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In the automated assembly workshop for white bodies, as the demand for bolt connections continues to rise, challenges arise not only from the automatic feeding of large-diameter screws but also from complex interference at assembly stations, poor dimensional accuracy of the vehicle body, and limited workstation layouts. Faced with these diverse assembly challenges, what technical solutions does Danikor offer?

I. Complex Tightening Positions and Space Interference

The bolt assembly stations for white bodies are mainly distributed in the floor assembly, side assembly, engine compartment assembly, and the four doors and two covers. These stations involve numerous tightening positions with various types of interference, mainly categorized into no interference, multi-sided interference, and countersunk interference. Additionally, some stations have limited tightening space, with internal vehicle tightening involving tight front-to-back interference or closely spaced tightening holes.

Solution: Screw picking via vacuum suction. Depending on the interference distance, the corresponding avoidance stroke is selected. The screw is picked up by the vacuum suction principle of the screw picking tube and delivered into the tightening hole. Compared to magnetic picking, vacuum suction not only allows for full-process detection of screw positioning, saving on sensor detection devices, but also picks up impurities, ensuring the verticality and stability of screw adsorption. The filter's dirt condition can be visually checked for easy regular cleaning of the equipment.

Furthermore, different conveying methods are chosen based on the screw's length-to-diameter ratio characteristics, typically divided into picking modules and blow-and-suck modules. The picking module has a compact structure, making it easy to integrate into systems such as robotic arms, suitable for tightening in narrow spaces in any direction and meeting the needs of multi-axis synchronous tightening. This not only avoids uneven force distribution but also improves tightening efficiency.

II. Poor Hole Positioning Accuracy Due to Product Processing Factors

The welding workshop has an automation level of up to 90%, with a large and complex manufacturing system that can easily cause dimensional accuracy differences in the vehicle body. This leads to deviations in the through-holes and threaded holes during bolt assembly.

Traditional solutions usually involve using 2D camera positioning, which has spatial recognition angle deviations. Camera imaging not only affects the production cycle but also incurs high hardware costs. Alternatively, floating mechanisms can be used to move the sleeve and tightening tool, but this complicates the overall structure, increases costs, and adds to the robot's load requirements.

Solution: Floating technology, which allows the sleeve to have a certain degree of float within a range and can adjust the floating distance according to changes in the avoidance length. Compared to other methods, sleeve floating technology is simpler and more efficient.

Additionally, considering the need for floating technology due to poor vehicle positioning accuracy, even interference-free stations are recommended to use blow-and-suck modules.

III. Workstation Layout Flexibility Challenges

In the automated assembly line for white bodies, assembly equipment is mainly distributed on both sides of the vehicle body and works in conjunction with six-axis robots to complete tightening actions. Therefore, to ensure production cycle consistency, the equipment layout requirements are high.

Solution: When using picking vacuum modules, screws are blown to the receiver, shortening the picking distance and facilitating layout. The screw feeder is independently located outside the fence, making material addition more convenient and easier to maintain. When using vacuum modules, screws are directly blown to the nozzle through the feeding tube. The feeding tube process is self-made, wear-resistant, and flexible, meeting certain bending ranges and supporting long-distance conveyance, thus flexibly adapting to on-site workstation layouts.