CN113741573B - Electric control torque system - Google Patents
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D17/00—Control of torque; Control of mechanical power
- G05D17/02—Control of torque; Control of mechanical power characterised by the use of electric means
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Abstract
The invention discloses an electric control torque system. The system comprises a server, a client and a system server, wherein the server is used for acquiring process card information and sending the process card information to the client; the scanning equipment is used for scanning the VIN code of the vehicle and sending the part model number to the client; the client is used for determining a tightening program according to the VIN code of the vehicle, the part model and the process card information and sending the tightening program to the controller; the tightening device is used for judging whether the tightening operation is successful or not according to the operation data; a controller for sending control instructions to the power tool according to the configured tightening program; the system is used for acquiring operation data and sending the operation data to a client; and the electric tool is used for performing tightening operation according to the control command. The invention realizes material mistake proofing, tightening quality control and tracing, realizes automatic detection and judgment of tightening torque in the part assembling process, and finally records assembling process data for data tracing after problems appear in the subsequent testing process.
Description
Technical Field
The invention belongs to the technical field of automobile assembly, and particularly relates to an electric control torque system.
Background
The quality control in the process of assembling the trial-made sample car is crucial to the quality control of the whole sample car, and the process control is combined with the inspection after the sample car is assembled, so that the quality control before the trial-made sample car is delivered is realized.
Patent CN104571037A discloses a key torque assembly system, which implements torque tightening execution, control and tracing through an MES torque management module, a sweep vehicle VIN code is compared with a scheduling queue in an MES production system, and when the comparison is consistent, operation is performed, a corresponding vehicle MTOC code is extracted from the MES production system according to the vehicle VIN code, part configuration and key torque configuration of the vehicle are judged according to the vehicle MTOC code, and a production instruction is made, a worker selects a part and tightens a torque according to the production instruction for assembly, a tightening torque value and an angle are collected and compared with a preset value for confirmation, if the parts and the key torque configuration are consistent, the fastening point is judged to be OK, and data is stored for tracing; and if the VIN information is inconsistent with the VIN information, prompting that the NG needs to be repaired, and prompting the NG information when the VIN code information of the vehicle is scanned every time before the repairing is finished. The system can meet the assembly requirement of key torque points in automobile batch production, but does not support off-line work and data breakpoint continuous transmission, can only be operated on line, cannot improve efficiency, only supports the access of tools of tool manufacturers and tools of the same brand, and cannot be used for various tools in general.
Disclosure of Invention
The invention aims to solve the defects of the background technology and provide an electric control torque system.
The technical scheme adopted by the invention is as follows: an electric control torque system comprises
The server is used for acquiring the process card information and sending the process card information to the client;
the scanning equipment is used for scanning the VIN code of the vehicle and sending the part model number to the client;
the client is used for determining a tightening program according to the VIN code of the vehicle, the part model and the process card information and sending the tightening program to the controller; the tightening device is used for judging whether the tightening operation is successful or not according to the operation data;
a controller for sending control instructions to the power tool according to the configured tightening program; the system is used for acquiring operation data and sending the operation data to a client;
and the electric tool is used for performing tightening operation according to the control command.
Further, the process card information comprises vehicle configuration, codes, VIN codes, working procedures, part information, electric tool information, tightening data and operation requirements.
Further, the process of judging whether the tightening operation is successful or not according to the operation data includes the steps of:
step 1, collecting a first tightening torque of the current tightening operation, calculating a first difference value between the first tightening torque and a first set value, and entering step 2
Step 2, if the absolute value of the first difference is smaller than or equal to a first threshold, judging that the screwing operation is successful; if the absolute value of the first difference is larger than the first threshold, acquiring current tightening data, judging whether the part is qualified for tightening according to the current tightening data, and entering step 3;
step 3, if the product is qualified, judging that the screwing operation is successful; if not, judging the number of times of failure, and entering the step 4;
step 4, if the unqualified times are less than or equal to the set times, controlling the electric tool to perform loosening and re-screwing operations, and returning to the step 1; if the unqualified times are greater than the set times, entering the step 5;
step 5, collecting unqualified tightening data for multiple times, determining a second set value according to the unqualified tightening data, controlling the electric tool to perform loosening and tightening operations again, collecting a second tightening torque, calculating a second difference value between the second tightening torque and the second set value, and entering step 6;
step 6, if the absolute value of the second difference value is less than or equal to a second threshold value, judging that the screwing operation is successful; and if the absolute value of the second difference is larger than the second threshold, judging that the screwing operation fails, and replacing the part to perform the screwing operation again.
Further, the tightening data includes tightening torque, tightening angle, tightening curve.
Further, the set number of times is 2-4 times.
Furthermore, the client comprises a plurality of tightening programs, and each tightening program corresponds to different tightening data.
Further, the server acquires the process card information through a web end and/or a TIMS system.
Further, still include the tool bogie, scanning equipment, customer end, controller and electric tool all integrate on the tool bogie.
Furthermore, the client is provided with a storage module for storing the process card information and the operation data.
Furthermore, the client is provided with an alarm module, and when the client judges that the part model is inconsistent with the part information in the process card information, the client alarms through the alarm module.
The invention has the beneficial effects that:
1. the system can realize material mistake proofing, screw up quality control and trace back. The early design of the sample car assembling process, the automatic detection and judgment of the tightening torque in the part assembling process are realized, and the assembling process data are finally recorded for data tracing after problems occur in the subsequent testing process.
2. The system supports offline work and data breakpoint continuous transmission, all data can be separated from the server to perform offline work after being synchronized to the client, the assembled data is cached locally, and when the server is online, the data can be automatically uploaded to the server.
3. The system is compatible with mainstream tightening tools in the market, and the system does not need to be adapted and developed again.
4. The system has the advantages of timely analyzing the tightening data, accumulating the process data, verifying the tightening process and the like in the assembling process, and can judge whether the operation is successful according to the collected data.
Drawings
FIG. 1 is a schematic diagram of the system of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made with reference to the accompanying drawings. It should be noted that the description of the embodiments is provided to help understanding of the present invention, but the present invention is not limited thereto. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
As shown in fig. 1, the present invention provides an electric control torque system, which comprises a server, a client, a controller, an electric tool, a tool trolley, and the like, wherein the functions of the components are as follows:
a Web management platform is released on a server, and after a user logs in the system, basic information including information of the user, a controller, tools, processes and the like can be maintained; meanwhile, receiving tightening data, curves and assembling process data, and storing the tightening data, the curves and the assembling process data in a centralized manner for tracing analysis of statistical reports; and acquiring the process card information and sending the process card information to the client. And the TIMS transmits the vehicle type configuration information to the server.
The client supports multiple login modes (user name, password and card swiping), displays information such as the current product model, working procedure, parts and tools, visually guides, prompts and prevents errors after assembly, and collects tightening data, curves and part information; determining a tightening program according to the VIN code of the vehicle, the part model and the process card information and sending the tightening program to a controller; for judging whether the tightening operation is successful or not according to the operation data. And the client is internally provided with a storage module for storing the process card information and the operation data.
An alarm module is arranged in the client, and client software establishes a connection with vehicle type configuration information by scanning vehicle VIN codes and part information, locks information in a process card and calls parts; if the part information is wrong, alarming is carried out; meanwhile, identifying a screwing program in the process card, and automatically matching a screwing tool; comparing the collected tightening data with preset tightening parameters, and judging whether the tightening operation is successful; when the screwing operation is failed, a corresponding loosening part is formulated to carry out second screwing or a new part is replaced to carry out a second screwing process on the loosening part, and a second screwing torque set value is set based on the correspondingly collected screwing data.
The scanning equipment is used for scanning the VIN code and the part model of the vehicle and sending the VIN code and the part model to the client;
a controller for sending control instructions to the power tool according to the configured tightening program; and the operation data acquisition module is used for acquiring operation data and sending the operation data to the client.
The electric tool is used for performing screwing operation according to a control command, comprises commercially available mainstream brand screwing tool access systems such as Atlas, desouter, apex, bosch, rexroth, ingersoll and Cleco, and does not need to be adapted and developed again.
The scanning device, the client, the controller and the electric tool are all integrated on the tool trolley. The tool trolley comprises a tool rack, a scalable power supply scroll, a storage drawer, an Uninterruptible Power Supply (UPS), a scanning gun, a streak-free universal caster with a brake, a side-mounted tool rack, a pre-mounted power socket, an accessory port and an industrial router. An industrial all-in-one machine, a card reader, a tightening controller and a tightening tool are integrated.
The client is provided with various kinds of software for configuring the client into corresponding equipment, for example, tightening program editing software is set for tightening program editing and is issued to the controller and the electric tool, and tightening data acquisition software is set for acquiring the tightening torque/Nm, the tightening angle/degree and the tightening curve of the part; the web-side customization software is used to assemble all the process information designs involved.
The working process of the torque system comprises the following steps:
1. the upstream system or the local (and the web end and/or the TIMS system) imports the process card (operation task and operation data) to the server.
2. The client rapidly calls the part in a searching and scanning mode according to the tightening program editing software, and an alarm is given if part information errors occur; and meanwhile, a screwing program in the process card is identified, and a screwing tool is automatically matched, and an alarm is given if the information of the screwing tool is wrong.
3. The controller controls the electric tool to perform tightening operation according to a tightening torque set value set by the process card, a tightening torque program background exists in a basic database, and after all tightening programs are initialized, the tightening programs needing to be set are newly added subsequently and stored in the basic database.
4. The client collects and stores a first tightening torque of the current tightening operation, and compares the first tightening torque with a first set value (calibration value);
when the absolute value of the difference between the first tightening torque and the first set value is smaller than or equal to a first threshold value A1, judging that the first tightening operation is successful, outputting a tightening result report, and sending an operation ending instruction;
when the absolute value of the difference between the first tightening torque and the first set value is greater than a first threshold value A1, judging that the current tightening operation fails, reporting an error by the system, executing step 55, and analyzing the working condition of the part according to a first tightening torque/Nm, a tightening angle/DEG and a tightening curve in the collected tightening data;
and when the quality of the part is judged to be still in the qualified range, judging that the bolt is qualified to be screwed by software, and calculating whether all the bolts of the part are completely screwed.
If so, the next part of the process is automatically selected and a tightening command is sent to perform step 4. When all parts are assembled, the system automatically judges that the process is finished and automatically enters the next process. When all the procedures of the vehicle in the process area are finished, the system automatically judges that the state of the vehicle type in the current process area is finished, and calculates the consumption number of parts.
If not, the system automatically locates the next bolt, automatically identifies the tool according to preset process data, issues a tightening instruction, and executes the step 4.
And if the part is not screwed down within the qualified range, the system sends a back loosening instruction, the part is checked and disassembled, after the part is to be disassembled, the screwing instruction is sent again, and one bolt is allowed to be screwed down at most twice. If the screw is not qualified for the second time (the screw is judged to be the same as the first time), the step 6 is executed after the part is loosened;
and when the part is judged to have larger deformation or quality problems, sending a part replacing and re-screwing instruction, and executing the step 7.
6. The method comprises the steps that according to a tightening torque/Nm, a tightening angle/° and a tightening curve which are collected for multiple times, a tightening control method is used according to torque and angle, the tightening control method is combined with the tightening curve, the reason of unqualified tightening is analyzed, the torque and the angle are too large or too small, according to the corresponding relation of the torque and the angle, the material of a part and the connection characteristics of the part (such as hard connection), a system is matched with a preset data model (the data model is divided into a system built-in mode and a user-defined mode, the system built-in mode is that a model which is commonly used in the industry is preset in the system, and a user can conveniently and quickly select the model, the model comprises a plurality of necessary input conditions, such as bolt grade, thread size, target torque, torque upper and lower limits, final torque, target angle upper and lower limits, final angle, soft and hard connection and the like, after relevant input variables are associated, the second tightening torque is calculated according to preset calculation logic, the second tightening torque is output to designated variables, simple bar code judgment and calculation logic comprises can be used for visualization programming, and a proper set value is calculated; executing the tightening operation again, collecting and storing a second tightening torque of the tightening operation, and comparing the second tightening torque with a second set value;
when the absolute value of the difference between the second tightening torque and the second set value is smaller than or equal to a second threshold value A2, judging that the tightening operation is successful, outputting a tightening result report, and sending an operation ending instruction, wherein A2 may be equal to or not equal to A1;
when the absolute value of the difference between the second tightening torque and the second set value is greater than a second threshold value A2, judging that the second tightening operation fails, and reporting an error by the system; a replacement part retightening command is issued and step 7 is performed.
The determination of the second set value can be customized by the system. If for a bolt, first a suitable target torque is determined according to ISO 898/1 standard, for example, the thread is M8, the bolt rating is 8.8, the recommended torque is 24Nm, and a range is set, for example, ± 10% (which may be set manually), then the recommended range of this torque is 21.6Nm-26.4Nm. And then combining a tightening curve, finding out the torque of a joint point (the angle change is close to 0) of the bolt and the surface of the part according to the tightening angle, and multiplying the torque by a correlation coefficient, such as 1.1, according to the soft and hard connection characteristics to obtain a second set value. If the torque of the joint point is not found, the torque target torque is set to be smaller, and the torque target torque can be adjusted (set) on the basis of the original target torque and then tightened again.
7. Re-tightening operation of replacing parts is executed, and the re-tightening operation is executed according to a first tightening torque set value set by the process card; and re-executing the steps 4-7 until the system sends an operation ending instruction.
According to the collected first tightening torque/Nm, tightening angle/DEG and tightening curve, analyzing the working condition of the part, specifically: when the actual tightening value of the tool exceeds the set value range for more than 2 times (or 3 times or four times), judging that the part has larger deformation or quality problem; and when the actual tightening value of the tool exceeds the set value range within 2 times, judging that the quality of the part is still within a qualified range.
The invention realizes the preset tightening program of the webpage end of the controller and meets the setting requirement of the tightening program of more than or equal to 300 types/vehicle types. The process design, the process execution and the process instant change of the 1000+ assembly process of the single-vehicle type are realized, and the internal information change of the process card in a single process can be realized: when the internal information of a certain locally imported process card contains any one of part information, equipment/tool information, moment information, operation description, picture screenshot and the like, and the like is locally changed, the moment system at the server can realize timely change, the response time of each change does not exceed 30 seconds, and the change of the part information, the equipment/tool information and the moment information is synchronously updated to a moment tightening result report. The process card sequence change of different procedures can be realized: the server-side torque system can realize the sequential adjustment among process cards in any different procedures under the condition that the internal information (part information, equipment/tool information, torque information, operation description, picture screenshot and the like) of the process cards is not changed, and the response time of each change is not more than 30 seconds. The tightening curves may exhibit different forms of torque-time, angle-time, torque-angle, and the like. The curve can be locally amplified for more detailed analysis of the tightening process; a reference curve may be set and may be displayed with 1000 curves superimposed.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are also within the scope of the present invention. Those not described in detail in this specification are well within the skill of the art.
Claims (8)
1. An electronic control torque system, characterized in that: comprises that
The server is used for acquiring the process card information and sending the process card information to the client; the process card information comprises vehicle configuration, codes, VIN codes, operation procedures, part information, electric tool information, tightening data and operation requirements;
the scanning equipment is used for scanning the VIN code and the part model of the vehicle and sending the VIN code and the part model to the client;
the client is used for determining a tightening program according to the VIN code of the vehicle, the part model and the process card information and sending the tightening program to the controller; the tightening device is used for judging whether the tightening operation is successful or not according to the operation data; the system is used for separating from the server to perform off-line work, the assembly data is cached locally, and when the server is on line, the operation data is automatically uploaded to the server;
a controller for sending control instructions to the power tool according to the configured tightening program; the system is used for acquiring operation data and sending the operation data to a client;
the electric tool is used for performing tightening operation according to the control command;
the process of judging whether the tightening operation is successful according to the operation data comprises the following steps:
step 1, collecting a first tightening torque of the current tightening operation, calculating a first difference value between the first tightening torque and a first set value, and entering step 2
Step 2, if the absolute value of the first difference is smaller than or equal to a first threshold, judging that the screwing operation is successful; if the absolute value of the first difference is larger than a first threshold, acquiring current tightening data, judging whether the part is qualified for tightening according to the current tightening data, and entering step 3;
step 3, if the product is qualified, judging that the screwing operation is successful; if not, judging the number of times of failure, and entering the step 4;
step 4, if the unqualified times are less than or equal to the set times, controlling the electric tool to perform loosening and re-screwing operations, and returning to the step 1; if the unqualified times are greater than the set times, entering the step 5;
step 5, collecting unqualified tightening data for many times, determining a second set value according to the unqualified tightening data, controlling the electric tool to perform loosening and tightening operation again, collecting a second tightening torque, calculating a second difference value between the second tightening torque and the second set value, and entering step 6;
step 6, if the absolute value of the second difference is less than or equal to a second threshold, judging that the screwing operation is successful; if the absolute value of the second difference is larger than the second threshold, the screwing operation is judged to be failed, and the part is replaced to perform the screwing operation again.
2. The electric control torque system according to claim 1, characterized in that: the tightening data includes a tightening torque, a tightening angle, and a tightening curve.
3. The electric control torque system according to claim 1, characterized in that: the set times are 2-4 times.
4. The electric control torque system according to claim 1, characterized in that: the client comprises a plurality of tightening programs, and each tightening program corresponds to different tightening data.
5. The electric control torque system according to claim 1, characterized in that: and the server acquires the process card information through a web end and/or a TIMS system.
6. The electric control torque system according to claim 1, characterized in that: the scanning equipment, the client, the controller and the electric tool are all integrated on the tool trolley.
7. The electric control torque system according to claim 1, characterized in that: the client is provided with a storage module for storing the process card information and the operation data.
8. The electric control torque system according to claim 1, characterized in that: the client side is provided with an alarm module, and the client side alarms through the alarm module when judging that the part model is inconsistent with the part information in the process card information.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202110959597.2A CN113741573B (en) | 2021-08-20 | 2021-08-20 | Electric control torque system |
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| CN202110959597.2A CN113741573B (en) | 2021-08-20 | 2021-08-20 | Electric control torque system |
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| CN113741573A CN113741573A (en) | 2021-12-03 |
| CN113741573B true CN113741573B (en) | 2022-11-29 |
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Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102354210B (en) * | 2011-09-07 | 2012-09-05 | 华中科技大学 | Quality early warning system and method for automobile assembling workshop |
| CN102622002B (en) * | 2012-04-01 | 2014-04-02 | 广州信邦汽车装备制造有限公司 | Wireless intelligent torque management system |
| CN104571037A (en) * | 2014-12-30 | 2015-04-29 | 广州汽车集团乘用车有限公司 | Key torque assembling system |
| CN105033921B (en) * | 2015-07-06 | 2017-09-29 | 中国第一汽车股份有限公司 | The method for preventing bolt leakage from tightening |
| CN114423568A (en) * | 2019-07-23 | 2022-04-29 | 米沃奇电动工具公司 | Power tool including machine learning block for controlling installation of fasteners |
| CN112051815B (en) * | 2020-08-31 | 2021-09-28 | 安徽江淮汽车集团股份有限公司 | Assembly line tightening operation monitoring method, device, equipment and storage medium |
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