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Robotic piping
Figure 1 tire mold and fixture 
Figure 2 Roller system Conclusion
Robot rolling process
The door is the exterior assembly of the car body. After assembly, it is required to maintain a uniform door gap and good shape difference with the surrounding parts. The edging generally means that when two sheet metal parts are assembled (mainly the inner and outer plates of the door cover type opening and closing member), the flange of one part is wrapped around the other part. The door trim is a special process in the manufacture of the door assembly. After the edging, the surface of the assembly is required to be smooth and flat, without external defects such as crushing, convex and concave, and to ensure the accurate and stable shape of the door and the overall size along the circumference. Therefore, the requirements for equipment and tooling are very high, and the requirements for the outer parts of the door and the inner panel are also high, so that a high-quality door assembly can be manufactured.
The main types of edging are: hand-made gold edging; tires + hand-made gold edging; tires + hand-held edging machine edge; mechanical automatic edging or door edging production line. The first three are used for single or small batch production, and the fourth is for mass production.
The mechanical automatic wrapping method is as follows:
(1) Mold edging is composed of a hydraulic press or a press and a edging die. The hydraulic press is universal and the edging die is dedicated. Through the one-step forming of the hydraulic press, the 45° and 90° edging is completed by the mold, and the mold edging is widely used in some automobile factories in Japan. Most of the commercial vehicles and passenger cars of Jianghuai Automobile Co., Ltd. rely on dedicated The edging die completes the edging. The advantage is that the land occupation is small, the replacement variety is convenient, and it is suitable for multi-variety production.
(2) Hydraulic automatic edge wrapping machine This mechanism is driven by a hydraulic cylinder through a linkage mechanism to complete the 45° and 90° edge. There are two types of such hemming machines. One is to divide the 45° and 90° hemming into two or three sets of hemming machines, which are connected by a transmission device or a robot. Currently, Shenlong Automobile Co. is using this method. The other is to combine the 45° and 90° edging on a set of edging machine, and complete the door edging at one time. Both the Dongfeng Motor Company Light Vehicle Factory and the Nanjing Yuejin Automobile Factory are used.
(3) Motor-type automatic edge wrapping machine This mechanism is driven by a motor through a reducer and a linkage mechanism to drive 45° and 90° bezel inserts, and a vertical frame to install a cylinder type pressing device. Once the 45° and 90° edging are completed, it is also possible to only press or only 45°. The mechanism is easy to adjust, the quality of the edging is good, the working condition is stable, but the cost is high. Jianghuai Automobile Company light truck factory is used.
(4) Robot Rolling The robot arm drives the roller to press the hemming roller and wrap the other part to achieve assembly. The wrapping process is typically completed in two or three stages.
If the mechanical automatic edge wrapping machine connects the parts on the line, glue, edging, and out of the parts through the transmission device and the robot, the door edge production line or the fully automatic production line can be formed. Depending on the manufacturing situation, the wire can be long or short. Although there are many types of mechanical automatic edge wrapping machines, the working procedures are basically the same, that is, the parts are positioned → compacted → 45° edged → 90° edged.
The edging usually has two implementations of crimping and piping. The crimping is a traditional mold edging, using a press or some cylinder-driven compact to compress the hem and wrapping the other part for assembly purposes. The piping is rolled and wrapped around another part using a roller (usually driven by a robotic arm) to achieve assembly. By robot rolling, not only can the appearance quality of the part (edge ​​portion) be improved, but also the outer surface can be smoothed and smoothed without defects such as indentation and dent, and the overall strength and rigidity can be increased while ensuring a small working area. Flexible manufacturing, shortened commissioning cycle, small one-time investment in equipment, and low maintenance and repair costs in the later period. Robot hemming technology is widely used in the four-door and two-cover of the car body, the fender, the sunroof, the C-pillar and the wheel cover. The door and window frame of a certain A-class car of Jianghuai Automobile adopts the robot piping.
1. Robot piping system
The robotic piping system mainly consists of three parts: the piping fixture system, the roller system, the robot and its control system.
(1) Rolling fixture system The piping fixture system is a central area for flexible production using robotic piping technology. The system consists of a rolled tire mold and a positioning clamp (see Figure 1).
When using a robot for piping, there are several ways to position and clamp the inner panel:
1) Clamp clamping on the tire mold: directly clamp the upper and lower plates with the clamp on the tire mold.
2) External cylinder clamping: The external cylinder drives the clamping unit to press the inner plate of the workpiece.
3) Upper tire mold clamping: The upper tire mold is pressed against the inner plate of the workpiece, and the upper mold clamps the upper tire mold.
4) Swing arm clamp clamping: The swing arm drives the clamp to clamp the upper plate and the lower plate.
5) Positioning gripper clamping: Use the positioning gripper to press the inner panel of the workpiece.
6) Roller clamping: The two rollers press the workpiece and roll simultaneously.
(2) Roller system The roller system is the part responsible for the folding and rolling, which is composed of rollers of various shapes (see Figure 2). Due to the characteristics of the piping technology itself, the piping process is generally completed in 2 to 4 times. Therefore, the rollers are usually designed as 90° wheels, 60° wheels, 30° wheels, forming wheels and special special wheels. According to the product structure and the production cycle, Jianghuai Automobile Co., Ltd. completes the 90° piping and generally divides into 45° edging and 90° edging two stages or 30° edging, 60° edging and 90° edging. . Roller pressing force generally has three adjustment methods, spring plate adjustment, cylinder buffer adjustment and spring adjustment.
(3) Robot and its control system The robot control system is mainly used to control the movement track of the wheel and the communication between the robot and other related systems. The hemming process is performed by the robot grasping the roller frame to perform the piping procedure, and the entire door is rolled in sequence.
2. Robot edge defect
Factors affecting the hemming process include the material of the inner and outer panels and the pre-formed, edging contact surface conditions, the edging tool and the mold and the edge defects. Rolling is a complex sheet forming process that differs from simple sheet bending and is often accompanied by forming defects such as indentation and expansion, bounce and deformation, and wrinkling. As the final process of the assembly of the four-door and two-cover assembly, the quality of the edging, that is, the dimensional accuracy and the surface quality, affects the important performances such as the sealing performance and appearance quality of the vehicle assembly.
Common type of edge defect: the end position of the edge to be folded is inside/outside the ideal position; the end position of the shape defect edge is below/above the predetermined edge line position.
In order to obtain good body assembly accuracy and appearance quality, the selection of the door trimming process of the door is particularly important.
There are three main factors affecting the quality of the piping process:
(1) Geometric characteristics of the part itself The high degree of flanging of the stamping part is easy to wrinkle, and the low height of the flanging will result in the inability to meet the product design requirements.
(2) the reasonableness of piping trim robot programming and parameter setting of stress can cause cracking of piping components, piping pressure will result in a small edging too loose, wrinkled trim. Unevenness of the rolling edge pressure can also cause bubbles to appear after the sealant is applied and baked, which affects the appearance quality of the rolled parts. The high rolling speed causes wrinkles in the rolling parts of the part, and the slow rolling speed increases the manufacturing time of the parts, thereby increasing the manufacturing cost.
(3) Tire mold design and positioning accuracy The design of the tire mold affects the stability of the piping pressure. The surface quality of the tire mold and the roller directly affects the surface quality of the outer panel of the rolling element. The accuracy of the positioning mechanism directly affects the internal and external plates of the front part of the edging. Relationship, which affects the quality of the final edge.