Research On Key Technology Of Padlock Automatic Assembly System

Padlock is a commonly used security products in people’s daily life.It has been favored by customers for its low price,simple and convenient way of use,wide range of application and so on.Due to the low price and low profit,padlocks have been mainly assembled manually by workers.This assembly method has the disadvantages of heavy workload,high cost,low assembly efficiency and high failure rate.With the continuous increase of labor cost in recent years,the outdated assembly production method of padlock hand assembly will inevitably be eliminated and replaced by automatic assembly,which can effectively improve the efficiency of padlock assembly to meet the growing demand of padlock market.that’s why this dissertation presents the project of padlock automatic assembly system.Through thorough and meticulous research on the process of padlock assembly,according to its own structure and characteristics of the padlock,the assembly strategy and steps of the padlock assembly are analyzed and studied,and a complete set of padlock automated assembly system is independently designed and developed.This dissertation mainly solves and focus on the following key technical difficulties in the automated assembly system:1.Analyze the padlock manual assembly steps,combined with the actual operation and business requirements,to determine the form of automated assembly.And make preliminary planning on the types of automated assembly,steps,delivery methods of fixtures,and work stations.2.Work station design: In order to maximize the degree of automation,some key workstations were intensively studied and designed,accurate and efficient assembly structure was obtained,and the movement structure of each station was optimized.3.Because the depth of the key tooth and the sorting are both pre-given by the machine in advance and can’t be predicted,we propose a method using a machine vision inspection system to measure the depth of the key tooth,through a series of image acquisition,processing and finally measured the depth of the key tooth flower,and the data passed to the host computer;4.Control system design: The padlock automatic assembly system uses the PLC as the main controller to control the entire system,so that the servo motor,cylinder,solenoid valve and other components and visual inspection devices to work together to coordinate.5.Prototype debugging: After the basic design is completed and the installation is completed,the prototype is debugged and run.After the prototype runs smoothly,the overall stability of the prototype is analyzed and the reasons that affect the reliability of the padlock automatic assembly system are summarized.After completing the design,manufacture,installation and commissioning of all padlock automation systems,through the various mechanical institutions,control systems and visual inspection systems,etc.between the mutual cooperation,the ultimate goal of smooth operation of equipment.Padlock daily average assembly volume reached about 2,700,the failure rate of only 0.58%,compared with manual assembly of workers to enhance the economic efficiency of 75.84%,to meet business requirements and expectations.