Seat Belt Retractor Pre-Winding With Stop Slot Positioning
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Solution Overview
Problem
Manual or semi-automatic assembly of safety belt retractors results in inconsistent pre-tightening of coil springs and low work efficiency, leading to quality issues and non-standard products.
Innovation Solution
A safety belt retractor pre-winding and baffle installation device with a rotary table and multiple stations, including a winding mechanism, position detection mechanism, multi-axis manipulator, and visual sensors, to automate the pre-winding, stop slot positioning, baffle installation, and quality control processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual or semi-automatic assembly is used for baffle installation and pre-winding, then device complexity is reduced, but manufacturing precision and productivity deteriorate
Solution Approach 1:
The assembly process is segmented into distinct functional modules: a winding mechanism with motor for automated pre-winding, a position detection mechanism with sensors for stop slot detection, and a multi-axis manipulator for baffle installation. Each module operates independently but coordinates through the control system, enabling precise control of pre-winding circles and stop slot positioning while maintaining manageable device complexity through modular architecture.
Solution Approach 2:
The position detection mechanism provides real-time feedback to the control system about the stop slot position during rotation. The sensor detects when the stop slot aligns with the socket and sends signals to halt rotation, ensuring precise positioning. This feedback loop guarantees consistent pre-winding circles and accurate stop slot alignment across all products, resolving the precision issue in automated assembly.
2Device complexity
If manual or semi-automatic assembly is used, then device complexity is reduced, but productivity deteriorates
Solution Approach 1:
The automated assembly system enables continuous operation through the rotary table that sequentially positions safety belt retractors at different stations. The winding mechanism continuously winds the coil spring for the specified number of circles without interruption, and the multi-axis manipulator continuously installs baffles as products move through the workstation. This continuous automated process eliminates manual handling delays and significantly improves assembly efficiency compared to manual or semi-automatic methods.
3Manufacturing precision
If automated pre-winding and baffle installation is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The rotary table serves multiple functions: it transports safety belt retractors between stations, positions them for pre-winding, and facilitates their movement to the next processing stage. The winding mechanism not only winds the coil spring but also integrates the position detection mechanism for stop slot alignment. The multi-axis manipulator handles both baffle installation and product transfer. This multi-functionality reduces the number of separate devices needed, managing overall system complexity while maintaining high manufacturing precision.
4Manufacturing precision
If automated position detection and control is implemented, then manufacturing precision is improved, but use of energy increases
Solution Approach 1:
The winding mechanism operates in periodic cycles: the motor rotates the safety belt retractor at a controlled speed, the position detection mechanism continuously monitors for stop slot alignment, and upon detection, the motor stops precisely. This periodic operation with clear start-stop points based on sensor feedback ensures accurate stop slot positioning while minimizing energy consumption by avoiding continuous rotation. The system only consumes energy during active winding and positioning cycles, not continuously.
Data Source
AI summary
A safety belt retractor pre-winding and baffle installation device is provided, including a rotary table, which is provided with a loading station, a winding station, a stop slot positioning station, a baffle installation station, a NG discharging station, and a qualified product discharging station. The rotation shaft of the safety belt retractor is installed on the profiling fixture. After winding to the set number of turns through the winding mechanism, the position of the stop slot is found through the position detection mechanism, and finally the baffle is successfully installed by the multi-axis manipulator. The disclosure also uses the visual sensor to identify the type, control the number of turns of the servo motor in the pre-winding step, and check whether the torque fed back by the servo motor is within the set range, it can realize the processing of products with multiple specifications.