The integrated solution of intelligent electric screwdrivers and automated production lines

From the perspective of communication connection,the intelligent electric screwdriver needs to establish a stable and effective communication link with the control system of the automated production line.Common communication protocols such as RS232/485 Modbus RTU are widely used.They can ensure stable data transmission between devices and achieve instruction issuance and status feedback.Some smart electric screwdrivers also support non-standard customized TCP/IP network ports,creating conditions for remote monitoring and management.For instance,the Jianfeng mechanical smart electric screwdriver DP-FXL-001,due to its support for such communication protocols,can be seamlessly integrated with various industrial control systems,facilitating the construction of smart factories.On the actual automated production line of electronic equipment,through RS485 communication,the production line controller can accurately control the start,stop,adjustment of torque and speed of the intelligent electric screwdriver,and at the same time obtain the working status information of the electric screwdriver in real time,such as whether the tightening is completed and whether there are any fault alarms.

In terms of system control integration,the intelligent electric screwdriver should be incorporated into the overall control logic of the automated production line.The production line is usually controlled by a PLC(Programmable Logic Controller)or an industrial computer as the main control core,which needs to be programmed to make the intelligent electric screwdriver operate in an orderly manner according to the production process.For instance,in the 3C product assembly production line,when the products reach the tightening station along the conveyor belt,the PLC sends a start signal to the intelligent electric screwdriver according to the preset program,and the electric screwdriver then performs the tightening operation.After completion,the electric screwdriver feeds back the tightening result signal to the PLC,which then controls the product to flow to the next station.During this process,the working mode of the intelligent electric screwdriver(such as single-stage and multi-stage tightening modes)and tightening parameters(torque,rotational speed,number of turns,etc.)can all be uniformly set and managed in the production line control system to ensure the coordination and consistency of tightening operations at each workstation.

The process adaptation and integration need to optimize the functions of the intelligent electric screwdriver according to the screw tightening process requirements of different products.The intelligent electric screwdriver has multi-segment programming capabilities and can set parameters for the thread insertion stage,quick screw insertion stage and tightening stage according to different specifications of screws and tightening processes.For instance,in the assembly of automotive parts,due to the diverse specifications and materials of screws,the requirements for tightening accuracy are very high.The intelligent electric screwdriver can be programmed to use low torque and low speed when inserting threads to prevent damage to the threads.Increase the rotational speed during the rapid screwing stage to enhance efficiency.During the tightening stage,accurately control the torque to ensure the connection strength.Meanwhile,by leveraging the torque and Angle monitoring functions of the intelligent electric screwdriver,in conjunction with the production line's visual inspection system,it can effectively identify adverse conditions such as missed driving,misalignment,and floating nails,ensuring assembly quality.

Data interaction and integration are the key to achieving digital management of the production process.The intelligent electric screwdriver generates a large amount of data during the tightening process,such as real-time torque value,number of turns,tightening time,peak torque,etc.These data can be uploaded to the Manufacturing Execution System(MES)in real time,providing a basis for production management.On the one hand,data analysis can optimize the tightening process.If it is found that the tightening torque of a certain batch of products fluctuates greatly,the parameters of the electric screwdriver can be adjusted in time or the quality of the screws and workpieces can be checked.On the other hand,the data traceability function can assist in quality control.When quality issues occur with the products,the problems in the production process can be quickly located based on the tightening data of the electric screwdriver,achieving accurate traceability and rectification.