Automatic bending and steering mechanism for resistor assembly

Abstract

The invention discloses an automatic bending and steering mechanism for resistor assembly, which realizes breakthrough progress in a resistor disc assembly technology: manual intervention is thoroughly eliminated through full-process automation, and the requirement of a single-line operator is reduced to zero; the working procedures are highly integrated, so that the time consumed from feeding to assembling of a single resistor disc is shortened, and the production speed is remarkably increased compared with that of a traditional production line; the systematized precision guarantee ensures that the bending angle qualification rate and the assembly dislocation rate approach to zero, and the technical advantages are converted into remarkable market efficiency and efficiency dimensions in industrial-grade mass production, and the output per unit time is improved; in the cost dimension, the manpower cost is saved, and the repair cost of defective products is reduced; in the aspect of space dimension, the occupied area of equipment is reduced, the flexibility of production line recombination is greatly enhanced, and comprehensively, the relation of resistor assembly production lines is redefined fundamentally, an automatic upgrading normal form with high economical efficiency and replicability is provided for the electronic manufacturing industry, and excellent comprehensive efficiency and industrial value are created.

Description

Technical Field

[0001] This article belongs to the field of electronic manufacturing automation equipment technology, specifically relating to an automated bending and steering mechanism for resistor assembly. Background Technology

[0002] As a core component in power control, electronic equipment, and industrial automation systems, the structural precision of resistor plates directly affects circuit stability and equipment lifespan. Traditional resistor plates require a precision bending process to bend the metal resistor sheets at specific angles to meet assembly requirements. In this process, the efficiency and precision of the bending machine directly determine production efficiency. A bending machine with high stability and rapid response capabilities can significantly improve product qualification rates and enable high-speed, mass production, meeting the output demands of modern industry for resistor components. Therefore, automated bending equipment has become a key infrastructure for improving quality and efficiency in the resistor manufacturing industry.

[0003] However, the resistance sheet bending equipment widely used in industry currently suffers from some systemic defects, and its technical bottlenecks are mainly reflected in the following dimensions:

[0004] Efficiency bottlenecks caused by manual intervention: Most semi-automatic bending machines do not integrate a steering module. Operators need to manually flip the resistor sheet to meet the requirements of bidirectional bending or assembly direction. The time consumed per operation increases, resulting in a decrease in the theoretical capacity of the production line. In addition, the manual steering process is prone to causing axial displacement of the resistor sheet, resulting in misalignment of the socket during subsequent assembly and an increase in the product defect rate.

[0005] Collaboration failures caused by process separation: The bending station and the assembly area are physically isolated and need to be connected by manual transfer or secondary conveying devices. Research by the electromechanical engineering laboratory shows that this design prolongs the production cycle time, and the interruption rate of material flow from feeding to bending to assembly reaches 15 times per hour. This leads to a mismatch between the output rhythm of the bending machine and the receiving frequency of the assembly line, forcing the production line to add a buffer storage module, which increases the area occupied and violates the principle of intensive layout of modern factories.

[0006] Lack of precision assurance mechanism: The spacing of the assembly trays of traditional conveyor belts is fixed. When the robotic arm places the resistor sheet, the inertial displacement of the conveyor belt causes the landing point to deviate, requiring secondary manual calibration. At the same time, the bending machine mold will undergo thermal deformation after continuous stamping, but the existing equipment lacks a real-time pressure feedback system for compensation.

[0007] High overall operating costs: Each production line requires at least 3 operators, resulting in high labor costs and significantly increased downtime due to manual operation.

[0008] To address the aforementioned pain points, future automation of resistor assembly should develop in the following directions:

[0009] By replacing manual operations with robot clusters, seamless integration of resistor sheets from material feeding and bending to assembly can be achieved.

[0010] Develop a bending system with built-in steering function to eliminate manual intervention;

[0011] Build an intelligent cycle control system to ensure efficient and coordinated operation of all production units.

[0012] In summary, the resistor assembly automated bending and steering mechanism proposed in this patent is an engineering practice of the above-mentioned technical directions based on an innovative architecture. This mechanism achieves a breakthrough in resistor sheet forming and assembly at a single workstation for the first time through a four-level collaborative mechanism of vibratory feeder, bending machine, feeding machine and intelligent conveyor belt. The following will analyze in depth how the design of the key subsystems of this mechanism specifically overcomes the existing technical barriers. Summary of the Invention

[0013] Based on the shortcomings of the background technology, such as efficiency reduction due to manual intervention, collaborative failure caused by process fragmentation, lack of accuracy assurance mechanism and high overall operating cost, this paper proposes an integrated resistor assembly automated bending and turning mechanism. This mechanism breaks through the limitations of the modular fragmentation of traditional production lines through a four-level collaborative architecture of vibratory feeder, bending machine, feeding machine and intelligent conveyor belt, and realizes the whole process closed loop of resistor sheet forming, turning and assembly in a single workstation.

[0014] An automated bending and turning mechanism for resistor assembly is innovative in that it completes bidirectional synchronous bending and flipping of both ends of the resistor sheet through the built-in fixtures, molds, and robotic arm system of the double-sided bending machine. The bending and assembly areas are physically connected by an arched feeder. The accuracy drift problem in the dynamic operation of the conveyor belt is solved based on the real-time matching algorithm (d = v × t) between the assembly tray spacing and the conveyor belt speed. The following section will analyze the collaborative design principle of each sub-module.

[0015] The double-sided bending machine of this device is located on the right side of the bending station. Its built-in fixtures, molds and bending robot can directly perform the synchronous inward bending and flipping process of both ends of the resistor sheet, thereby eliminating the manual flipping step required by traditional single-sided bending. The mold of the bending machine integrates a temperature and pressure dual feedback system, which can compensate for the bending angle deviation caused by thermal deformation in real time, so that the bending angle control accuracy reaches ±0.5°.

[0016] The vibratory feeder is located at the rear of the bending station and is equipped with a vibratory feeder conveyor independent of the main conveyor belt. This device directly transports the neatly arranged and pre-set polarity resistance sheets to the feed inlet of the double-sided bending machine through a directional track, which greatly shortens the material flow path and significantly improves the orientation success rate of the resistance sheets.

[0017] The arched feeding machine spans the left side of the bending station with a truss structure. The arched truss spans the working areas of the two bending machines, the bending station area, and the conveyor belt feeding area. After the multiple robotic arms of the feeding machine pick up the bent resistor sheet, they perform axial rotation of 0°-180° within the arched track, and finally accurately transport the resistor sheet to the feeding area, which is located directly below the part of the arched structure that spans the conveyor belt.

[0018] The conveyor belt system is located at the front end of the bending station. It carries the assembly trays for assembly line transportation. The assembly trays on the conveyor belt are installed at a preset fixed interval (d). This interval is strictly matched with the conveyor belt running speed (v) and the action cycle (t) of the loading robot arm, precisely satisfying the relationship (d=v×t). This design ensures that the resistors can fall accurately into the designated position of the assembly tray during the continuous dynamic operation of the conveyor belt.

[0019] The support chassis is installed below the entire bending station, serving as both a mechanical load-bearing base and an electrical control center. As a base, it supports all the devices in the station; as a control center, it integrates the drive motor and program processing device. This PLC system realizes bending pressure compensation, vibratory feeder feeding rhythm control, and precise synchronization of the conveyor belt and the movement of each robotic arm, effectively reducing the wiring complexity of the system.

[0020] Beneficial effects:

[0021] Our organization has achieved a breakthrough in resistor assembly technology through an innovative collaborative architecture: full-process automation completely eliminates manual intervention, reducing the need for single-line operators to zero; high integration of processes shortens the time from material supply to assembly of a single resistor, significantly improving production speed compared to traditional production lines; systematic precision assurance ensures a high pass rate for bending angles and near-zero assembly misalignment rate. These technological advantages translate into significant market effectiveness in industrial-grade mass production. In terms of efficiency, output per unit time is increased; in terms of cost, labor costs are saved and the cost of reworking defective products is reduced; in terms of space, equipment footprint is reduced and the flexibility of production line reconfiguration is greatly enhanced. In summary, this solution fundamentally redefines the relationship of resistor assembly production lines, providing the electronics manufacturing industry with a highly economical and replicable automation upgrade paradigm, creating outstanding comprehensive efficiency and industrial value. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of an automated bending and steering mechanism for resistor assembly;

[0023] In the diagram, 1 is a double-sided bending machine, 2 is a feeding machine, 3 is a vibratory feeder, 4 is a conveyor belt, 5 is an assembly tray, and 6 is a load-bearing housing. Detailed Implementation

[0024] To enhance understanding of the present invention, the invention will be further described in detail below with reference to embodiments and accompanying drawings. These embodiments are only for explaining the invention and do not constitute a limitation on the scope of protection of the invention.

[0025] Double-sided bending machine, feeding machine, vibratory feeder, conveyor belt, assembly tray, and load-bearing housing.

[0026] A specific implementation structure of an automated bending and steering mechanism for resistor assembly is as follows: Figure 1 As shown, it includes the following components and collaborative workflows:

[0027] 1. Overall layout and workstation division

[0028] The bending station is the core area. A double-sided bending machine is installed on the right side, an arched feeder is set on the left side, a vibratory feeder is connected to the rear end, a conveyor belt is arranged at the front end, and a fixed load-bearing box is below.

[0029] The double-sided bending machine integrates fixtures, molds, and bending robots. The robots simultaneously grasp both ends of the resistor sheet and bend it inward to form the shape.

[0030] The mold is equipped with a dual feedback system for temperature and pressure to compensate for thermal deformation in real time and ensure bending angle accuracy of ±0.5°.

[0031] The vibratory feeder, located at the rear of the bending station, uses an independent vibratory feeder conveying device to orient the resistance sheets and directly transport them to the feed inlet of the double-sided bending machine, ensuring the correct polarity of the resistance sheets.

[0032] 2. Cross-regional design of the arched feeder

[0033] The arched structure spans the working area of ​​the double-sided bending machine, the bending station area, and the material feeding area of ​​the conveyor belt;

[0034] The feeding machine is equipped with multiple feeding robotic arms, and its working process is as follows:

[0035] Pick up the resistance sheet after it has been processed by the double-sided bending machine;

[0036] Perform axial rotation from 0° to 180° within the arched track;

[0037] The resistor sheet is precisely placed in the feeding area of ​​the conveyor belt.

[0038] 3. Dynamic matching of conveyor belt and assembly tray

[0039] Multiple assembly trays are installed on the conveyor belt at a preset fixed interval (d);

[0040] The spacing (d) is strictly matched with the conveyor belt speed (v) and the loading robot arm's action cycle (t), satisfying the relationship: d=v×t;

[0041] This design ensures that the assembly tray stops precisely at the loading area and the resistor sheet falls accurately into the designated position when the conveyor belt is running continuously.

[0042] 4. Dual function of the chassis

[0043] Mechanical load-bearing base: supports all equipment in the bending station;

[0044] Electrical Control Center: Equipped with a built-in drive motor and PLC program processing device, it realizes bending pressure compensation, vibratory feeder feeding rhythm control, and synchronous movement of conveyor belt and robotic arm.

[0045] Implementation Example

[0046] The following example illustrates the operation of this mechanism using the entire process of resistor sheet feeding and assembly:

[0047] Step 1: Feeding and Orienting of Resistor Sheets

[0048] The vibratory feeder is started, and the resistance elements are oriented and transported to the feed inlet of the double-sided bending machine through an independent conveying device.

[0049] Step 2: Synchronous bending and steering

[0050] The clamps of the double-sided bending machine grip the resistor sheet, and the bending robot simultaneously bends both ends inward.

[0051] The mold monitors pressure and temperature in real time and automatically compensates for bending angle deviations.

[0052] Step 3: Transfer by arched feeder

[0053] The loading robotic arm picks up the bent resistor sheet, moves it along the arched track and rotates it 180° to turn it toward the assembly direction;

[0054] The robotic arm moves to the area where the arched structure spans the conveyor belt.

[0055] Step 4: Dynamic Assembly

[0056] The conveyor belt runs at a constant speed (v), and the assembly trays pass through the loading area sequentially at preset intervals (d);

[0057] The PLC system controls the loading robotic arm to release the resistor within a cycle (t), ensuring that d = v × t is satisfied:

[0058] When the assembly tray arrives at the loading area, the robotic arm simultaneously places the resistor sheet, achieving dynamic and precise material placement.

[0059] Step 5: System Cooperative Control

[0060] Real-time control of the PLC in the chassis:

[0061] The vibratory feeder frequency is matched to the bending machine cycle time;

[0062] The conveyor belt speed (v) is adaptively adjusted according to the robotic arm's motion cycle (t) to maintain a constant d value.

[0063] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automated bending and steering mechanism for resistor assembly, characterized in that, Includes: bending station, double-sided bending machine, feeding machine, vibratory feeder, conveyor belt, assembly tray and carrier box; The double-sided bending machine is located on the right side of the bending station. It is equipped with a fixture, a mold and a bending robot inside. The bending robot bends the two ends of the resistor sheet inward to form the shape. The feeding machine is located on the left side of the bending station. It has an arched structure and spans the entire bending station. The feeding machine is equipped with multiple feeding robotic arms. The feeding robotic arms pick up the resistance sheets processed by the double-sided bending machine and transport them to the feeding area. The feeding area is located below the arched structure on the conveyor belt. The vibratory feeder is located at the rear end of the bending station and has an independent vibratory feeder conveying device. The vibratory feeder conveying device transports the neatly arranged resistance sheets to the double-sided bending machine. The conveyor belt is located at the front end of the bending station and serves as a conveyor belt for the assembly line. Multiple assembly trays are arranged at a preset interval on the conveyor belt. They move with the conveyor belt and pass through the loading area of ​​the loading machine. In the loading area, the loading robot arm installs the bent resistors into the assembly trays. The carrier housing is located below the bending station, and a drive motor and a program processing device for controlling the operation of the entire mechanism are installed inside it.

2. The automated bending and steering mechanism for resistor assembly according to claim 1, characterized in that, The arched structure of the feeding machine spans the working area of ​​the double-sided bending machine, the bending station area, and the feeding area of ​​the conveyor belt located below it.

3. The automated bending and steering mechanism for resistor assembly according to claim 1, characterized in that, The independent vibratory feeder conveying device of the vibratory feeder directly and orderly conveys the resistance sheet to the feeding position of the double-sided bending machine.

4. The automated bending and steering mechanism for resistor assembly according to claim 1, characterized in that, The preset spacing between the multiple assembly trays on the conveyor belt is matched with the working cycle of the loading robot and the running speed of the conveyor belt to ensure that the resistors are accurately installed in the designated positions on the assembly trays.

5. The automated bending and steering mechanism for resistor assembly according to claim 1, characterized in that, The aforementioned load-bearing chassis is not only the electrical control center integrating the drive motor and control program, but also the mechanical load-bearing base for all devices on the bending station.

6. The automated bending and steering mechanism for resistor assembly according to claim 1, characterized in that, The loading area is located below the section of the arched loading machine that spans the conveyor belt, and is the designated area where the loading robotic arm performs the resistor placement operation.

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