Full-automatic sorting equipment for gas discharge tubes

Abstract

Full-automatic sorting equipment for gas discharge tubes comprises a mechanical movement assembly, an electrical control assembly and a detection assembly, the mechanical movement assembly is composed of a vibration disc, a conveying belt and a Cyerature Delta robot, the vibration disc conducts feeding through vibration, and the Delta robot achieves high-precision grabbing and sorting through a pneumatic flexible clamping jaw; the electrical control assembly is integrated with an eight-position valve terminal and a multi-axis motion controller; the base adopts a T-shaped groove aluminum frame and is provided with composite ground trundles, and stability and moving flexibility are both considered. Through high-precision sensing, an intelligent algorithm and modular design, the problems of low detection efficiency, high misjudgment rate and insufficient intelligence in the prior art are solved, the sorting speed of more than 60 pieces per minute is realized, the misjudgment rate is less than or equal to 0.1%, the energy consumption is reduced by 30%, flexible production and remote data management of multi-specification discharge tubes are simultaneously supported, and the working efficiency is improved. And production efficiency and product quality are improved, and high-standard sorting requirements in the fields of electric power, communication and the like are met.

Description

Technical Field

[0001] This utility model belongs to the field of industrial automation and electronic component testing technology, specifically a fully automated sorting device for gas discharge tubes. Background Technology

[0002] As a key component for overvoltage protection in power systems, the performance testing and sorting of gas discharge tubes are crucial to product reliability. Currently, the industry commonly employs the following technical solutions:

[0003] 1. Manual and semi-automatic sorting systems: Traditional insulation resistance testing methods mainly rely on manual operation, such as using a megohmmeter or a high-voltage power supply to gradually increase the voltage and measure the leakage current. This type of equipment typically includes components such as an industrial frequency AC power supply, relays, circuit breakers, rectifier and filter circuits, discharge circuits, and test sample slots. Its working principle is to test the discharge characteristics of the discharge tube through a control circuit, adjusting components such as resistors and capacitors to simulate different circuit conditions and test the performance of the discharge tube.

[0004] 2. Fully Automated Testing Equipment: This equipment utilizes robotic arms, rotating frames, and gas purging devices to achieve automated feeding and sorting. For example, a robotic arm transfers discharge tubes to the testing station, and defective products are rejected. However, existing automated equipment still has problems, such as the difficulty in eliminating residual current in discharge tubes in high-voltage or high-frequency lines, affecting the accuracy of test results; in high-voltage environments, traditional sensors struggle to accurately capture the dynamic characteristics of discharge tubes, leading to a high false positive rate; most equipment lacks remote monitoring and data traceability capabilities, requiring manual inspection for maintenance, resulting in high costs; the sorting process suffers from redundant mechanical movement paths, high energy consumption, and incompatibility with the flexible sorting requirements of multiple discharge tube specifications. Utility Model Content

[0005] This invention addresses the technical shortcomings of existing gas discharge tube sorting equipment, such as the problem of continuous flow, low detection efficiency, insufficient accuracy, and lack of intelligent functions. It provides a fully automated gas discharge tube sorting device that achieves efficient, high-precision, and low-energy discharge tube detection and classification, while enhancing remote monitoring and flexible production capabilities.

[0006] The technical solution of this utility model is as follows:

[0007] A fully automated gas discharge tube sorting device, characterized in that it includes:

[0008] The mechanical motion component consists of a vibrating plate (8), a conveyor belt (7), and a Cyerature Delta robot (2); wherein, the vibrating plate (8) arranges the gas discharge tubes (3) in an orderly manner and transports them to the conveyor belt (7) through vibration; the Cyerature Delta robot (2) drives a pneumatic flexible gripper through a three-axis robotic arm to achieve precise grasping, transfer and sorting of the gas discharge tubes to be tested;

[0009] The electrical control components include an 8-position valve island (5) and a PLC controller. The 8-position valve island (5) integrates pneumatic and electrical signals and communicates with the PLC controller via the EtherCAT bus protocol to control the coordinated movement of the conveyor belt (7), the vibrating plate (8), and the Cyerature Delta robot (2).

[0010] The detection component includes a detection table (4), a hopper (6), and a tri-color light (1); wherein the hopper (6) is divided into upper and lower layers, the upper layer is the qualified product area, the lower layer is the unqualified product area, and a photoelectric counter is provided at the bottom; the tri-color light (1) communicates with the PLC controller to display the detection results in real time.

[0011] The base (9) is made of T-shaped aluminum profile and has a cable management channel embedded inside, which centrally arranges motor drive lines, sensor signal lines and power lines.

[0012] Furthermore, it also includes composite casters (10), which are installed at the four corners of the bottom of the base (9) and have self-locking function and height adjustment capability.

[0013] Furthermore, the Cyerature Delta robot is suspended above the detection tray via a T-slot aluminum frame, and the gripping force and motion trajectory of its pneumatic flexible gripper are controlled by an electronic cam to achieve efficient and precise sorting.

[0014] Furthermore, the pneumatic flexible gripper is made of polyurethane-carbon fiber composite material, and the gripping surface is provided with a wave-shaped buffer groove. The contact pressure is ≤0.5MPa, and it is compatible with gas discharge tubes with a diameter of 5-20mm (3).

[0015] Furthermore, the 8-position valve island is located behind the testing platform, and the testing platform and sorting bin are located on the left side of the base. The testing platform has a built-in high-voltage testing module and a visual inspection unit for dual inspection of the electrical performance and appearance of the gas discharge tube.

[0016] Furthermore, the electrical control component also includes a multi-axis motion controller with a built-in EtherCAT bus communication protocol, a response time of ≤10ms, and uses a Bezier curve algorithm to optimize the robot's motion trajectory.

[0017] Furthermore, the probe surface of the detection stage (4) is gold-plated, and the detection circuit is equipped with an RC absorption circuit to suppress follow current interference.

[0018] Furthermore, a vibration guide device is provided between the conveyor belt (7) and the vibratory plate (8) to ensure continuous and stable feeding of the gas discharge tube (3).

[0019] Furthermore, the motion path of the Cyerature Delta robot (2) is implemented through modular programming, which supports automatic identification of gas discharge tubes (3) of different specifications and adjustment of sorting strategies.

[0020] Furthermore, the device uses a permanent magnet synchronous motor to drive the conveyor belt (7), and the Delta robot (2) servo motor is equipped with regenerative braking function.

[0021] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0022] 1. Higher degree of automation:

[0023] This design achieves full-process automation, reducing human intervention and increasing production efficiency (by 85%) compared to traditional manual operation. Overall efficiency is improved by 30% compared to similar automated equipment.

[0024] 2. Advantages of energy conservation and emission reduction:

[0025] Energy consumption is reduced by 60% due to intelligent energy allocation and optimized movement trajectories, effectively lowering production costs. Defective products are reduced by 70% thanks to precise detection and sorting, thereby reducing scrap rates and resource waste.

[0026] 3. High-precision detection and sorting:

[0027] Advanced sensors and high-voltage detection technology are used to ensure sorting accuracy, reduce misjudgment rate, and improve product quality stability.

[0028] 4. Flexible adaptability:

[0029] The system can automatically identify gas discharge tubes of different specifications and classify them accordingly, adapting to various product types.

[0030] 5. Intelligent Management:

[0031] The intelligent control system enables real-time analysis, storage, and adjustment of detection data, providing data traceability and improving production controllability.

[0032] 6. Low maintenance costs:

[0033] Key components (such as joints and grippers) use wear-resistant materials and optimized lubrication systems to extend service life and reduce maintenance frequency. Attached Figure Description

[0034] Figure 1 Front view of the engineering drawing of the automated gas discharge tube testing equipment

[0035] Figure 2 3D engineering drawing of automated testing equipment for gas discharge tubes

[0036] Figure 3 3D engineering drawing of the testing platform

[0037] Figure 4 Cyerature Delta robot looking at the engineering drawing

[0038] Figure 5 3D coloring diagram of automated gas discharge tube testing equipment

[0039] In the diagram: 1. Tricolor LED light; 2. Cyerature Delta robot; 3. Gas discharge tube; 4. Detection platform; 5. 8-position valve island; 6. Hopper; 7. Conveyor belt; 8. Vibratory feeder; 9. Base; 10. Composite casters. Detailed Implementation

[0040] The following detailed description of the fully automated gas discharge tube sorting device of the present invention, in conjunction with the accompanying drawings and embodiments, will enable those skilled in the art to fully understand and implement the present invention.

[0041] like Figure 1-5As shown, a fully automated sorting device for gas discharge tubes is provided. A vibratory plate (8) is installed on the right platform of the base (9). It is equipped with a vibration motor and a directional guide rail. The gas discharge tubes (3) are arranged in an orderly manner and transported to the conveyor belt (7) by vibration. The surface of the conveyor belt (7) is provided with an anti-slip silicone layer to ensure that the discharge tubes move smoothly to the detection station. The Cyerature Delta robot (2) is fixed above the detection table (4) by a T-slot aluminum frame. A pneumatic flexible gripper is installed at the end of its three-axis robotic arm. The gripper is embedded with a pressure sensor, and the gripping force can be dynamically adjusted to avoid damage to the surface of the discharge tubes. The robot's motion path is planned by a multi-axis motion controller and the trajectory is optimized by a Bezier curve algorithm. The repeatability accuracy is ≤ ±0.1mm. An 8-position valve island is integrated at the rear of the detection table (4). The gas circuit and circuit signal linkage is realized through a PLC controller (model: Siemens S7-1200). The valve island output ports are connected to the pneumatic gripper, conveyor belt (7) motor, and vibratory plate (8) vibration module of Delta robot (2), respectively, and the input ports receive feedback signals from the detection components. The multi-axis motion controller has a built-in EtherCAT bus communication protocol, receives detection data in real time and dynamically adjusts the robot's actions, with a response time ≤10ms. The surface of the detection table is covered with an insulating ceramic plate and has a built-in high-voltage detection module. The probe contacts the two poles of the discharge tube, applies a simulated working condition voltage, and synchronously collects leakage current and breakdown time parameters. The three-color light (1) is installed on the top of the equipment and communicates with the PLC through the Modbus TCP protocol. The light is green when the test is qualified, red when it is unqualified, and yellow when it is abnormal. The hopper (6) is divided into upper and lower layers. The upper layer is the unqualified product area, and the lower layer is the qualified product area. A photoelectric counter is installed at the bottom of the hopper to count the sorted quantity. The base frame is made of T-shaped aluminum profile, and the door panel has a cable management channel to centrally arrange the motor drive line, sensor signal line and power line to avoid interference with mechanical movement. The composite casters (10) are made of polyurethane and have a self-locking function. When the equipment is stationary, the height of the casters is adjusted by screws to keep it level; when moving, the casters are retracted and the equipment slides using rollers.

[0042] The specific operating steps of this device are as follows:

[0043] Step 1: Feeding and Conveying

[0044] Pour the discharge tubes (3) to be tested into the vibrating plate (8) in batches, start the vibration motor (frequency: 30Hz), and the discharge tubes enter the conveyor belt (7) along the guide rail. The conveyor belt transports them to the waiting position next to the test table (4) at a speed of 1m / s.

[0045] Step 2: Capture and Detection

[0046] The Delta robot (2) grasps the discharge tube based on the photoelectric sensor signal and places it at the probe position of the detection stage (4). The detection module applies a 5kV / 1kHz test voltage for 10ms and records the leakage current and breakdown time.

[0047] Step 3: Result Determination and Sorting

[0048] If the detection parameters are qualified, the PLC sends an instruction to the Delta robot to move it to the lower layer of the qualified hopper (6); if it is not qualified, it is moved to the upper layer. The three-color lights (1) display the status synchronously, and the detection data is uploaded to the cloud database through the industrial IoT gateway, supporting real-time monitoring on mobile devices.

[0049] Step 4: Looping and Statistics

[0050] The single detection cycle is 3 seconds, and the maximum sorting capacity per hour is 1200 pieces. When the hopper (6) is full, the equipment will automatically stop and trigger an audible and visual alarm. It will resume operation after the hopper is replaced with an empty one.

[0051] The above embodiments are merely examples. Those skilled in the art can adjust the structure, parameters, and control logic according to actual needs, and all such adjustments fall within the protection scope of this utility model.

Claims

1. A fully automated sorting apparatus for gas discharge tubes, characterized in that, include: The mechanical motion component consists of a vibrating plate (8), a conveyor belt (7), and a Cyerature Delta robot (2); wherein, the vibrating plate (8) arranges the gas discharge tubes (3) in an orderly manner and transports them to the conveyor belt (7) through vibration; the Cyerature Delta robot (2) drives a pneumatic flexible gripper through a three-axis robotic arm to achieve precise grasping, transfer and sorting of the gas discharge tubes to be tested; The electrical control components include an 8-position valve island (5) and a PLC controller. The 8-position valve island (5) integrates pneumatic and electrical signals and communicates with the PLC controller via the EtherCAT bus protocol to control the coordinated movement of the conveyor belt (7), the vibrating plate (8), and the Cyerature Delta robot (2). The detection component includes a detection table (4), a hopper (6), and a tri-color light (1); wherein the hopper (6) is divided into upper and lower layers, the upper layer is the qualified product area, the lower layer is the unqualified product area, and a photoelectric counter is provided at the bottom; the tri-color light (1) communicates with the PLC controller to display the detection results in real time. The base (9) is made of T-shaped aluminum profile and has a cable management channel embedded inside, which centrally arranges motor drive lines, sensor signal lines and power lines.

2. The fully automated sorting apparatus of gas discharge tubes according to claim 1, characterized in that, It also includes composite casters (10), which are installed at the four corners of the bottom of the base (9) and have self-locking function and height adjustment capability.

3. The fully automated sorting apparatus of gas discharge tubes according to claim 1, characterized in that, The CyeratureDelta robot is suspended above the inspection tray via a T-slot aluminum frame. Its pneumatic flexible gripper's gripping force and movement trajectory are controlled by an electronic cam, enabling efficient and precise sorting.

4. The fully automated sorting apparatus of gas discharge tubes according to claim 3, characterized in that, The pneumatic flexible gripper is made of polyurethane-carbon fiber composite material, and the gripping surface is provided with a wave-shaped buffer groove. The contact pressure is ≤0.5MPa, and it is compatible with gas discharge tubes with a diameter of 5-20mm (3).

5. The fully automated sorting apparatus of gas discharge tubes according to claim 1, characterized in that, The 8-position valve island is located behind the testing platform. The testing platform and the sorting bin are located on the left side of the base. The testing platform has a built-in high-voltage testing module and a visual inspection unit, which are used to perform dual inspections on the electrical performance and appearance of the gas discharge tube.

6. The fully automated sorting apparatus of gas discharge tubes according to claim 1, characterized in that, The electrical control components also include a multi-axis motion controller with built-in EtherCAT bus communication protocol, a response time of ≤10ms, and a Bezier curve algorithm to optimize the robot's motion trajectory.

7. The fully automated gas discharge tube sorting equipment according to claim 1, characterized in that, The probe surface of the detection stage (4) is gold-plated, and the detection circuit is equipped with an RC absorption circuit to suppress follow current interference.

8. The fully automated sorting apparatus of gas discharge tubes according to claim 1, characterized in that, A vibration guide device is provided between the conveyor belt (7) and the vibratory plate (8) to ensure continuous and stable feeding of the gas discharge tube (3).

9. The fully automated sorting apparatus of gas discharge tubes according to claim 1, characterized in that, The motion path of the CyeratureDelta robot (2) is implemented through modular programming, which supports automatic identification of gas discharge tubes (3) of different specifications and adjustment of sorting strategies.

10. The fully automated sorting apparatus of gas discharge tubes according to claim 1, characterized in that, The device uses a permanent magnet synchronous motor to drive the conveyor belt (7), and the Delta robot (2) servo motor is equipped with regenerative braking function.

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