In the flexible multi-tray manufacturing system for automotive parts production lines, pallets must carry components of varying specifications, such as engine blocks, chassis brackets, and body panels, and must precisely stop at processing stations like milling, drilling, and welding. This requires positioning technology that can adapt to the flexible demands of multi-category pallets while meeting the high-precision standards of automotive parts processing. Photoelectric sensor positioning is a widely used foundational technology in this system. This technology employs photoelectric sensors placed on either side of the processing station or at the end of the conveyor track, using the principle of light obstruction to identify the pallet's edges or pre-set positioning bumps. When a pallet carrying automotive parts approaches the processing station along the track, it blocks the light emitted by the sensor. The system then determines the pallet's real-time position based on the timing of the signal triggers, and then controls the conveyor mechanism to gradually slow down until it stops, achieving initial positioning. This technology's advantage lies in the lack of hardware modifications required for different automotive parts pallet sizes. Simply fine-tuning the sensor's mounting height or signal response threshold based on the pallet's size allows for rapid switching between engine component pallets and small electronic component pallets. This meets the core requirements of flexible multi-tray manufacturing systems for automotive parts production lines, requiring a wide variety of products and quick changeovers. Its simple structure and rapid response also enable it to adapt to the continuous production pace of the production line, avoiding the impact of positioning delays on processing efficiency.
Laser positioning technology provides higher-precision docking for flexible multi-tray manufacturing systems in automotive parts production lines, making it particularly suitable for the production of components with demanding machining precision, such as engine cylinder heads and transmission housings. This technology utilizes a laser ranging module installed above the processing station to emit a laser beam toward a dedicated reflective marker on the pallet's surface or the component's own reference surface. Leveraging the laser's high directivity and ranging accuracy, the system captures in real time the relative positional deviation between the pallet and the processing equipment's spindle and fixture. The system converts this deviation data into adjustment commands, controlling the conveyor mechanism's servo motor to fine-tune the pallet's lateral position or rotation angle, ensuring perfect alignment between the component's positioning holes and reference surfaces on the pallet and the machining fixture. While automotive parts production lines are often subject to environmental interference such as cutting fluid splash and metal dust, laser positioning is unaffected by these factors and maintains consistent accuracy, preventing parts from being scrapped due to positioning errors. Furthermore, its non-contact measurement method does not scratch the pallet or part surface, making it suitable for processing a variety of automotive parts materials, including aluminum alloy and high-strength steel, further enhancing the reliability of flexible multi-tray manufacturing systems for automotive parts production lines.
Vision positioning technology, with its "intelligent recognition" feature, has become a key technology for flexible multi-tray manufacturing systems in automotive parts production lines to handle irregular-shaped part pallets. When producing irregular-shaped parts such as door hinges and suspension arms, pallets often lack fixed positioning points, and the part placement must be precisely aligned with the processing sequence. In this case, vision positioning employs industrial cameras deployed above the processing station and, combined with image recognition algorithms, captures and analyzes the pallet's overall contours and part features (such as bolt holes and contour edges) in real time. The system compares the captured image with a pre-set standard model (including pallet specifications and part placement guidelines), accurately calculating the translational and angular deviations between the pallet's current position and its ideal resting position. It then actuates auxiliary positioning devices (such as side thrust cylinders and rotating platforms) to fine-tune the pallet, ensuring that the parts precisely fit into the positioning slots of the processing fixture. This technology eliminates the need for dedicated positioning hardware for each custom-shaped pallet. Simply updating the corresponding image recognition model within the system allows for rapid adaptation to new part specifications, significantly reducing changeover time for flexible multi-tray manufacturing systems on automotive parts production lines. It also addresses issues such as minor pallet deformation and minor part placement misalignment, improving the system's fault tolerance for production anomalies.
Magnetic or optical grating positioning technology plays a crucial role in long-distance conveying scenarios within flexible multi-tray manufacturing systems on automotive parts production lines. For example, when pallets are transported from storage to processing locations via multiple sections of track, precise tracking is crucial throughout the process to prevent positioning errors caused by track splicing errors and accumulated errors in the conveyor mechanism. Magnetic grating positioning employs a magnetic scale installed alongside the conveyor track and a magnetic head mounted on the bottom of the pallet. This head reads the magnetic signals from the scale in real time as the pallet moves, generating absolute position data. Optical grating positioning utilizes the moiré pattern principle of optical gratings, using both scales and readheads on both sides of the track, for continuous position detection. These two technologies provide the system with continuous position feedback throughout the entire process, ensuring the pallet remains within a controllable range during long-distance movement. When approaching the processing position, a secondary precise calibration can be performed in conjunction with pre-processed optical or laser positioning, creating a "full-range tracking + end-of-line fine-tuning" positioning mode. This mode not only adapts to the multi-station and cross-area conveying requirements of automotive parts production lines, but also resists vibration interference from the production line, ensuring a stable stop after high-speed conveyance. This provides continuous position assurance for the efficient operation of flexible multi-tray manufacturing systems in automotive parts production lines.
In practice, flexible multi-tray manufacturing systems in automotive parts production lines typically employ a combination of multiple positioning technologies to achieve a balance between flexibility and precision. For example, photoelectric sensing is first used to achieve coarse positioning of the pallet, quickly bringing it into the processing range. Laser or visual positioning is then used for fine-tuning to correct minor deviations. If the pallet requires multi-angle adjustment, a servo motor-driven rotation mechanism is used to achieve precise alignment based on the positioning data. Furthermore, positioning technology must be deeply integrated with the system's production scheduling logic. When the scheduling system issues a production instruction for a certain type of automotive part, the corresponding pallet specifications and positioning parameters are sent to the positioning module in advance. The positioning module pre-loads the parameters and quickly initiates the positioning process upon arrival, avoiding delays in parameter switching that could affect production flow. This multi-technology collaboration and system linkage model not only meets the automotive parts production line's demand for flexible processing of a wide variety of parts, but also ensures the precise positioning of the pallet at the processing location. This provides reliable support for the high-quality and efficient production of automotive parts, fully leveraging the core advantages of the flexible multi-tray manufacturing system of the automotive parts production line.
