Sheet metal deformed plug-in block detection machine

Abstract

The application discloses a sheet metal deformation plug-in block detection machine, which comprises a rack, a deformation detection tool, a pressing mechanism, a deformation detection mechanism, a control assembly and an NG processing assembly. The pressing mechanism comprises at least two pressing air cylinders which are synchronously pressed by the same electromagnetic valve. The deformation detection mechanism comprises at least three groups of detection air cylinders and deformation detection plug-in blocks. The control assembly is provided with a start button and a touch screen, which can guarantee safety and display the state in real time. The NG processing assembly comprises an inclined flow channel and a photoelectric detector, which can realize closed-loop control of NG products. During work, the sheet metal is pressed by the pressing air cylinder after artificial feeding and starting by both hands, and the plug-in block is detected by the detection air cylinder. The OK products are manually taken away, and the NG products are triggered by the flow channel to release the alarm of the photoelectric detection. The device overcomes the defects of low artificial detection efficiency, high misjudgment, high visual detection cost and long debugging time, is safe and convenient to operate, is suitable for multiple models of sheet metal and is applicable to small and large batch production.

Description

Technical Field

[0001] This utility model relates to the field of deformation detection technology for automotive stamped sheet metal parts, and in particular to a sheet metal deformation insert detection machine, which is suitable for rapid post-production deformation detection of small to medium batches or large batches of automotive stamped sheet metal parts (such as door panels, chassis brackets, body panels, etc.). Background Technology

[0002] After automotive sheet metal parts are stamped, critical areas such as edges, holes, and curved surfaces are prone to deformation due to uneven stamping pressure, die wear, or material springback. These parts must pass inspection and screening before proceeding to subsequent assembly processes. Currently, the mainstream inspection methods in the industry have the following significant drawbacks: 1. Manual inspection method: Operators use special inspection tools (such as go / no-go gauges and contour templates) to compare the key positions of sheet metal parts one by one. The inspection time for a single part generally exceeds 10 seconds. Moreover, long-term operation can easily lead to personnel fatigue, and the misjudgment rate has increased from the initial 3%-5% to 8%-12%. At the same time, manual inspection relies on personal experience, and the inspection standards of different operators are different, resulting in poor consistency of inspection results.

[0003] 2. Visual line scan inspection method: This method uses a high-definition camera to capture images of sheet metal parts and combines them with deep learning algorithms to analyze deformation. The equipment purchase cost is as high as 200,000 to 500,000 yuan per unit. Moreover, this method has strict requirements for the inspection environment. Dust in the workshop and changes in lighting (such as switching between natural light during the day and artificial light at night) will cause a decrease in image acquisition accuracy, and the algorithm parameters need to be calibrated regularly. In addition, for new models of sheet metal parts, hundreds of sample images need to be re-acquired to train the algorithm. The initial debugging cycle is as long as 1-2 weeks, which is not suitable for multi-variety, small-batch production scenarios.

[0004] 3. Deficiencies of existing automated testing equipment: Some simple automated testing equipment only uses a single cylinder to drive the test parts, which cannot cover the testing of multiple key positions of sheet metal parts; and it lacks a closed-loop management mechanism for non-compliant products, which can easily lead to the problem of missed detection when non-compliant products are not processed in time and enter the next testing cycle.

[0005] In summary, the industry urgently needs a sheet metal deformation detection solution that combines high detection efficiency, low equipment cost, low false positive rate, and strong environmental adaptability to address the shortcomings of existing technologies. Utility Model Content

[0006] The purpose of this invention is to address the problems of "low efficiency and poor consistency of manual inspection", "high cost and environmental sensitivity of visual inspection", and "incomplete inspection and lack of control of simple automated equipment" in the existing technology. It provides a sheet metal deformation insert inspection machine, which achieves automation, high efficiency and low error judgment of sheet metal deformation inspection through the design of "multi-cylinder synchronous pressing + multi-insert precise inspection + closed-loop control of NG products", while reducing equipment cost and operation threshold.

[0007] To achieve the above objectives, the technical solution adopted by this utility model is: a sheet metal deformation insert detection machine, including a frame, on which a deformation detection fixture is provided, and on which a pressing mechanism, a deformation detection mechanism, a control component and an NG processing component are also assembled; The pressing mechanism includes at least two pressing cylinders and a solenoid valve. The solenoid valve is connected to each pressing cylinder through an air circuit and is used to control the pressing cylinders to extend or reset synchronously. The deformation detection mechanism includes at least three sets of deformation detection cylinders and a corresponding number of deformation detection blocks. The output end of the deformation detection cylinder is fixedly connected to the deformation detection blocks and is used to drive the blocks to extend into or out of the sheet metal detection area. The control component includes a start button, which is electrically connected to a solenoid valve and a deformation detection cylinder, and is used to trigger the action of the pressing mechanism and the deformation detection mechanism. The NG processing component includes an NG flow channel and a photodetector. The photodetector is installed at the end of the NG flow channel and is electrically connected to the control component to identify whether NG products have entered the flow channel.

[0008] In a preferred embodiment, the pressing cylinders in the pressing mechanism are evenly distributed along the edge of the deformation detection fixture, and the pressing cylinders are connected in parallel to the same solenoid valve.

[0009] In a preferred embodiment, the deformation detection cylinders in the deformation detection mechanism correspond to the key deformation detection positions of the sheet metal, and all deformation detection cylinders synchronously receive the action signals from the control components.

[0010] In a preferred embodiment, the control component further includes a touch screen, which is electrically connected to a photoelectric detector, a solenoid valve, and a deformation detection cylinder, and is used to display the operating status of the equipment and receive manual operation commands.

[0011] In a preferred embodiment, a pressure reducing valve is further included, which is connected in series in the main air path of the pressing cylinder and the deformation detection cylinder.

[0012] In a preferred embodiment, the start button is a two-hand start button, with the two buttons respectively installed on the left and right ends of the operating side of the frame. The control component will only trigger the pressing mechanism to operate when both hands are pressed simultaneously.

[0013] In a preferred embodiment, the detection end of the deformation detection plug is made of hard alloy material, and the shape of the deformation detection plug matches the contour of the corresponding detection position of the qualified sheet metal part.

[0014] Due to the application of the above technical solution, the beneficial effects of this application compared with the prior art are as follows: 1. Significantly improved inspection efficiency: The single-piece inspection cycle is only 5.5-6 seconds, which is more efficient than manual inspection (more than 10 seconds); it can inspect about 4,800 pieces in 8 hours of continuous operation, meeting the needs of mass production.

[0015] 2. High detection accuracy and low false judgment rate: The physical detection method of "hard alloy insert + cylinder stroke precision control" avoids human experience error or environmental interference of visual detection, thus reducing the false judgment rate; the insert has strong wear resistance and a service life of ≥100,000 tests, and the accuracy is stable over long-term use.

[0016] 3. Low equipment cost and high cost performance: The overall equipment cost is about 50,000 yuan, which is only 10%-25% of the visual line scanning detection equipment (200,000-500,000 yuan); no complex algorithm training is required, and the equipment debugging time is ≤2 hours, reducing the initial investment and usage threshold.

[0017] 4. Safe and convenient operation: The dual-hand start button design eliminates the safety hazards of single-handed operation; the touch screen provides visual operation, and ordinary workers can operate independently after 1 hour of training, without the need for professional technicians.

[0018] 5. High adaptability and fast changeover: By changing the deformation detection fixture and insert, it can be adapted to different models of sheet metal parts, with a changeover time of ≤30 minutes; the air pressure is adjustable and it is suitable for various automotive stamping sheet metal parts with a thickness of 0.5-3mm. Attached Figure Description

[0019] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0020] Appendix Figure 1 This is a structural schematic diagram of a sheet metal deformation insert detection machine according to the present invention; Appendix Figure 2 This is a top view of a sheet metal deformation insert detection machine according to the present invention; The components include: 1. Frame; 2. Deformation detection fixture; 3. Pressing cylinder; 4. Deformation detection cylinder; 5. Deformation detection insert; 6. Start button; 7. Pressure reducing valve. Detailed Implementation

[0021] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0022] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this application described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0023] In this application, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing the present invention and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0024] Furthermore, in addition to indicating direction or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this utility model according to the specific circumstances.

[0025] Furthermore, the terms "installation," "setup," "equipped with," "connection," "linking," and "socketing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this utility model based on the specific circumstances.

[0026] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0027] Example 1 Appendix Figure 1 and 2 The sheet metal deformation insert detection machine of this utility model specifically includes the following parts in its core structure: Frame 1: As the basic support structure of the equipment, it is made of Q235 carbon steel welded and the surface is treated with powder coating for rust prevention (coating thickness 60-80μm). The overall dimensions are 1200mm×800mm×1500mm (length×width×height), and the maximum load capacity is ≥50kg. A guardrail (800mm high) is installed on the operating side of Frame 1 to prevent non-operators from accidentally touching it.

[0028] Deformation detection fixture 2: Customized according to the shape of the sheet metal part to be inspected, it is made of 45# steel and the surface is hardened (hardness HRC50-55); the fixture is equipped with 2-4 positioning pins (accuracy ±0.05mm) for quick positioning of the sheet metal part to ensure consistent position each time it is loaded; the fixture is detachably connected to the frame 1 by bolts, which is convenient to replace to adapt to different models of sheet metal parts.

[0029] The pressing mechanism includes at least two pressing cylinders 3 and a single electrically controlled solenoid valve (model 4V210-08); the pressing cylinders 3 are evenly distributed along the rectangular edge of the deformation detection fixture 2 (located on the front, left, and right sides of the fixture respectively), model SC63×50 (cylinder diameter 63mm, stroke 50mm), working pressure 0.4-0.6MPa, maximum pressing force 80N; the pressing cylinders 3 are connected in parallel to the same solenoid valve to ensure synchronous extension or reset, avoiding secondary deformation of the sheet metal parts due to uneven local stress.

[0030] Deformation detection mechanism: includes at least three sets of deformation detection cylinders 4 and a corresponding number of deformation detection blocks 5; the deformation detection cylinders 4 are controlled by dual-electro-controlled solenoid valves (model 4V220-08), model SC40×30 (cylinder diameter 40mm, stroke 30mm), stroke accuracy ±0.1mm, response time ≤0.2s; the deformation detection blocks 5 are fixedly connected to the piston rod of the deformation detection cylinders 4 by threads (fit clearance ≤0.02mm), the detection end of the blocks is made of WC-Co hard alloy (containing 10% cobalt), hardness HRC60-65, and has strong wear resistance; the shape of the blocks is completely matched with the corresponding detection position contour of the qualified sheet metal parts (tolerance ±0.03mm), and the blocks can only be fully inserted into the detection position when the sheet metal has no out-of-tolerance deformation.

[0031] Control components include a two-hand start button 6, a touch screen (model MT8102iE, 7-inch color LCD screen), and a PLC controller (model S7-200 SMART). The two-hand start button 6 is installed on the left and right ends of the operating side of the frame 1 (600mm apart). The PLC only outputs an action signal when both hands are pressed simultaneously to prevent hand injury caused by single-handed operation. The touch screen is electrically connected to the PLC and can display the equipment operating status in real time (such as detection cycle, cumulative detection quantity, OK / NG quantity statistics), fault alarm information (such as cylinder not reset, insufficient air pressure), and supports manual operation (such as alarm cancellation, parameter setting). The PLC is electrically connected to the solenoid valve of the pressing mechanism, the solenoid valve of the deformation detection cylinder 4, and the photoelectric detector to realize the action sequence control of each mechanism.

[0032] NG processing components include an NG flow channel and a photoelectric detector. The NG flow channel is made of stainless steel sheet bent into shape (2mm thick) with a 15° tilt angle (ensuring that NG items slide down by their own weight). The end of the flow channel connects to the NG item box. The photoelectric detector is a diffuse reflective type (model E3Z-LS63), installed on the side of the end of the NG flow channel (detection distance 50-100mm), and its signal output is connected to the PLC. When an NG item slides past the end of the flow channel, the photoelectric detector sends a signal to the PLC. The PLC controls the touch screen to deactivate the alarm and allows the equipment to start the next detection cycle. If the NG item does not enter the flow channel, the photoelectric detector has no signal, and the equipment remains in an alarm-locked state.

[0033] Air circuit auxiliary components include pressure reducing valve 7 (model AR2000-02), pressure gauge (range 0-1MPa), and oil-water separator; pressure reducing valve 7 is connected in series in the main air circuit of pressing cylinder 3 and deformation detection cylinder 4, and can adjust the air circuit pressure (usually set to 0.5MPa) to prevent excessive pressure from damaging sheet metal parts or insufficient pressure from causing insecure clamping; oil-water separator is used to filter moisture and impurities in compressed air to avoid air circuit blockage or cylinder wear.

[0034] Workflow and control logic: Material loading and positioning: The operator places the sheet metal part to be inspected into the deformation detection fixture 2 and uses the positioning pins on the fixture to achieve precise positioning, ensuring that the inspection position of the sheet metal part is aligned with the deformation detection block 5.

[0035] Start pressing: The operator presses the start button 6 with both hands at the same time. After receiving the signal, the PLC first controls the solenoid valve of the pressing mechanism to be energized. Multiple pressing cylinders 3 are set to extend synchronously and press the sheet metal parts onto the tooling. The PLC confirms that the pressing cylinder 3 is fully extended through the magnetic switch on the cylinder (feedback time ≤ 0.3s) before proceeding to the next step to prevent detection deviation caused by insufficient pressing.

[0036] Deformation detection: After the material is pressed, the PLC controls the solenoid valve of the deformation detection cylinder 4 to be energized, and multiple sets of deformation detection cylinders 4 synchronously drive the inserts to extend into the sheet metal detection position; if all inserts are fully inserted (the cylinder magnetic switch feedback "extended in place"), the PLC determines the product to be OK, and the touch screen displays "qualified"; if any set of inserts is not fully inserted (the magnetic switch has no "extended in place" signal), the PLC determines the product to be NG, the touch screen triggers an audible and visual alarm (red light flashing + buzzer sounding), and records the NG information.

[0037] Cylinder Reset: After the test is completed, the PLC first controls the solenoid valve of the deformation test cylinder 4 to de-energize, and all plug blocks are reset synchronously; after the deformation test cylinder 4 is fully reset (magnetic switch feedback), the PLC then controls the solenoid valve of the pressing cylinder 3 to de-energize, the pressing cylinder 3 is reset, and the sheet metal parts are released.

[0038] Material unloading and NG handling: The operator removes the inspected sheet metal parts, OK parts are placed in the qualified parts turnover box, and NG parts are put into the NG flow channel; when the NG part slides to the end of the flow channel, the photoelectric detector sends a signal to the PLC, the PLC controls the touch screen to clear the alarm, the equipment returns to standby state, and the next inspection cycle can be started; if no NG part is detected in the flow channel within 10 seconds, the PLC extends the alarm time and displays "NG part not processed" on the touch screen.

[0039] Post-maintenance and related handling: Gas circuit maintenance: Drain and clean the oil-water separator every 3 months, and replace the seal of pressure reducing valve 7 every 6 months to ensure stable gas circuit pressure; Insert maintenance: When the detection end of the deformation detection insert 5 is worn (wear amount ≥0.05mm), the insert needs to be replaced in time to avoid a decrease in detection accuracy; Tooling calibration: Every month of use, the deformation detection tooling 2 must be calibrated using standard qualified sheet metal parts. If the positioning pin is found to be offset, it must be adjusted to its original position (accuracy ±0.05mm). Troubleshooting: If the equipment alarms "Pressure cylinder 3 not reset", check if the cylinder magnetic switch is loose or damaged, or if there is a blockage in the air path; if the alarms "NG product not detected", check if the lens of the photoelectric detector is blocked by dust, or if there is a blockage in the NG flow channel.

[0040] Example 2 The sheet metal deformation insert detection machine described in this utility model is used to inspect automotive door panel sheet metal, as detailed below: Applicable sheet metal parts: automotive front door panel stamping parts, dimensions 800mm×500mm×2mm, 7 key locations need to be inspected (including the upper edge flange, lower edge flange, left side mounting hole perimeter, right side mounting hole perimeter, central groove, door handle mounting position, and lock hole perimeter).

[0041] Equipment configuration: It adopts 7 sets of deformation detection cylinders 4, corresponding to 7 detection positions; the deformation detection fixture 2 is equipped with 4 positioning pins to match the 4 process holes of the door panel; the pressing cylinder 3 is set with a pressing force of 60N to avoid deformation of thin door panel materials; the air pressure is adjusted to 0.5MPa through the pressure reducing valve 7.

[0042] Operational Testing: A continuous 8-hour test was conducted in the stamping workshop of an automotive parts factory, with an ambient temperature of 25-30℃, humidity of 40%-60%, and slight dust in the workshop. A total of 4800 door panel sheet metal parts were inspected, including 4560 OK parts and 240 NG parts (mainly edge flanging deformation and mounting hole misalignment). The equipment's testing cycle time was stable at 5.8s / pcs, the NG part identification accuracy was 100%, with no missed detections or misjudgments. During the test, the equipment had no fault alarms, the action of the pressing cylinder 3 and the deformation detection cylinder 4 was well synchronized, and the insert blocks showed no obvious wear.

[0043] Test conclusion: The equipment fully meets the batch inspection requirements of automotive door panel sheet metal parts. Compared with the original manual inspection method, it can reduce the number of inspectors by 2 per day, improve the inspection efficiency by 42%, and reduce the error rate from 7% to 0.2%.

[0044] Finally, it should be noted that the above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A sheet metal deformation insert detection machine, comprising a frame, wherein a deformation detection fixture is provided on the frame, characterized in that: The frame is also equipped with a material pressing mechanism, a deformation detection mechanism, a control component, and an NG processing component; The pressing mechanism includes at least two pressing cylinders and a solenoid valve. The solenoid valve is connected to each pressing cylinder through an air circuit and is used to control the pressing cylinders to extend or reset synchronously. The deformation detection mechanism includes at least three sets of deformation detection cylinders and a corresponding number of deformation detection blocks. The output end of the deformation detection cylinder is fixedly connected to the deformation detection blocks and is used to drive the blocks to extend into or out of the sheet metal detection area. The control component includes a start button, which is electrically connected to a solenoid valve and a deformation detection cylinder, and is used to trigger the action of the pressing mechanism and the deformation detection mechanism. The NG processing component includes an NG flow channel and a photodetector. The photodetector is installed at the end of the NG flow channel and is electrically connected to the control component to identify whether NG products have entered the flow channel.

2. The sheet metal deformation insert detection machine according to claim 1, characterized in that: The pressing cylinders in the pressing mechanism are evenly distributed along the edge of the deformation detection fixture, and the pressing cylinders are connected in parallel to the same solenoid valve.

3. The sheet metal deformation insert detection machine according to claim 1, characterized in that: The deformation detection cylinders in the deformation detection mechanism correspond to the key deformation detection positions of the sheet metal, and all deformation detection cylinders synchronously receive the action signals from the control components.

4. The sheet metal deformation insert detection machine according to claim 1, characterized in that: The control component also includes a touch screen, which is electrically connected to a photoelectric detector, a solenoid valve, and a deformation detection cylinder, and is used to display the operating status of the equipment and receive manual operation commands.

5. The sheet metal deformation insert detection machine according to claim 1, characterized in that: It also includes a pressure reducing valve, which is connected in series in the main air circuit of the pressing cylinder and the deformation detection cylinder.

6. The sheet metal deformation insert detection machine according to claim 1, characterized in that: The start button is a two-hand start button, with the two buttons installed on the left and right ends of the machine frame operation side respectively. The control component will only trigger the material pressing mechanism to operate when both hands are pressed at the same time.

7. The sheet metal deformation insert detection machine according to claim 1, characterized in that: The detection end of the deformation detection plug is made of hard alloy, and the shape of the deformation detection plug matches the contour of the corresponding detection position of the qualified sheet metal part.

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