aluminum panels.

[0007] The technical solution implemented by this utility model is as follows: a fully automatic flexible production line for aluminum single panels, including a central control system, a dual-station loading robot, an automatic wire drawing machine, a first automatic turning machine, a first material transfer robot, an automatic bending center, a second material transfer robot, an automatic welding machine, a reinforcing rib placement robot, a third material transfer robot, a nut locking robot, an automatic laser welding robot, a second automatic turning machine, a fourth material transfer robot, an automatic grinding robot, and a dual-station unloading robot.

[0008] The central control system is installed at the central control console; the dual-station loading robot and automatic wire drawing machine are installed in the automatic loading and wire drawing area; the first automatic turning machine, the first material transfer robot, and the automatic bending center are installed in the automatic bending area; the second material transfer robot and the automatic stud welding machine are installed in the stud automatic welding station; the reinforcing rib placement robot is installed in the reinforcing rib automatic placement station; the third material transfer robot and the nut locking robot are installed in the nut automatic locking station; the automatic laser welding robot is installed in the reinforcing rib and panel laser welding station; the second automatic turning machine, the fourth material transfer robot, and the automatic grinding robot are installed in the weld point grinding workstation; and the dual-station unloading robot is installed in the automatic unloading workstation.

[0009] All equipment for the automated production of aluminum single panels is installed on the fully automated flexible production line for aluminum single panels; the main control console, automatic feeding and wire drawing area, automatic bending area, automatic stud welding station, automatic reinforcing rib placement station, automatic nut fastening station, laser welding station for reinforcing ribs and panels, weld point grinding workstation and automatic unloading workstation are connected by transmission lines between areas, between areas and stations, and between stations.

[0010] The overall control system adopts centralized PLC control, integrating servo drives, Modbus TCP protocol communication, and an industrial tablet HMI to coordinate the control of various processes. The system has unit activation permission management, and is equipped with a dual HMI interface of an operator console computer and an industrial tablet, displaying equipment status, parameters, and fault codes in real time. The PLC issues instructions to each execution unit through a high-speed bus, and a safety interlock mechanism is integrated to ensure precise and controllable production cycle. At the same time, an industrial IoT interface is reserved to be compatible with factory-level data acquisition and remote monitoring requirements. The system also integrates full-process work order management, supports manual / automatic generation of work order numbers and binding of parameter templates, and enables work order drag-and-drop sorting, priority adjustment, and progress tracking. It also supports automatic matching of equipment parameters by associating product dimensions with a program relationship lookup table.

[0011] The communication between the central control system and each process unit adopts the Modbus TCP protocol, and the software platform is a self-developed software platform to complete the distribution and collection of parameters and information. Each process unit shall feed back the following information to the central control system: when starting, the unit shall report whether it can run; when running, the unit shall report the running status; when ending, the workstation shall collect the running and processing information and generate reports.

[0012] The central control system includes a computer, an industrial tablet dual-user interface, an integrated servo drive mechanism, an industrial IoT interface, and a high-speed data bus. The software of the central control system includes a data acquisition module, a PLC control module, a parameterized management module, a work order management module, an equipment management module, and a production execution module. The central control system connects to the industrial tablet dual-user interface, the integrated servo drive mechanism, and the control terminals of each zone and station via the high-speed data bus, displaying equipment status, parameters, and fault codes in real time. The work order module categorizes work orders into six types based on their status: pending production, in production, paused, canceled, completed, and production changeover. The work order management module displays the cumulative number of work orders and the cumulative number of workpieces. The work order module enables drag-and-drop sorting of work orders, priority adjustment, and progress tracking, and supports automatic matching of equipment parameters using a program relationship lookup table based on product dimensions. The parameterized management module enables dynamic template maintenance, batch parameter distribution, manual retrying of abnormal distributions, and real-time status feedback. The production execution module supports one-click start / pause switching of work orders and synchronously records completion data.

[0013] The central control system supports manual input or automatic generation of work order numbers based on time. Work orders must be bound to a parameter template and include information such as production quantity, planned start time, and estimated completion time. Successfully created work orders are displayed in the work order list, sorted by planned start time by default. Workers can drag and drop to prioritize production, and the system supports querying production time, completion time, and quantity by work order number. It also receives information on successful but incomplete orders, displaying them in a list format, defaulting to showing all incomplete orders for the day, and supporting sorting by planned start time and priority.

[0014] The automated feeding and wire drawing zone adjusts the final fine grinding process into the first wire drawing process to solve the design challenges of the fine grinding process and improve grinding efficiency and quality, ensuring the quality and effect of subsequent fluorocarbon spraying. The dual-station feeding robot and automatic wire drawing machine perform surface wire drawing on the aluminum panels in the automated feeding and wire drawing zone. An AGV cart delivers the aluminum panels to the designated position, and the dual-station feeding robot immediately grabs the aluminum panels, realizing the automated feeding process. The aluminum panels then enter the automatic wire drawing machine via a conveyor belt for surface wire drawing. The finished aluminum panels are then sent to the automatic bending zone. The automatic wire drawing machine supports stepless speed adjustment from 0-10 meters / minute, controls the single-sided wire drawing roughness within the range of 1-2 μm, and is equipped with a dust collection system to ensure no residue.

[0015] The automatic bending zone bends and shapes the aluminum panels that enter the zone. After the aluminum panels are wire-drawn, they are flipped by the first automatic flipping machine and then sent to the automatic bending center by the first material transfer robot for bending. The bent aluminum panels are then sent to the buffer station by the first material transfer robot. The bending accuracy of the bending center is ±0.5° and ±0.1mm / m. The equipment is linked with the central control system via the Modbus TCP protocol to realize automatic parameter programming and operation status monitoring. It supports rapid mold change within 2 minutes and production line changeover within 5 minutes. It is equipped with a robot loading and unloading station and an on-site programming workstation to meet the requirement of 8-blade processing cycle time ≤60s. It also has automatic bending parameter compensation, fault feedback, and process data interaction functions.

[0016] The automatic stud welding station performs stud welding on aluminum panels. After bending and forming, the aluminum panels are removed from the buffer station by a second material transfer robot and placed into the automatic stud welding machine, which automatically plants the studs. The automatic stud welding station consists of a robot loading / unloading unit, an intelligent stud feeding and welding module, and a digital control platform, meeting the high-precision welding requirements of M6×15 studs. The system integrates an automatic stud feeding mechanism, a multi-gun collaborative energy storage welding machine, and a full-steel frame T-slot positioning platform, supporting a six-axis robot to grasp the workpiece and automatically position and clamp it. It generates welding point programs through CAD drawings, achieving precise welding with ±0.3mm center offset, ±0.3mm / m straightness, and 0.3mm perpendicularity. The welding gun is equipped with dual capacitor banks for dynamic switching, allowing adjustment of the downward pressure / clamping speed, real-time detection of stud positioning status, and automatic pause in case of abnormalities. The welding process is free of blackening / deformation, with a back protrusion <0.1mm, no defects after painting, and a single stud tensile strength ≥1000N. The system uses Modbus... The TCP protocol interacts with the central control system to transmit equipment status, fault alarms, and parameter feedback in real time. It supports a high-speed cycle of 40 pins per minute and can achieve model changeover in 5 minutes. It is equipped with a self-developed host computer system that is compatible with office information interaction, ensuring highly flexible and fully automated continuous production.

[0017] The automatic reinforcing rib placement station places reinforcing ribs on the aluminum panels. After nailing, the aluminum panels are transported to the automatic reinforcing rib placement station by a second material transfer robot for reinforcing rib placement and assembly. The reinforcing rib placement robot in the automatic reinforcing rib placement station uses a robot to grab the aluminum panels to a servo positioning fixture, and combines displacement sensors to detect and correct deviations to ensure assembly accuracy. Five material carts are configured, which are grabbed and installed by a six-axis robot and a three-axis gantry robot, respectively. External sensors detect the orientation of the materials, and abnormal parts are automatically temporarily stored. The automatic reinforcing rib placement station is integrated and controlled by a PLC, coordinating the interaction between the robot, the servo transfer platform, and the entire production line. It is equipped with AB station servo positioning, electric cylinders, and a safety protection system, and is compatible with the overall control protocol to achieve high-speed and precise assembly and risk management.

[0018] The automatic nut-locking station locks nuts onto the aluminum studs of the aluminum panels. The reinforced, assembled aluminum panels are then fed into the automatic nut-locking station by a third material handling robot. The automatic nut-locking station integrates a truss mechanical structure, a vision positioning unit, an intelligent electric screwdriver tightening unit, servo positioning fixtures, and a buffer feeding mechanism. The vision positioning unit has anti-light interference detection capabilities, ensuring accurate positioning even in complex factory lighting environments. The intelligent electric screwdriver tightening unit can flexibly adjust and monitor the tightening force in real time according to the nut size and material to prevent damage, with a repeatability accuracy of ±3°-±5°, adjustable torque and speed, and complete locking result data recording. The buffer feeding mechanism has a single-discharge nut detection function, equipped with a display screen for real-time monitoring, which, in conjunction with the buffer mechanism, reduces robot idle travel, speeds up the cycle time, and ensures uninterrupted material supply. Supports Modbus TCP protocol to achieve bidirectional communication with the central control system; the system automatically adjusts the product tooling positioning through servo drive to complete the centering and locking of the reinforcing ribs in the length and width directions, and is equipped with a display screen to monitor the running data in real time, and a three-color light fault alarm; the tightening process is fully traceable, the buffer mechanism reduces the robot's idle stroke, and the changeover time is less than 5 minutes.

[0019] The laser welding station for reinforcing ribs and panels reinforces the four corner seams of the aluminum panel's folded edges and the junctions between the reinforcing ribs and the folded edges. After reinforcement and assembly, the aluminum panel is fed into the laser welding station via a third material transfer robot for welding the four corner seams of the panel's folded edges and diagonal welding reinforcement at the junctions of the reinforcing ribs and the folded edges. After welding, the third material transfer robot sends the panel to the weld point grinding workstation. The automatic laser welding robot in this workstation consists of a dual-arc welding robot, dual ground rails, a servo transfer platform, and a laser positioning system. It integrates a gun cleaning device and a PLC control system to achieve fully automated welding of the aluminum panel's reinforcing ribs and corner welds. The robot is equipped with anti-collision sensors, and the welding power supply supports ultra-low spatter, reducing weld slag spatter by 90% and intermittent bridging welding processes.

[0020] The weld point grinding workstation grinds the weld seams and nail positions of the aluminum single-panel. After welding, the aluminum single-panel is flipped by a second automatic turning machine, and then fed into the automatic grinding machine by a fourth material transfer robot. The automatic grinding robot of the weld point grinding workstation includes two six-axis robots, integrating high-precision force-controlled grinding and intelligent dust removal functions. The six-axis robots are equipped with a 300N force control compensator to achieve dynamic adjustment of force control in multiple segments from 5-300N and gravity compensation. They are equipped with dual electric spindles to achieve a single weld mark grinding cycle of 3 seconds. The dual six-station hybrid tool magazine includes a sandpaper tearing and pasting mechanism and an in-situ detection sensor. The dust cover design allows for 2 hours of continuous operation and consumable reserves. The tool change success rate is fed back in real time. The automatic grinding robot supports parameterized start and stop nail mark grinding modes based on plate thickness and servo positioning fixtures. It integrates a flared dust collection port at the bottom and a side dust extraction pipe, with a dust recovery rate of ≥99%. It is controlled by a PLC cabinet and Modbus. The dust removal chamber is controlled by a TCP protocol and features an embedded wet filter. The chamber is designed with negative pressure, and the external dust concentration is <1mg / m³. The robot is equipped with an IP54 protective suit and a pipeline package, and features a touch screen for real-time status monitoring and alarms, as well as three-color warning lights.

[0021] The automated unloading workstation uses a dual-station unloading robot to deliver polished aluminum panels to a conveyor platform. After manual inspection, the dual-station unloading robot unloads and stacks the panels, completing the entire automated aluminum panel production line process. The dual-station unloading robot automatically sorts and vertically stacks products based on the manual inspection results through the unloading and stacking system. The number and layout of stacks are dynamically adapted by the robot's arm reach. Equipped with a 5-meter travel rail, it can operate over a wide range, meeting the needs for efficient and precise automated sorting and stacking.

[0022] The automated processing and manufacturing process of aluminum single panels of this utility model is as follows: manual start-up (AGV feeding) → automatic aluminum plate wire drawing (automatic wire drawing machine with loading and unloading robot) → automatic bending (four-meter automatic bending machine) → automatic welding machine welding (dual tool head operation) → automatic feeding of reinforcing ribs (truss and robot arm work together to pick up and put down materials) → automatic locking of nuts (robot vision positioning) → automatic laser welding (robot welding the four corner seams of the plate and the diagonal of the reinforcing ribs, laser positioning) → automatic grinding (grinding the weld points and nail marks, vision and laser dual positioning) → manual full inspection → automatic stacking (AGV picking up and putting down materials).

[0023] The beneficial effects of this utility model are that, by changing the traditional aluminum single-panel manufacturing process and combining existing production equipment with automated selection, modification, upgrading, and configuration, a fully automated flexible production line for aluminum single panels is formed. After being put into operation, compared with the traditional production line, the number of workers is reduced from 24 to 3-4, and the annual production capacity increases from 210,000 square meters to 310,000 square meters, representing a 47.6% increase in capacity. Attached Figure Description

[0024] Figure 1This is a plan view of a fully automated flexible production line for aluminum single panels according to this utility model. Figure 2 This is a layout diagram of a fully automated flexible production line for aluminum single panels according to this utility model on the production line; Figure 3 Layout diagram of the main control console and automatic feeding and wire drawing area equipment; Figure 4 Layout diagram of the automatic bending area equipment; Figure 5 Layout diagram of the automatic stud welding station equipment; Figure 6 Layout diagram of the automatic reinforcement bar placement station; Figure 7 Layout diagram of the automatic nut-locking station equipment; Figure 8 Layout diagram of the laser welding station equipment for reinforcing ribs and panels; Figure 9 Layout diagram of the workstation for grinding weld joints; Figure 10 Layout diagram of the automated material unloading workstation; Figure 11 This is a schematic diagram of the aluminum single-panel product structure; In the diagram, 1 is the main control console; 2 is the automatic feeding and wire drawing area; 3 is the automatic bending area; 4 is the buffer station; 5 is the automatic stud welding station; 6 is the automatic reinforcing rib placement station; 7 is the automatic nut fastening station; 8 is the laser welding station for reinforcing ribs and panels; 9 is the weld point grinding workstation; 10 is the manual full inspection station; 11 is the automatic unloading workstation; 12 is the main control system; 13 is the dual-station feeding robot; 14 is the automatic wire drawing machine; 15 is the first automatic material turning machine; and 16 is the first material transfer machine. 17 is an automatic bending center; 18 is a second material transfer robot; 19 is an automatic welding machine; 20 is a reinforcing rib placement robot; 21 is a third material transfer robot; 22 is a nut locking robot; 23 is an automatic laser welding robot; 24 is a second automatic material turning machine; 25 is a fourth material transfer robot; 26 is an automatic grinding robot; 27 is a dual-station unloading robot; 101 is a reinforcing rib; 102 is a welding stud; 103 is a nut; 104 is a bending point. Detailed Implementation

[0025] like Figure 1 As shown in the figure, this embodiment is a plan view of the installation location of a fully automatic flexible production line equipment for aluminum single panels. Along the production process flow, it includes a main control console 1, an automatic feeding and wire drawing area 2, an automatic bending area 3, a buffer station 4, an automatic stud welding station 5, an automatic reinforcing rib placement station 6, an automatic nut fastening station 7, a reinforcing rib and panel laser welding station 8, a weld point grinding workstation 9, a manual full inspection station 10, and an automatic unloading workstation 11.

[0026] like Figure 2 The diagram shown is a production equipment layout diagram of a fully automated flexible aluminum panel production line according to this embodiment. The production equipment includes: a central control system 12 installed on the central control console 1, as shown below. Figure 3 As shown; the dual-station feeding robot 13 and the automatic wire drawing machine 14 are installed in the automatic feeding and wire drawing area 2, as follows. Figure 3 As shown; the first automatic material turning machine 15, the first material transfer robot 16, and the automatic bending center 17 are installed in the automatic bending area 3, as follows. Figure 4 As shown; the second material transfer robot 18 and the automatic stud welding machine 19 are installed in the stud automatic stud welding station 5. Figure 5 As shown; the reinforcing rib placement robot 20 is installed at the automatic reinforcing rib placement station 6, as... Figure 6 As shown; the third material transfer robot 21 and the nut-locking robot 22 are installed at the automatic nut-locking station 7, as shown. Figure 7 As shown; the automatic laser welding robot 23 is installed at the laser welding station 8 for reinforcing ribs and panels, as... Figure 8 As shown; the second automatic material turning machine 24 is installed at the weld point grinding workstation 9, as... Figure 8 As shown; the fourth material handling robot 25 and the automatic grinding robot 26 are installed at the weld point grinding workstation 9, as follows. Figure 8 As shown; the dual-station unloading robot 27 is installed in the automatic unloading workstation 11, as... Figure 10 As shown.

[0027] The automated manufacturing process for aluminum single-panel panels in this embodiment is as follows: Manual start (main control console) → AGV trolley feeding → robotic arm loading (dual-station loading robot) → automatic wire drawing (automatic wire drawing machine) → aluminum panel flipping (first automatic flipping machine) → material transfer (first material transfer robot) → automatic bending (automatic bending center) → material transfer (first material transfer robot) → buffer station (ensuring continuous production of subsequent stations when adjusting the panel shape) → material transfer (second material transfer robot) → automatic stud welding (automatic welding machine) → material transfer (second material transfer robot) Robotic arm → Automatic feeding of reinforcing ribs (reinforcing rib placement robot) → Material transfer (third material transfer robotic arm) → Automatic nut locking (nut locking robot) → Material transfer (third material transfer robotic arm) → Automatic laser welding (automatic laser welding robot) → Material transfer (third material transfer robotic arm) → Automatic flipping (second automatic flipping machine) → Material transfer (fourth material transfer robotic arm) → Automatic grinding (automatic grinding robot) → Material transfer (fourth material transfer robotic arm) → Manual full inspection → Automatic slagging (dual-station unloading robotic arm) → AGV trolley material collection.

[0028] The structural diagram of the aluminum single-panel product in this embodiment is as follows: Figure 11As shown, the finished aluminum panel includes reinforcing ribs 101, welding studs 102, nuts 103, and bends 104, all of which relate to the automated processing and manufacturing process of the aluminum panel in this embodiment.

[0029] In this embodiment, the central control system 1 is installed on the central control console 12, and it coordinates the control of each process. The central control system 1 employs centralized PLC control, integrating servo drives, Modbus TCP protocol communication, and an industrial tablet HMI. Through a modular architecture, the central control system 1 coordinates the efficient collaborative operation of each production process and equipment, supporting both automatic and manual (maintenance) modes. In automatic mode, it achieves fully unmanned operation based on preset protocol logic; in manual mode, it can independently control a single motor for debugging or maintenance. The central control system 1 features unit activation permission management (operation is prohibited for inactive devices), and is equipped with both an operator console computer and an industrial tablet HMI, displaying real-time equipment status, parameters, and fault codes. The PLC issues instructions to each execution unit via a high-speed bus, and integrates a safety interlock mechanism (such as emergency stop and motion interference detection) to ensure precise and controllable production cycle time. It also reserves an industrial IoT interface to accommodate factory-level data acquisition and remote monitoring needs. The system integrates full-process work order management, supporting manual / automatic generation of work order numbers and binding to parameter templates (including product model, size, program number, etc.). It enables drag-and-drop sorting of work orders, priority adjustment, and progress tracking (real-time display of production quantity / time). It also supports automatic matching of equipment parameters (such as bending machines and welding robots) by associating product dimensions with program relationship tables. The parameterized management module enables dynamic template maintenance and batch parameter distribution (adapting to equipment such as wire drawing machines and robots). Abnormal distributions can be manually retried with real-time status feedback. The production execution module supports one-click start / pause switching of work orders and synchronously records completion data.

[0030] In this embodiment, a dual-station loading robot 13 and an automatic wire drawing machine 14 are installed in the automatic loading and wire drawing area 2 to perform surface wire drawing treatment on aluminum panels. This embodiment adjusts the final fine grinding process to be the first wire drawing process to solve the design challenges of the fine grinding process and improve grinding efficiency and quality, ensuring the quality and effect of subsequent fluorocarbon spraying. An AGV cart delivers the aluminum panel to the designated position, and the dual-station loading robot 13 immediately grabs the aluminum panel, realizing an automatic loading process. The aluminum panel then enters the automatic wire drawing machine 14 via a conveyor belt for surface wire drawing treatment. The treated aluminum panel is then sent to the automatic bending area 3. The dual-station loading robot 13 integrates raw material positioning and material shortage alarm functions. The loading system is responsible for positioning the panel, while the robot is responsible for grabbing it. The automatic wire drawing machine 14 supports stepless speed regulation from 0-10 meters / minute, controls the single-sided wire drawing roughness within the range of 1-2 μm, and is equipped with a dust collection system to ensure no residue. The equipment interacts with the central control system via the Modbus TCP protocol, automatically receiving product parameters (including thickness adaptive servo lifting ±0.1mm), providing feedback on operating status and fault alarms, and featuring a built-in grinding head life monitoring system that supports rapid changeover within 5 minutes. The aluminum plate width is adjustable, and there are no texture defects after painting; changeover downtime is ≤5 minutes.

[0031] In this embodiment, the first automatic material turning machine 15, the first material transfer robot 16, and the automatic bending center 17 are installed in the automatic bending zone 3 to bend and form aluminum panels. After the aluminum panels are wire-drawn, they are turned over by the first automatic material turning machine 15 and then fed into the automatic bending center 17 by the first material transfer robot 16 for bending and forming. The bent aluminum panels are then fed into the buffer station 4 by the first material transfer robot 16. The bending accuracy of this bending center is ±0.5° and ±0.1mm / m. The equipment is linked with the central control system via the Modbus TCP protocol to realize automatic parameter programming (including material, size, compensation process, etc.) and operation status monitoring, supporting rapid mold change within 2 minutes and production line changeover within 5 minutes. Equipped with robot loading and unloading stations and on-site programming workstations, it meets the requirement of 8-blade processing cycle time ≤60s, and has automatic bending parameter compensation, fault feedback, and process data interaction functions to ensure production continuity and accuracy stability.

[0032] In this embodiment, the second material transfer robot 18 and the automatic stud welding machine 19 are installed in the stud automatic stud welding station 5 to perform stud welding on aluminum single panels. After bending and forming, the aluminum single panel is taken out from the buffer station 4 by the second material transfer robot 18 and placed into the automatic stud welding machine 19, which automatically plants studs on the aluminum single panel. The automatic stud welding machine 19 in the stud automatic stud welding station 5 consists of a robot loading and unloading unit, an intelligent stud feeding and welding module, and a digital control platform, meeting the high-precision welding requirements of M6×15 studs. The system integrates an automatic stud feeding mechanism, a multi-gun collaborative energy storage welding machine, and a full steel frame T-slot positioning platform (with insulating and fireproof sheet material), supports a six-axis robot to grasp the workpiece and automatically position and clamp it, and generates welding point programs through CAD drawings to achieve precise welding with ±0.3mm center offset, ±0.3mm / m straightness, and 0.3mm perpendicularity. The welding torch is equipped with dual capacitor banks for dynamic switching, allowing adjustment of the downward pressure / clamping speed. It monitors the stud's positioning status in real time and automatically pauses in case of abnormalities. The welding process is free of blackening / deformation, with back protrusion <0.1mm, no defects after painting, and a single stud tensile strength ≥1000N. The system interacts with the central control unit via Modbus TCP protocol, transmitting equipment status, fault alarms, and parameter feedback in real time. It supports a high-speed cycle of 40 studs / minute, enabling changeover in 5 minutes. Equipped with a self-developed host computer system, it is compatible with office information interaction, ensuring highly flexible, fully automated continuous production.

[0033] In this embodiment, the reinforcing rib placement robot 20 is installed at the automatic reinforcing rib placement station 6 to place reinforcing ribs 101 on the aluminum panels according to the drawing requirements. After the aluminum panels are nailed, the second material transfer robot 18 delivers them to the automatic reinforcing rib placement station 6 for reinforcing rib placement and assembly. The reinforcing rib placement robot 20 at the automatic reinforcing rib placement station 6 uses a robot to grip the aluminum panels to a servo positioning fixture, and combines displacement sensors to detect and correct any deviations, ensuring assembly accuracy. It is equipped with 5 material carts (3 supplying short reinforcing ribs 600-1500mm; 2 supplying long reinforcing ribs 2500-4000mm), which are gripped and installed by a six-axis robot and a three-axis gantry robot, respectively. External sensors detect the orientation of the materials, and abnormal parts are automatically temporarily stored. The workstation is integrated and controlled by a PLC, coordinating the interaction between the robot, the servo transfer platform, and the entire production line. It is equipped with AB station servo positioning, electric cylinders, and a safety protection system, and is compatible with the overall control protocol, achieving high-speed and precise assembly and risk management.

[0034] In this embodiment, the third material handling robot 21 and the nut-locking robot 22 are installed in the automatic nut-locking station 7, relying on visual positioning to lock the aluminum studs of the aluminum panels with nuts. The reinforced and assembled aluminum panels are fed into the automatic nut-locking station 6 by the third material handling robot 21. The automatic nut-locking station 6 integrates a truss mechanical structure, a visual positioning unit (anti-light interference detection), an intelligent electric screwdriver tightening unit (compatible with M6 nuts, torque / speed adaptive adjustment), servo positioning fixtures, and a buffer feeding mechanism (automatic detection + uninterrupted material replenishment). It supports the Modbus TCP protocol to achieve bidirectional communication with the central control system (including parameter sending, status feedback, and fault alarms). The system automatically adjusts the product fixture positioning through servo drive to complete the centering and locking of the reinforcing ribs in the length and width directions. It is equipped with a display screen to monitor the operating data in real time, and a three-color light fault alarm; the tightening process is fully traceable (waveform recording / export / upload), the buffer mechanism reduces the robot's idle travel, and the changeover time is <5 minutes, ensuring high precision, high cycle time, and fully automated operation.

[0035] In this embodiment, the automatic laser welding robot 23 is installed in the laser welding station 8 for reinforcing ribs and panels, and performs welding reinforcement on the four corner seams of the aluminum panel and the junction of the reinforcing ribs and the folded edges. After the aluminum panel is assembled with reinforcement, it is fed into the laser welding station 8 by the third material transfer robot 21 for welding of the four corner seams of the panel folded edges and diagonal welding reinforcement at the junction of the reinforcing ribs and the folded edges. After welding, it is sent to the weld grinding workstation 9 by the third material transfer robot 21. The automatic laser welding robot 23 of this laser welding workstation consists of a dual-arc welding robot, dual ground rails, a servo transfer stage and a laser positioning system, and integrates a gun cleaning device and PLC control to realize fully automatic welding of aluminum panel reinforcing ribs and corner welds. The robot is equipped with anti-collision sensors and digital bus communication. The welding power supply supports ultra-low spatter (reduced by 90%) and gap bridging process. The workstation interacts with the central control via Modbus TCP protocol (including parameter sending, status feedback and fault alarm). It is equipped with three-color lights, safety light curtains (protective railing ≥1.2m), emergency stop interlock, meets the ±0.1mm positioning accuracy requirement, complies with IP54 protection standard, and realizes efficient, low thermal deformation, fully protected automated welding production.

[0036] In this embodiment, the second automatic material turning machine 24, the fourth material transfer robot 25, and the automatic grinding robot 26 are installed in the weld point grinding workstation 9. The automatic grinding robot 26 grinds the weld seams and nail positions of the aluminum single panel. After welding, the aluminum single panel is flipped over by the second automatic material turning machine 24, and then fed into the automatic grinding robot 26 by the fourth material transfer robot 25. The weld point grinding workstation 9 in this embodiment is based on two six-axis robots, integrating high-precision force-controlled grinding and intelligent dust removal functions. The six-axis robots are equipped with a 300N force control compensator to achieve dynamic adjustment of force control in multiple segments from 5 to 300N and gravity compensation. They are equipped with dual electric spindles to achieve a single weld point grinding cycle of 3 seconds. The dual six-station hybrid tool magazine includes a sandpaper tearing and pasting mechanism and an in-situ detection sensor. The dust cover design allows for 2 hours of continuous operation with consumable reserves, and the tool change success rate is fed back in real time. Supports parameterized start / stop for various nailing and grinding modes based on plate thickness and servo positioning fixtures (±0.5mm adaptive clamping). It features a bottom-integrated flared dust collection port and side dust extraction ducts, achieving a dust recovery rate of ≥99%. Controlled via PLC and Modbus TCP protocol, it utilizes an embedded wet filtration system (7.5kW explosion-proof fan / spray + dual-stage filter ball filtration / 300mm suction port) within the dust chamber. The chamber is designed with negative pressure (roller shutter door sealing + bottom dust extraction), ensuring an external dust concentration of <1mg / m³. The automatic grinding robot is equipped with IP54 protective clothing and a pipeline package, featuring a touchscreen for real-time status monitoring and alarms, and a three-color warning light, meeting the requirements for negative pressure dust collection, safety interlocks, and remote maintenance.

[0037] In this embodiment, the dual-station unloading robot 27 is installed in the automatic unloading workstation 11. After polishing, the aluminum panels are fed into the conveyor platform by the fourth material transfer robot 25. After inspection at the manual inspection station 10, the dual-station unloading robot 27 unloads and stacks the panels, completing the entire automated aluminum panel production line process. In this embodiment, the dual-station unloading robot 27 automatically sorts and vertically stacks products based on manual inspection results (OK / NG) through the robot unloading and palletizing system. The number and layout of pallets are dynamically adapted by the robot's arm reach. Equipped with a 5-meter travel rail, it enables large-scale operation, meeting the requirements for efficient and precise automated sorting and palletizing.

Claims

1. A fully automated flexible production line for aluminum single panels, characterized in that, The production line includes a central control system, a dual-station loading robot, an automatic wire drawing machine, a first automatic turning machine, a first material transfer robot, an automatic bending center, a second material transfer robot, an automatic seed welding machine, a reinforcing rib placement robot, a third material transfer robot, a nut locking robot, an automatic laser welding robot, a second automatic turning machine, a fourth material transfer robot, an automatic grinding robot, and a dual-station unloading robot. The central control system is installed at the central control console; the dual-station loading robot and automatic wire drawing machine are installed in the automatic loading and wire drawing area; the first automatic turning machine, the first material transfer robot, and the automatic bending center are installed in the automatic bending area; the second material transfer robot and the automatic stud welding machine are installed in the stud automatic welding station; the reinforcing rib placement robot is installed in the reinforcing rib automatic placement station; the third material transfer robot and the nut locking robot are installed in the nut automatic locking station; the automatic laser welding robot is installed in the reinforcing rib and panel laser welding station; the second automatic turning machine, the fourth material transfer robot, and the automatic grinding robot are installed in the weld point grinding workstation; the dual-station unloading robot is installed in the automatic unloading workstation; All equipment for the automated production of aluminum single panels is installed on the fully automated flexible production line for aluminum single panels; the main control console, automatic feeding and wire drawing area, automatic bending area, automatic stud welding station, automatic reinforcing rib placement station, automatic nut fastening station, laser welding station for reinforcing ribs and panels, weld point grinding workstation and automatic unloading workstation are connected by transmission lines between areas, between areas and stations, and between stations.

2. The fully automated flexible production line for aluminum single panels according to claim 1, characterized in that, The central control system includes a computer, an industrial tablet dual-user interface, an integrated servo drive mechanism, an industrial IoT interface, and a high-speed data bus; the high-speed data bus of the central control system connects the computer, the industrial tablet dual-user interface, the integrated servo drive mechanism, and the control terminals of the equipment in each area and station.

3. The fully automated flexible production line for aluminum single-panel according to claim 1, characterized in that, The dual-station loading robot and automatic wire drawing machine perform surface wire drawing on the aluminum panels in the automatic loading and wire drawing area; the AGV trolley delivers the aluminum panels to the designated position, and the dual-station loading robot then grabs the aluminum panels to realize the automatic loading process; the aluminum panels then enter the automatic wire drawing machine via the conveyor belt for surface wire drawing, and the finished aluminum panels are sent into the automatic bending area.

4. The fully automated flexible production line for aluminum single-panel according to claim 1, characterized in that, The automatic bending zone bends and shapes the aluminum panels that enter the zone; after the aluminum panels are wire-drawn, they are flipped by the first automatic flipping machine and then sent to the automatic bending center by the first material transfer robot for bending and shaping; the bent aluminum panels are then sent to the buffer station by the first material transfer robot.

5. The fully automated flexible production line for aluminum single-panel according to claim 1, characterized in that, The automatic stud welding station performs stud welding on aluminum panels. After bending and forming, the aluminum panels are taken out from the buffer station by the second material transfer robot and placed into the automatic stud welding machine, which automatically plants studs on the aluminum panels. The automatic stud welding station consists of a robot loading and unloading unit, an intelligent stud feeding and welding module, and a digital control platform, meeting the high-precision welding requirements of M6×15 studs. The system integrates an automatic stud feeding mechanism, a multi-gun collaborative energy storage welding machine, and a full steel frame T-slot positioning platform, supporting a six-axis robot to grasp the workpiece and automatically position and clamp it, achieving precise welding with ±0.3mm center offset, ±0.3mm / m straightness, and 0.3mm perpendicularity.

6. The fully automated flexible production line for aluminum single-panel according to claim 1, characterized in that, The automatic reinforcing rib placement station places reinforcing ribs on the aluminum panels. After nailing, the aluminum panels are transported to the automatic reinforcing rib placement station by a second material transfer robot for reinforcing rib placement and assembly. The reinforcing rib placement robot in the automatic reinforcing rib placement station uses a robot to grab the aluminum panels to a servo positioning fixture, and combines displacement sensors to detect and correct deviations to ensure assembly accuracy. Five material carts are configured, which are grabbed and installed by a six-axis robot and a three-axis gantry robot, respectively. External sensors detect the orientation of the materials, and abnormal parts are automatically temporarily stored. The automatic reinforcing rib placement station is integrated and controlled by a PLC, coordinating the interaction between the robot, the servo transfer platform, and the entire production line. It is equipped with AB station servo positioning, electric cylinders, and a safety protection system, and is compatible with the overall control protocol to achieve high-speed and precise assembly and risk management.

7. The fully automated flexible production line for aluminum single-panel according to claim 1, characterized in that, The automatic nut fastening station fastens nuts to the aluminum studs of the aluminum panels; the reinforced and assembled aluminum panels are fed into the automatic nut fastening station by a third material transfer robot; the automatic nut fastening station integrates a truss mechanical structure, a vision positioning unit, an intelligent electric screwdriver tightening unit, a servo positioning fixture and a buffer feeding mechanism. The system automatically adjusts the product tooling positioning through servo drive, completes the centering and locking of the reinforcing ribs in the length and width directions, and is equipped with a display screen to monitor the operating data in real time, and a three-color light fault alarm.

8. The fully automated flexible production line for aluminum single-panel according to claim 1, characterized in that, The laser welding station for reinforcing ribs and panels reinforces the four corner seams of the aluminum panel's folded edges and the junctions between the reinforcing ribs and the folded edges. After the aluminum panel is assembled with reinforcement, it is fed into the laser welding station for reinforcing ribs and panels via a third material transfer robot. The four corner seams of the panel's folded edges are welded, and the diagonal welds at the junctions between the reinforcing ribs and the folded edges are reinforced. After welding, the panel is fed into the weld spot grinding station by the third material transfer robot. The automatic laser welding robot of the laser welding station consists of a dual-arc welding robot, dual ground rails, a servo transfer platform, and a laser positioning system. It integrates a gun cleaning device and a PLC control system to achieve fully automatic welding of the aluminum panel's reinforcing ribs and corner welds.

9. The fully automated flexible production line for aluminum single-panel according to claim 1, characterized in that, The weld point grinding workstation grinds the weld seams and nail positions of the aluminum single panel. After welding, the aluminum single panel is flipped over by a second automatic turning machine, and then fed into the automatic grinding robot by a fourth material transfer robot. The automatic grinding robot of the weld point grinding workstation includes two six-axis robots, integrating high-precision force control grinding and intelligent dust removal functions. The six-axis robots are equipped with a 300N force control compensator to achieve dynamic adjustment of force control in multiple segments from 5 to 300N and gravity compensation. They are equipped with dual electric spindles to achieve a single weld mark grinding cycle of 3 seconds. The dual six-station hybrid tool magazine includes a sandpaper tearing and pasting mechanism and an in-situ detection sensor. The dust cover design allows for 2 hours of continuous operation and consumable reserves. The tool change success rate is fed back in real time. The automatic grinding robot supports parameterized start and stop nail mark grinding modes based on plate thickness and servo positioning fixtures. The bottom integrates a flared dust collection port and a side dust extraction pipe.

10. The fully automated flexible production line for aluminum single-panel according to claim 1, characterized in that, The automated unloading workstation uses a dual-station unloading robot to deliver polished aluminum panels to a conveyor platform. After manual inspection, the dual-station unloading robot unloads and stacks the panels, completing the entire automated aluminum panel production line process. The dual-station unloading robot automatically sorts and vertically stacks products based on the manual inspection results through the unloading and stacking system. The number and layout of stacks are dynamically adapted by the robot's arm reach. Equipped with a 5-meter travel rail, it can operate over a wide range, meeting the needs for efficient and precise automated sorting and stacking.

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