A special welding device for A-pillar trim panels

Abstract

This utility model relates to the field of automotive interior parts manufacturing technology, specifically a dedicated welding device for A-pillar trim panels, solving the problems mentioned in the background art. It includes a frame, a welding execution mechanism, a control system, a real-time quality monitoring system, and a modular fixture system. The real-time quality monitoring system includes a data acquisition module, a data processing and judgment module, and an execution module. The modular fixture system includes a base frame fixed to the frame and at least one dedicated positioning fixture detachably connected to the base frame. The dedicated positioning fixture has a positioning surface that matches the inner surface contour of a specific model of A-pillar trim panel. This utility model, through an integrated industrial camera, allows for visual inspection of weld points after welding, improving the ability to identify surface defects. The automatic welding head cleaning device helps maintain the stability of energy transmission and reduces quality fluctuations caused by contamination. The system works collaboratively.

Description

Technical Field

[0001] This utility model relates to the field of automotive interior parts manufacturing technology, specifically a special welding device for A-pillar trim panels. Background Technology

[0002] In the automotive interior parts manufacturing industry, the A-pillar trim panel, as an important interior covering, typically requires welding to fix reinforcing ribs, clips, and other structural components. Currently, the industry generally uses traditional ultrasonic welding equipment for this type of work. However, these devices have several technical limitations in practical applications: First, most equipment lacks the ability to finely monitor the welding process, failing to collect and analyze key process parameters such as welding power, energy, and downward speed in real time. This makes it difficult to guarantee the stability of welding quality, easily leading to defects such as incomplete welds and over-welds. Second, existing welding fixtures are mostly specialized structures. When producing A-pillar trim panels for different car models, the entire fixture module needs to be replaced. This process is usually time-consuming and has limited repeatability, severely affecting the flexibility of the production line. In addition, during continuous production, plastic residues easily accumulate on the welding head working surface, altering energy transmission characteristics, and traditional equipment lacks effective automated cleaning methods. Furthermore, conventional equipment generally lacks a visual verification step for the welding results, making it difficult to detect surface defects such as weld flaws. Therefore, a dedicated welding device for A-pillar trim panels is proposed. Utility Model Content

[0003] To solve the above problems, this utility model provides the following technical solution: A welding device for A-pillar trim panels includes a frame, a welding execution mechanism mounted on the frame, and a control system. The device further includes a real-time quality monitoring system and a modular fixture system. The real-time quality monitoring system includes: a data acquisition module for real-time acquisition of physical parameters during the welding process; a data processing and judgment module electrically connected to the data acquisition module for real-time comparison of the physical parameters with a preset standard process parameter curve and outputting a judgment signal; and an execution module electrically connected to the data processing and judgment module for performing qualified product transfer or unqualified product rejection operations based on the judgment signal. The modular fixture system includes: a base frame fixed to the frame; and at least one dedicated positioning fixture detachably connected to the base frame, the dedicated positioning fixture having a positioning profile matching the inner surface contour of a specific model of A-pillar trim panel.

[0004] Furthermore, the physical parameters collected by the data acquisition module of the real-time quality monitoring system include at least one of ultrasonic welding power, welding head descent speed, welding depth, and welding energy.

[0005] Furthermore, the modular fixture system is provided with a pneumatic-electric quick-connect coupling and a mechanical positioning and locking mechanism between the basic frame and the dedicated positioning fixture.

[0006] Furthermore, the mechanical positioning and locking mechanism is a zero-point positioning pin system or a snap-lock mechanism.

[0007] Furthermore, the device also integrates an industrial camera, which is communicatively connected to the real-time quality monitoring system for capturing images of the welded A-pillar trim panel to perform secondary judgment on weld quality and appearance defects.

[0008] Furthermore, the device also includes an automatic welding head cleaning device; the automatic welding head cleaning device is located on the welding head return path of the welding actuator and outside the welding station; the automatic welding head cleaning device includes a cleaning execution component and a cleaning control unit that drives its operation; the cleaning execution component is a soft scraper structure, a high-pressure air nozzle structure, or a combination of both; the cleaning control unit is communicatively connected to the control system and is used to drive the cleaning execution component to clean the working end face of the welding head after each welding cycle is completed and the welding head returns to a specific height.

[0009] Compared with the prior art, the beneficial effects of this utility model are: By setting up a real-time quality monitoring system, key parameters such as power and energy during the welding process can be collected and compared, providing data support for assessing the stability of welding quality and helping to reduce the generation of welding defects. The modular fixture system, together with quick-change connectors and positioning locking mechanisms, can shorten the fixture adjustment time when changing lines for different product models and help maintain repeatability and positioning accuracy. The integrated industrial camera can perform visual inspection of weld points after welding, complementing process monitoring and improving the ability to identify surface defects. In addition, the automatic welding head cleaning device can clean the welding head end face after each work cycle, which helps maintain the stability of energy transmission and reduce quality fluctuations caused by contamination. The system works in synergy to improve welding quality consistency and production efficiency while enhancing the equipment's adaptability to different production needs. Attached Figure Description

[0010] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention, but do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the overall front view of the present invention; Figure 2 This is a frontal sectional view of the modular clamping system of this utility model. Figure 3This is a frontal sectional view of the quality monitoring system of this utility model; Figure 4 This is a cross-sectional view of the automatic welding head cleaning device of this utility model.

[0011] In the diagram: 1. Frame; 2. Welding actuator; 3. Control system; 4. Real-time quality monitoring system; 41. Data acquisition module; 42. Data processing and judgment module; 43. Execution module; 5. Modular fixture system; 51. Basic frame; 52. Special positioning fixture; 53. Pneumatic-electric quick-connect coupling; 54. Mechanical positioning and locking mechanism; 6. A-pillar trim panel; 7. Industrial camera; 8. Automatic welding head cleaning device; 81. Cleaning actuator; 82. Cleaning control unit. Detailed Implementation

[0012] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the protection scope of the present utility model.

[0013] like Figure 1-4 As shown, the A-pillar trim panel welding device of this embodiment includes a frame 1, a welding execution mechanism 2 mounted on the frame 1, a control system 3, and a real-time quality monitoring system 4 and a modular fixture system 5. The real-time quality monitoring system 4 includes: a data acquisition module 41, used to acquire physical parameters of the welding process in real time during the welding process; a data processing and judgment module 42, electrically connected to the data acquisition module 41, used to compare the physical parameters with the preset standard process parameter curve in real time and output a judgment signal; and an execution module 43, electrically connected to the data processing and judgment module 42, used to perform qualified product transfer or unqualified product rejection operation according to the judgment signal. The modular fixture system 5 includes: a base frame 51 fixed on the frame 1; and at least one special positioning fixture 52 that can be detachably connected to the base frame 51. The special positioning fixture 52 is provided with a positioning surface that matches the inner surface contour of a specific model of A-pillar trim panel 6.

[0014] The physical parameters collected by the data acquisition module 41 of the real-time quality monitoring system 4 include at least those of ultrasonic welding power, welding head downward speed, welding depth and welding energy in this embodiment. This provides objective data support for evaluating the stability of welding quality, thereby helping to reduce defects such as incomplete welding or over-welding that may be caused by energy fluctuations.

[0015] The modular fixture system 5 has a pneumatic-electric quick-connect joint 53 and a mechanical positioning and locking mechanism 54 between its basic frame 51 and the dedicated positioning fixture 52. This can shorten the fixture switching time required when changing product models and help maintain the positioning accuracy when different fixtures are repeatedly installed.

[0016] The mechanical positioning and locking mechanism 54 is a zero-point positioning pin system or a snap-lock mechanism, which achieves locking and releasing with simpler mechanical actions, improving the reliability and efficiency of fixture changing operations.

[0017] The device also integrates an industrial camera 7, which is connected to the real-time quality monitoring system 4 to acquire images of the welded A-pillar trim 6 for secondary judgment of weld quality and appearance defects. This adds a visual verification step for the welding results, forming a quality assurance method that combines process and result, and can help identify some surface quality problems that are difficult to detect by parameter monitoring.

[0018] The device also includes an automatic welding head cleaning device 8; the automatic welding head cleaning device 8 is located on the welding head return path of the welding actuator 2 and outside the welding station; the automatic welding head cleaning device 8 includes a cleaning actuator 81 and a cleaning control unit 82 that drives its operation, the cleaning actuator 81 is a soft scraper structure, a high-pressure air nozzle structure or a combination of the two; the cleaning control unit 82 is communicatively connected to the control system 3 and is used to drive the cleaning actuator 81 to clean the working end face of the welding head after each welding cycle is completed and the welding head returns to a specific height.

[0019] The working principle is: The operator places the A-pillar trim panel and the component to be welded onto a dedicated positioning fixture of the modular clamping system. Positioning and fixation are achieved through the fixture's surface and vacuum adsorption. Under the control system's command, the welding actuator drives the welding head downwards, simultaneously initiating ultrasonic vibration upon contact with the workpiece. This applies mechanical and thermal energy to the welding interface, causing the plastic material to partially melt and bond. During welding, the real-time quality monitoring system's data acquisition module continuously records various physical parameters such as welding power and downward speed. This data is transmitted to the processing and judgment module for comparison and analysis against a preset standard process curve. If parameter fluctuations exceed the allowable range, the system issues a signal, prompting the execution module to differentiate and process the current workpiece. After welding, an industrial camera integrated into the device captures images of the weld area. Visual analysis assists in detecting appearance defects and welding morphology, serving as supplementary verification for process parameter monitoring. Furthermore, after each welding cycle, the welding head can be moved to a cleaning station where an automatic cleaning device cleans its end face to reduce the impact of residues on subsequent welding quality.

[0020] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0021] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A special welding device for A-pillar trim panels, comprising: a frame (1), a welding actuator (2) mounted on the frame (1), and a control system (3), characterized in that: The device also includes a real-time quality monitoring system (4) and a modular fixture system (5); The real-time quality monitoring system (4) includes: a data acquisition module (41) for acquiring physical parameters of the welding process in real time during the welding process; a data processing and judgment module (42) electrically connected to the data acquisition module (41) for comparing the physical parameters with the preset standard process parameter curve in real time and outputting a judgment signal; and an execution module (43) electrically connected to the data processing and judgment module (42) for performing qualified product transfer or unqualified product rejection operations according to the judgment signal. The modular clamping system (5) includes: a base frame (51) fixed to the frame (1); at least one dedicated positioning fixture (52) detachably connected to the base frame (51), the dedicated positioning fixture (52) having a positioning profile that matches the inner surface profile of a specific model A-pillar trim panel (6).

2. The welding device for A-pillar trim panels according to claim 1, characterized in that: The physical parameters collected by the data acquisition module (41) of the real-time quality monitoring system (4) include at least one of ultrasonic welding power, welding head downward speed, welding depth and welding energy.

3. A welding device for A-pillar trim panels according to claim 1 or 2, characterized in that: The modular clamping system (5) has a pneumatic quick-connect connector (53) and a mechanical positioning and locking mechanism (54) between its basic frame (51) and the special positioning fixture (52).

4. The welding device for A-pillar trim panels according to claim 3, characterized in that: The mechanical positioning and locking mechanism (54) is a zero-point positioning pin system or a snap-lock mechanism.

5. The welding device for A-pillar trim panels according to claim 1, characterized in that: The device also integrates an industrial camera (7), which is connected to the real-time quality monitoring system (4) for image acquisition of the welded A-pillar trim panel (6) to make secondary judgments on the quality of the weld and appearance defects.

6. The welding device for A-pillar trim panels according to claim 1, characterized in that: The device also includes an automatic welding head cleaning device (8); the automatic welding head cleaning device (8) is located on the welding head return path of the welding actuator (2) and outside the welding station; the automatic welding head cleaning device (8) includes a cleaning actuator (81) and a cleaning control unit (82) that drives it to work, the cleaning actuator (81) is a soft scraper structure, a high-pressure air nozzle structure or a combination of the two; the cleaning control unit (82) is communicatively connected to the control system (3) and is used to drive the cleaning actuator (81) to clean the working end face of the welding head after each welding cycle is completed and the welding head returns to a specific height.

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