Speaker full-automatic welding detection production line based on tin soldering and AI vision detection

Abstract

The application discloses a kind of based on molten solder and AI visual inspection's speaker full-automatic welding detection production line, it includes main flow pipeline, and the welding feeding conveying line that is vertically interfaced with the main flow pipeline and overall is L type distribution, several welding units are arranged along the main flow pipeline, welding in-out conveying line is vertically interfaced with one end of the welding feeding conveying line another end is vertically interfaced with the main flow pipeline and flows through the welding unit, carrying clamping mechanism is arranged above the main flow pipeline terminal end and removes and is placed to the cover plate return flow conveying line on the welding cover plate on product, AI visual inspection unit is detected to product welding spot, and waste mechanism is arranged.This application utilizes laser melting tin ball to be sprayed to pad position to reach the purpose of welding, while cooperating with AI deep learning model, the welding spot is automatically detected, product welding and detection efficiency are greatly improved, and the reliability of welding spot detection result is improved, welding quality is improved, product quality is guaranteed.

Description

[Technical Field]

[0001] This invention belongs to the field of automation equipment technology, and in particular relates to a fully automated welding and inspection production line for loudspeakers based on soldering and AI visual inspection. [Background Technology]

[0002] Currently, there is a Bluetooth headset speaker whose production process includes a soldering step. The traditional approach involves automated product feeding, flux application, solder ring placement, soldering, and solder joint inspection. However, solder joint inspection, flux application, and solder ring placement are all done manually. The entire process requires three soldering modules and two inspection stations, necessitating 22 workers. This results in low production capacity, poor soldering quality, and inconsistent quality. Furthermore, manual inspection is prone to visual fatigue, compromising product quality.

[0003] Therefore, it is necessary to provide a new fully automated speaker welding and inspection production line based on molten soldering and AI visual inspection to solve the above problems. [Summary of the Invention]

[0004] The main objective of this invention is to provide a fully automated welding and inspection production line for speakers based on solder fusion and AI visual inspection, which greatly improves the efficiency of product welding and inspection, enhances welding quality, and ensures product quality.

[0005] This invention achieves the above objectives through the following technical solution: a fully automated speaker welding and inspection production line based on solder fusion and AI visual inspection, comprising...

[0006] One main waterline;

[0007] A welding feeding conveyor line, wherein the welding feeding conveyor line is generally L-shaped and is perpendicularly connected to the main water line;

[0008] A welding unit, comprising multiple units distributed along the main waterline;

[0009] A welding inlet and outlet conveyor line, one end of which is perpendicularly connected to the welding feeding conveyor line, and the other end is perpendicularly connected to the main water line, while flowing through the welding unit;

[0010] A cover plate return conveyor line is set parallel above the main water line;

[0011] A handling and clamping mechanism is set above the end of the main water line and removes the welding cover plate from the product and places it on the cover plate return conveyor line;

[0012] An AI vision inspection unit performs welding inspection on products based on a deep learning model; and

[0013] A row of abandoned facilities.

[0014] Furthermore, the main water line is provided with a first steering and pushing mechanism at the docking point with the welding feeding conveyor line. The first steering and pushing mechanism includes a first cylinder located above the main water line and a first pushing plate driven by the first cylinder to move parallel to the conveying direction of the welding feeding conveyor line.

[0015] At least one pair of first baffle mechanisms are provided on the main waterline upstream of the first steering and pushing mechanism; the first baffle mechanisms are arranged along the conveying direction of the main waterline; the first baffle mechanism includes a second cylinder and a first baffle plate that is driven by the second cylinder to move up and down.

[0016] Furthermore, the welding feeding conveyor line includes a first welding feeding line perpendicularly connected to the main water flow line, a second welding feeding line perpendicularly connected to the end of the first welding feeding line and parallel to the main water flow line, a first turning conveyor mechanism disposed at the intersection of the first welding feeding line and the second welding feeding line, at least one pair of second blocking mechanisms disposed along the first welding feeding line, and a plurality of third blocking mechanisms disposed along the second welding feeding line and corresponding to the position of the welding inlet and outlet conveyor line.

[0017] Furthermore, the second baffle mechanism includes a third cylinder and a second baffle plate that is driven by the third cylinder to move up and down; the second baffle mechanism is located below the first welding feed line;

[0018] The third baffle mechanism includes a fourth cylinder, a third baffle plate driven by the fourth cylinder to move up and down, and a first sensor fixed on the third baffle plate to detect whether the product is in place; the third baffle mechanism is located below the second welding feed line.

[0019] Furthermore, the first steering conveying mechanism includes a first support, a fifth cylinder fixed to the upper surface of the first support, a first support plate driven by the fifth cylinder to move up and down, a first support roller rotatably disposed at the front and rear ends of the first support plate, a second support plate fixedly connected to the first support plate and located below the fifth cylinder, a second support roller rotatably disposed on the second support plate, a first motor fixed to the second support plate and driving the second support roller to rotate, and a first steering conveyor belt wound in a loop around the first support roller and the second support roller, wherein the first steering conveyor belt forms a conveying surface on the two first support rollers.

[0020] Furthermore, the input end of the welding feeder line is provided with a second deflecting conveyor mechanism that transfers the product from the second welding feeder line to the welding feeder line;

[0021] The second steering conveying mechanism includes a bracket rotatably mounted on a hinged seat, a first rotating shaft rotatably mounted on one end of the bracket and coaxial with the rotation axis of the bracket, a plurality of first synchronous pulleys mounted on the first rotating shaft, a plurality of second synchronous pulleys mounted on the other end of the bracket, a second steering conveyor belt wound around the first and second synchronous pulleys and forming the same conveying direction as the welding in-and-out conveying line, a second motor driving the first rotating shaft to rotate, and a sixth cylinder driving the bracket to rotate around the axis of the hinged seat;

[0022] The bracket is distributed perpendicular to the second welding feed line, and the second welding feed line is provided with a clearance notch for the bracket to sink below the second welding feed line.

[0023] Furthermore, a first lifting and positioning mechanism and a lifting and positioning adjustment mechanism for lifting, positioning and adjusting the angle of the product at the welding station are also provided below the welding inlet and outlet conveyor line along the conveying direction.

[0024] The first lifting and positioning mechanism includes a seventh cylinder and an eighth cylinder, a first lifting plate driven by the seventh cylinder to move up and down, and a second sensor driven by the eighth cylinder to move up and down and to detect whether the product is in position.

[0025] The lifting and positioning adjustment mechanism includes a ninth cylinder and a tenth cylinder, a third support plate driven by the ninth cylinder to move up and down, a second rotating shaft rotatably mounted on the third support plate, a second lifting plate fixed on the second rotating shaft, a third motor fixed on the third support plate and driving the second rotating shaft to rotate, and upper limit positioning components located on both sides of the second lifting plate to cooperate with and fix the product. A second positioning post is provided on the second lifting plate.

[0026] Furthermore, the output end of the welding inlet and outlet conveyor line is also provided with a second steering and pushing mechanism to push the product from the welding inlet and outlet conveyor line to the main water line; the second steering and pushing mechanism includes an eleventh cylinder, a fourth support plate driven by the eleventh cylinder to move parallel to the welding inlet and outlet conveyor line, a twelfth cylinder fixed on the fourth support plate, and a second pushing plate driven by the twelfth cylinder to move up and down.

[0027] Furthermore, the welding unit includes a three-axis transfer mechanism, a seventh support plate that is driven by the three-axis transfer mechanism to move in space, a solder molten head fixed on the seventh support plate, a solder ball feeding mechanism connected to the solder ball feeding channel of the solder molten head, a visual positioning component and a laser rangefinder disposed on the seventh support plate, and a detection camera for detecting whether solder is attached to the nozzle in the solder molten head.

[0028] Furthermore, it also includes an inspection conveyor line located above the end of the main flow line. The AI ​​vision inspection unit is positioned above the inspection conveyor line. The product is picked up from the main flow line and transferred to the inspection conveyor line by the handling and clamping mechanism. Then, the welding cover plate on the product is removed and placed on the cover plate return conveyor line. The inspection conveyor line is equipped with a lifting and positioning mechanism corresponding to the cover plate removal station and the AI ​​inspection station. The cover plate return conveyor line is parallel to the main flow line and located above the main flow line. One end of the cover plate return conveyor line extends to the input end of the main flow line.

[0029] The AI ​​visual inspection unit includes a first camera and a second camera set at an angle, and a host computer electrically connected to the first camera and the second camera and equipped with solder joint AI inspection system software.

[0030] The transport and clamping mechanism includes a fourth motor, a fifth support plate driven by the fourth motor to perform horizontal linear motion, a fifth motor fixed on the fifth support plate, a sixth support plate driven by the fifth motor to perform vertical motion, a thirteenth cylinder and a fourteenth cylinder fixed on the sixth support plate, a gripper driven by the thirteenth cylinder to perform clamping or opening actions, and a suction nozzle driven by the fourteenth cylinder to perform vertical motion.

[0031] Compared with existing technologies, the advantages of this invention's fully automated speaker welding and inspection production line based on molten soldering and AI visual inspection are as follows: it realizes fully automated feeding, conveying, solder ball spraying, AI visual automatic inspection, automatic waste removal, and automatic output for Bluetooth headset speakers, greatly improving welding inspection efficiency, welding quality, and the reliability of inspection results. Specifically, it uses laser-melted solder balls sprayed onto the solder pads to achieve the welding purpose, while simultaneously employing a novel deep analysis device for AI-inspected solder joints. This device has advantages such as non-contact operation, no flux, low heat generation, deep analysis, and precise controllability. Compared with ordinary welding methods, it features impact deformation and instantaneous solidification, while also possessing advantages such as high welding speed, small space requirements, and simple and controllable operation, making it particularly suitable for the manufacturing processes of high-precision electronic products such as headphones. The AI ​​recognition testing system, based on artificial intelligence learning, intelligent systems, image recognition, and natural language processing technologies, boasts advantages such as high precision, accuracy, stability, and high efficiency. [Attached Image Description]

[0032] Figure 1 This is a top view of the structure according to an embodiment of the present invention;

[0033] Figure 2 This is a partial structural diagram of the main waterline in an embodiment of the present invention;

[0034] Figure 3 This is a schematic diagram of the structure of the first welding feed line in an embodiment of the present invention;

[0035] Figure 4 This is a schematic diagram of the structure of the first steering and conveying mechanism in an embodiment of the present invention;

[0036] Figure 5 This is a schematic diagram of the structure of the welding unit, the second welding feeding line, and the welding inlet / outlet conveyor line in an embodiment of the present invention;

[0037] Figure 6 This is a partial structural schematic diagram of the second welding feeding line in an embodiment of the present invention;

[0038] Figure 7 This is a schematic diagram of the structure of the second steering and conveying mechanism in an embodiment of the present invention;

[0039] Figure 8 This is a schematic diagram of the welding inlet and outlet conveyor line in an embodiment of the present invention;

[0040] Figure 9 This is a schematic diagram of the structure of the first lifting and positioning mechanism in an embodiment of the present invention;

[0041] Figure 10 This is a schematic diagram of the lifting and positioning adjustment mechanism in an embodiment of the present invention;

[0042] Figure 11 This is a partial structural schematic diagram of the lifting and positioning adjustment mechanism in an embodiment of the present invention;

[0043] Figure 12 This is a partial structural schematic diagram of the welding unit in an embodiment of the present invention;

[0044] Figure 13 This is a schematic diagram of the structure at the end of the main waterline in an embodiment of the present invention;

[0045] Figure 14 This is a partial structural schematic diagram of the handling and clamping mechanism in an embodiment of the present invention;

[0046] The numbers in the diagram represent:

[0047] 100 fully automated speaker welding and inspection production lines based on solder fusion and AI vision inspection;

[0048] 1 Main water line, 11 First steering and pushing mechanism, 111 First cylinder, 112 First pushing plate, 12 First blocking mechanism, 121 Second cylinder, 122 First blocking plate;

[0049] 2 Welding feeding conveyor line, 21 First welding feeding line, 22 Second welding feeding line, 221 Avoidance gap, 23 First steering conveyor mechanism, 231 First support, 232 Fifth cylinder, 233 First support plate, 234 First support roller, 235 Second support roller, 236 First motor, 237 First steering conveyor belt, 238 Baffle, 239 Second support plate, 24 Second baffle mechanism, 241 Third cylinder, 242 Second baffle plate, 25 Third baffle mechanism, 251 Fourth cylinder, 252 Third baffle plate, 253 First sensor;

[0050] 3 Welding unit, 31 Three-axis transfer mechanism, 32 Seventh support plate, 33 Solder melting head, 34 Vision positioning component, 35 Laser rangefinder, 36 Inspection camera;

[0051] 4 Welding inlet and outlet conveyor lines, 41 Second steering conveyor mechanism, 411 Support, 412 First rotating shaft, 413 First synchronous pulley, 414 Second synchronous pulley, 415 Second steering conveyor belt, 416 Second motor, 417 Hinge seat, 418 Sixth cylinder, 42 First lifting and positioning mechanism, 421 Seventh cylinder, 422 Eighth cylinder, 423 First lifting plate, 424 Second sensor, 425 First positioning column, 43 Lifting and positioning adjustment mechanism, 431 Ninth cylinder, 432 Tenth cylinder, 433 Third support plate, 434 Second rotating shaft, 435 Second lifting plate, 436 Third motor, 437 Upper limit assembly, 438 Second positioning column, 439 Third sensor, 44 Second steering and pushing mechanism, 441 Eleventh cylinder, 442 Fourth support plate, 443 Twelfth cylinder, 444 Second pushing plate;

[0052] 5. Cover plate return conveyor line;

[0053] 6. Handling and clamping mechanism; 61. Fourth motor; 62. Fifth support plate; 63. Fifth motor; 64. Sixth support plate; 65. Thirteenth cylinder; 66. Fourteenth cylinder; 67. Gripper; 68. Nozzle.

[0054] 7 AI visual inspection units, 71 first camera, 72 second camera;

[0055] 8 Waste discharge mechanism, 81 Fifteenth cylinder, 82 Third pusher plate, 83 Defective product discharge channel;

[0056] 9 Inspection conveyor lines, 91 Lifting and positioning mechanism.

Detailed Implementation Methods

[0057] Example 1:

[0058] Please refer to Figures 1-14This embodiment is a fully automated speaker welding and inspection production line 100 based on solder fusion and AI visual inspection. It includes a main water line 1, a welding feeding conveyor line 2 that is perpendicular to the main water line 1 and is distributed in an L-shape, several welding units 3 arranged along the main water line 1, a welding inlet and outlet conveyor line 4 that is perpendicular to the welding feeding conveyor line 2 at one end and perpendicular to the main water line 1 at the other end and flows through the welding units 3, a handling and clamping mechanism 6 that is set above the end of the main water line 1 and removes the welding cover plate from the product and places it on a cover plate return conveyor line 5, an AI visual inspection unit 7 that performs solder joint inspection on the product, and a waste removal mechanism 8.

[0059] A first steering and pushing mechanism 11 is provided at the junction of the main water line 1 and the welding feeding conveyor line 2. The first steering and pushing mechanism 11 includes a first cylinder 111 located above the main water line 1 and a first pushing plate 112 driven by the first cylinder 111 to move parallel to the conveying direction of the welding feeding conveyor line 2. The first pushing plate 112 horizontally pushes the products on the main water line 1 onto the welding feeding conveyor line 2, realizing the steering and conveying of the products.

[0060] At least one pair of first baffle mechanisms 12 are provided upstream of the first steering and pushing mechanism 11 on the main water line 1. The first baffle mechanisms 12 are arranged along the conveying direction of the main water line 1. The first baffle mechanism 12 includes a second cylinder 121 and a first baffle plate 122 driven by the second cylinder 121 to move up and down. By setting up the two first baffle mechanisms 12, the products are controlled to be conveyed one by one to the position of the first steering and pushing mechanism 11 within a set time.

[0061] The welding feeding conveyor line 2 includes a first welding feeding line 21 that is perpendicularly connected to the main water line 1, a second welding feeding line 22 that is perpendicularly connected to the end of the first welding feeding line 21 and parallel to the main water line 1, a first turning conveyor mechanism 23 located at the intersection of the first welding feeding line 21 and the second welding feeding line 22, at least one pair of second blocking mechanisms 24 located along the first welding feeding line 21, and several third blocking mechanisms 25 located along the second welding feeding line 22 and corresponding to the positions of the welding inlet and outlet conveyor lines 4.

[0062] The second baffle mechanism 24 includes a third cylinder 241 and a second baffle plate 242 driven by the third cylinder 241 to move up and down. By setting two second baffle mechanisms 24, the main purpose is to transport products one by one to the position of the first turning conveyor mechanism 23 within a set time. The second baffle mechanism 24 is located below the first welding feed line 21.

[0063] The third baffle mechanism 25 includes a fourth cylinder 251, a third baffle plate 252 driven by the fourth cylinder 251 to move up and down, and a first sensor 253 fixed on the third baffle plate 252 to detect whether the product is in position. The third baffle mechanism 25 is located below the second welding feed line 22.

[0064] The first steering conveyor mechanism 23 includes a first support 231, a fifth cylinder 232 fixed to the upper surface of the first support 231, a first support plate 233 driven by the fifth cylinder 232 to move up and down, first support rollers 234 rotatably disposed at the front and rear ends of the first support plate 232, a second support plate 239 fixedly connected to the first support plate 233 and located below the fifth cylinder 232, a second support roller 235 rotatably disposed on the second support plate 239, a first motor 236 fixed on the second support plate 239 and driving the second support roller 235 to rotate, and a first steering conveyor belt 237 wound in a loop around the first support rollers 234 and the second support rollers 235. The first steering conveyor belt 237 forms a conveying surface on the two first support rollers 234. A baffle 238 for blocking products is disposed at one end of the first support plate 233 located on one side of the first steering conveyor belt 237.

[0065] In the initial state, the fifth cylinder 232 is in the retracted state, and the first steering conveyor belt 237 is lower than the conveying surface of the first welding feed line 21. When the product reaches the set position, the fifth cylinder 232 extends, the first steering conveyor belt 237 lifts the product upward, and the first motor 236 turns on to transport the product to the second welding feed line 22.

[0066] The input end of the welding feed line 4 is provided with a second deflecting conveyor mechanism 41 that transfers products from the second welding feed line 22 to the welding feed line 4. The second deflecting conveyor mechanism 41 includes a bracket 411 rotatably mounted on a hinge seat 417, a first rotating shaft 412 rotatably mounted on one end of the bracket 411 and coaxial with the rotation axis of the bracket 411, a plurality of first synchronous pulleys 413 mounted on the first rotating shaft 412, a plurality of second synchronous pulleys 414 mounted on the other end of the bracket 411, a second deflecting conveyor belt 415 wound around the first synchronous pulleys 413 and the second synchronous pulleys 414 and forming the same conveying direction as the welding feed line 4, a second motor 416 that drives the first rotating shaft 412 to rotate, and a sixth cylinder 418 that drives the bracket 411 to rotate around the axis of the hinge seat 417. The bracket 411 is distributed perpendicular to the second welding feed line 22, and the second welding feed line 22 is provided with a clearance notch 221 for the bracket 411 to sink below the second welding feed line 22. The second motor 416 is connected to the first rotating shaft 412 through a synchronous belt and a synchronous pulley to achieve rotational transmission.

[0067] The support 411 is a hollow rectangular frame structure. One side of it is connected by the first rotating shaft 412. The second steering conveyor belt 415 is wound around the other two pairs of sides. The second steering conveyor belt 415 and the corresponding support side enter the clearance gap 221 together under the drive of the sixth cylinder 418, and then sink down to the bottom of the second welding feeding line 22, or lift up from the bottom of the second welding feeding line 22 to transfer the products on the second welding feeding line 22 to the welding inlet and outlet conveyor line 4.

[0068] Below the welding inlet / outlet conveyor line 4, along the conveying direction, are also provided a first lifting and positioning mechanism 42 and a lifting and positioning adjustment mechanism 43 for lifting, positioning, and adjusting the angle of the product at the welding station. The first lifting and positioning mechanism 42 includes a seventh cylinder 421 and an eighth cylinder 422, a first lifting plate 423 driven by the seventh cylinder 421 to move up and down, and a second sensor 424 driven by the eighth cylinder 422 to detect whether the product is in position. A barcode scanner is provided above the first lifting and positioning mechanism 42 for scanning the QR code on the product and binding it to the subsequent welded image. A first positioning post 425 is provided on the first lifting plate 423. The lifting and positioning adjustment mechanism 43 includes a ninth cylinder 431 and a tenth cylinder 432, a third support plate 433 driven by the ninth cylinder 431 to move up and down, a second rotating shaft 434 rotatably mounted on the third support plate 433, a second lifting plate 435 fixed on the second rotating shaft 434, a third motor 436 fixed on the third support plate 433 and driving the second rotating shaft 434 to rotate, upper limit positioning components 437 located on both sides of the second lifting plate 435 and cooperating with it to fix the product, and a third sensor 439 driven by the tenth cylinder 432 to move up and down and detect whether the product is in position. A second positioning post 438 is provided on the second lifting plate 435. The upper limit positioning component 437 includes an upper limit plate and a third positioning post provided on the upper limit plate.

[0069] The output end of the welding inlet / outlet conveyor line 4 is also equipped with a second steering and pushing mechanism 44 that pushes the product from the welding inlet / outlet conveyor line 4 to the main water line 1. The second steering and pushing mechanism 44 includes an eleventh cylinder 441, a fourth support plate 442 driven by the eleventh cylinder 441 to move parallel to the welding inlet / outlet conveyor line 4, a twelfth cylinder 443 fixed on the fourth support plate 442, and a second pushing plate 444 driven by the twelfth cylinder 443 to move up and down.

[0070] The welding unit 3 includes a three-axis transfer mechanism 31, a seventh support plate 32 driven by the three-axis transfer mechanism 31 to move in space, a solder molten head 33 fixed on the seventh support plate 32, a solder ball feeding mechanism (not shown in the figure) connected to the solder ball feeding channel of the solder molten head 33, a visual positioning component 34 and a laser rangefinder 35 set on the seventh support plate 32, and a detection camera 36 for detecting whether solder is attached to the nozzle in the solder molten head 33.

[0071] The soldering head 33 and the solder ball feeding mechanism can be purchased directly from the market.

[0072] The vision positioning component 34 is used to acquire the position of the solder pads, transmit signals to the nozzle, define the nozzle position, and reduce soldering defects.

[0073] The laser rangefinder 35 is used to assist the three-axis transfer mechanism 31 in driving the soldering head 33 to move precisely, measure the relative height of the soldering pads on the product along the Z-axis, transmit the signal to the nozzle, define the Z-axis height of the nozzle, and avoid collision between the nozzle and the soldering pads.

[0074] The detection camera 36 is used to detect whether there is solder residue on the nozzle in the soldering head 33. It is checked once after processing a set number of products. If there is solder residue, an alarm is triggered to notify cleaning.

[0075] The soldering head 33 is equipped with a nozzle connected to a nitrogen gas source via a pipeline; it also features a laser fiber coaxially positioned with the nozzle, using nitrogen to spray molten solder balls onto the solder pads. When the solder balls dissolve and block the nozzle, the nitrogen pressure increases, propelling the solder balls towards the solder pads. Simultaneously, the nitrogen protection effectively prevents the solder balls from oxidizing inside the nozzle.

[0076] At the welding station, the product is lifted by the lifting and positioning adjustment mechanism 43 and fixed in the set welding position and state by the positioning column and the upper limit component. The position of the solder pad is obtained by the vision positioning component 34 and the height of the solder pad is measured by the laser rangefinder 35 to ensure that the distance between the welding nozzle and the solder pad is the same each time, thus ensuring the uniformity and stability of the welding quality. The solder ball feeding mechanism automatically feeds the solder ball into the molten soldering head 33, melts the solder ball with the laser, and then sprays the solder ball out with high-pressure nitrogen to complete the welding. Then, the vision positioning component 34 takes a picture of the welded product to obtain the welding image bound to the product and uploads it to the system.

[0077] In this embodiment, one welding unit 3 is used in conjunction with two welding inlet and outlet conveyor lines 4, and two welding units 3 are provided to reduce the cycle time of the welding process.

[0078] This embodiment also includes an inspection conveyor line 9 located above the end of the main flow line 1. An AI vision inspection unit 7 is positioned above the inspection conveyor line 9. A handling clamping mechanism 6 picks up the product from the main flow line 1 and transfers it to the inspection conveyor line 9. Then, the welded cover plate on the product is removed and placed onto the cover plate return conveyor line 5. The inspection conveyor line 9 is equipped with a lifting and positioning mechanism 91 corresponding to the cover plate removal station and the AI ​​inspection station. The cover plate return conveyor line 5 is parallel to and above the main flow line 1. One end of the cover plate return conveyor line 5 extends to the input end of the main flow line 1, allowing manual or robotic arms to assemble the welded cover plate with a carrier without a welded cover plate before it flows back into the main flow line 1. A barcode scanner is also installed upstream of the AI ​​vision inspection unit 7 on the inspection conveyor line 9 to scan the QR code on the product, binding the AI ​​inspection image acquired by the AI ​​vision inspection unit 7 to the product and uploading it to the system.

[0079] The handling and clamping mechanism 6 includes a fourth motor 61, a fifth support plate 62 driven by the fourth motor 61 for horizontal linear motion, a fifth motor 63 fixed on the fifth support plate 62, a sixth support plate 64 driven by the fifth motor 63 for vertical motion, a thirteenth cylinder 65 and a fourteenth cylinder 66 fixed on the sixth support plate 64, a gripper 67 driven by the thirteenth cylinder 65 for clamping or opening actions, and a suction nozzle 68 driven by the fourteenth cylinder 66 for vertical motion. The gripper 67 is used to clamp the carrier product, and the suction nozzle 68 is used to suck up the welding cover plate.

[0080] The AI ​​visual inspection unit 7 includes a first camera 71 and a second camera 72 set at an angle, and a host computer electrically connected to the first camera 71 and the second camera 72 and equipped with weld point AI inspection system software. In this embodiment, the AI ​​visual inspection unit 7 is based on a recognition model built using artificial intelligence deep learning. The recognition model is trained by collecting images of qualified and unqualified products, and then the trained recognition model is used to identify and judge the welding images collected by the first camera 71 and the second camera 72.

[0081] The waste discharge mechanism 8 includes a fifteenth cylinder 81 located on one side of the inspection conveyor line 9, a third pusher plate 82 driven by the fifteenth cylinder 81 to move perpendicular to the inspection conveyor line 9, and a non-conforming product discharge channel 83 located on the other side of the inspection conveyor line 9 and receiving non-conforming products pushed out by the third pusher plate 82.

[0082] The working principle of the fully automated speaker welding and inspection production line 100 based on soldering and AI visual inspection in this embodiment is as follows: Products with welding covers are placed in a carrier and flow into the main water line 1; then, the carrier is controlled by two first baffle mechanisms 12 to output to the input end of the first welding feed line 21. The carrier is pushed onto the first welding feed line 21 by the first steering and pushing mechanism 11, and then conveyed to the top of the end first steering conveyor 23. The first steering conveyor 23 rises and transfers the carrier to the second welding feed line 22, and then the second welding feed line 22 conveys it to the welding inlet and outlet conveyor line 4 corresponding to the two welding units 3. The carrier is transferred from the second welding feed line 22 to the welding inlet and outlet conveyor line 4 by the second steering conveyor 41, and then lifted and positioned by the first lifting and positioning mechanism 42; then it enters the welding station, and is lifted off the surface of the conveyor line by the lifting and positioning adjustment mechanism 43, and the upper limit component 437 is used to guide the carrier. The angle is adjusted and fixed; with the assistance of a laser rangefinder and a vision positioning component, the welding position of the product is obtained. The three-axis transfer mechanism 31 drives the soldering head 33 to move above the product and perform solder ball welding on the product. After welding, the carrier moves to the end through the welding inlet and outlet conveyor line 4 and is pushed back to the main flow line 1 by the second steering pusher mechanism 44. Then it is transported to the end of the main flow line 1. The carrier is clamped onto the inspection conveyor line 9 by the handling clamping mechanism 6 and lifted and positioned by the lifting positioning mechanism 91. At the same time, the welding cover plate on the product is removed by the handling clamping mechanism 6 and placed on the cover plate return conveyor line 5 for recycling. After the cover plate is removed, the carrier moves to the inspection station. The welding quality is inspected by the AI ​​vision inspection unit 7 and the inspection results are displayed and counted on the control panel. Qualified products will continue to be directly output through the inspection conveyor line 9, while unqualified products will be rejected from the inspection conveyor line 9 by the waste removal mechanism 8.

[0083] This embodiment presents a fully automated speaker welding and inspection production line 100 based on molten soldering and AI visual inspection. It achieves fully automated feeding, conveying, solder ball spraying, AI visual automatic inspection, automatic waste removal, and automatic output for Bluetooth headset speakers, significantly improving welding inspection efficiency, welding quality, and the reliability of inspection results. Specifically, it uses laser-melted solder balls sprayed onto the solder pads to achieve the welding purpose, while simultaneously employing a novel deep analysis device for AI-based solder joint inspection. This device offers advantages such as non-contact operation, no flux, low heat generation, deep analysis, and precise control. Compared to ordinary welding methods, it features impact deformation and instantaneous solidification, along with advantages such as high welding speed, small space requirements, and simple and controllable operation, making it particularly suitable for the manufacturing processes of high-precision electronic products such as headphones. The AI-based recognition testing system, based on artificial intelligence learning, intelligent systems, image recognition, and natural language processing technologies, offers advantages such as high precision, accuracy, stability, and high efficiency.

[0084] The above descriptions are merely some embodiments of the present invention. Those skilled in the art can make various modifications and improvements without departing from the inventive concept of the present invention, and these all fall within the scope of protection of the present invention.

Claims

1. A full-automatic speaker welding and detection production line based on molten solder welding and AI visual detection, characterized in that: It includes: a main flow line; a welding feeding conveying line, which is L-shaped as a whole and vertically connected with the main flow line; a welding unit, which is provided with a plurality of welding units along the main flow line; a welding in-out conveying line, one end of which is vertically connected with the welding feeding conveying line, the other end is vertically connected with the main flow line, and the welding in-out conveying line flows through the welding unit; a cover plate reflow conveying line, which is provided in parallel above the main flow line; a carrying and clamping mechanism, which is provided above the end of the main flow line, removes the welding cover plate on the product and puts it on the cover plate reflow conveying line; an AI visual detection unit, which detects the welding of the product based on a deep learning model; and a waste sorting mechanism. The welding feeding conveying line includes a first welding feeding line vertically connected with the main flow line and a second welding feeding line vertically connected with the end of the first welding feeding line and parallel with the main flow line; the input end of the welding in-out conveying line is provided with a second turning conveying mechanism for transferring the product from the second welding feeding line to the welding in-out conveying line; the second turning conveying mechanism includes a support rotatably arranged on a hinge seat, a first rotating shaft rotatably arranged on one end of the support and coaxially arranged with the rotating shaft of the support, a plurality of first synchronous pulleys arranged on the first rotating shaft, a plurality of second synchronous pulleys arranged on the other end of the support, a second turning conveying belt wound around the first synchronous pulleys and the second synchronous pulleys and formed in the same direction as the conveying direction of the welding in-out conveying line, a second motor for driving the first rotating shaft to rotate, and a sixth cylinder for driving the support to rotate around the hinge seat axis.

2. The full-automatic speaker welding detection production line based on the molten solder welding and AI visual detection according to claim 1, characterized in that: The main flow line is provided with a first turning pushing mechanism at the joint with the welding feeding conveying line, and the first turning pushing mechanism includes a first cylinder above the main flow line and a first pushing plate driven by the first cylinder to move parallel to the conveying direction of the welding feeding conveying line. The main flow line is provided with at least one pair of first blocking mechanisms upstream of the first turning pushing mechanism; the first blocking mechanisms are arranged along the conveying direction of the main flow line; the first blocking mechanisms include a second cylinder and a first blocking plate driven by the second cylinder to move up and down.

3. The full-automatic speaker welding detection production line based on the molten solder welding and AI visual detection according to claim 1, characterized in that: The welding feeding conveying line further includes a first turning conveying mechanism arranged at the intersection of the first welding feeding line and the second welding feeding line, at least one pair of second blocking mechanisms arranged along the first welding feeding line, and a plurality of third blocking mechanisms arranged along the second welding feeding line and corresponding to the position of the welding in-out conveying line.

4. The full-automatic speaker welding detection production line based on the molten solder welding and AI visual detection according to claim 3, characterized in that: The second blocking mechanism includes a third cylinder, a second blocking plate driven by the third cylinder to move up and down, and is arranged below the first welding feeding line. The third blocking mechanism includes a fourth cylinder, a third blocking plate driven by the fourth cylinder to move up and down, and a first sensor fixed on the third blocking plate to detect whether the product is in place; the third blocking mechanism is arranged below the second welding feeding line.

5. The full-automatic speaker welding detection production line based on the molten solder welding and AI visual detection of claim 3, wherein: The first turning conveying mechanism comprises a first support, a fifth cylinder fixed on the upper surface of the first support, a first support plate driven by the fifth cylinder to move up and down, first support rollers rotatably arranged at the front and rear ends of the first support plate, a second support plate fixedly connected with the first support plate and located below the fifth cylinder, second support rollers rotatably arranged on the second support plate, a first motor fixed on the second support plate and driving the second support rollers to rotate, and a first turning conveying belt in a loop arranged on the first support rollers and the second support rollers, and a conveying surface is formed on the first support rollers.

6. The full-automatic speaker welding detection production line based on the molten solder welding and AI visual detection of claim 1, wherein: The supports are perpendicular to the second welding feeding line, and the second welding feeding line is provided with an avoiding gap for the supports to sink below the second welding feeding line.

7. The full-automatic speaker welding detection production line based on the molten solder welding and AI visual detection of claim 1, wherein: A first jacking positioning mechanism is further arranged below the welding in-out conveying line along the conveying direction, and a jacking positioning adjusting mechanism is arranged for jacking positioning and angle adjustment of the product at the welding station. The first jacking positioning mechanism comprises a seventh cylinder and an eighth cylinder, a first jacking plate driven by the seventh cylinder to move up and down, and a second sensor driven by the eighth cylinder to move up and down and detect whether the product is in place; a code scanner is arranged above the first jacking positioning mechanism to scan a two-dimensional code on the product, so that the picture after subsequent welding is bound with the product. The jacking positioning adjusting mechanism comprises a ninth cylinder and a tenth cylinder, a third support plate driven by the ninth cylinder to move up and down, a second rotating shaft rotatably arranged on the third support plate, a second jacking plate fixed on the second rotating shaft, a third motor fixed on the third support plate and driving the second rotating shaft to rotate, an upper limiting assembly located on both sides of the second jacking plate and cooperating with the second jacking plate to fix the product, and a second positioning column arranged on the second jacking plate.

8. The full-automatic speaker welding detection production line based on the molten solder welding and AI visual detection of claim 1, wherein: An output end of the welding in-out conveying line is further provided with a second turning pushing mechanism for pushing the product from the welding in-out conveying line to the main flow line; the second turning pushing mechanism comprises an eleventh cylinder, a fourth support plate driven by the eleventh cylinder to move parallel to the welding in-out conveying line, a twelfth cylinder fixed on the fourth support plate, and a second pushing plate driven by the twelfth cylinder to move up and down.

9. The full-automatic speaker welding detection production line based on the molten solder welding and AI visual detection of claim 1, wherein: The welding unit comprises a three-axis moving mechanism, a seventh support plate driven by the three-axis moving mechanism to move in space, a soldering head fixed on the seventh support plate, a solder ball feeding mechanism in communication with a solder ball feeding channel of the soldering head, a visual positioning assembly and a laser range finder arranged on the seventh support plate, and a detection camera for detecting whether solder is hung on a nozzle in the soldering head.

10. The full-automatic speaker welding detection production line based on the molten solder welding and AI visual detection of claim 1, wherein: Also include the detection conveying line located at the end of the main flow line, the AI vision detection unit is arranged above the detection conveying line, the product is grabbed from the main flow line to the detection conveying line through the carrying clamping mechanism, and then the welding cover plate on the product is taken out and placed on the cover plate reflow conveying line; The detection conveying line is provided with a jacking positioning mechanism corresponding to the cover plate taking-out station and the AI detection station; The cover plate reflow conveying line is arranged parallel to and above the main flow line, and one end of the cover plate reflow conveying line extends to the input end of the main flow line; The AI vision detection unit comprises a first camera and a second camera arranged at an angle, and an upper computer electrically connected with the first camera and the second camera and installed with a welding spot AI detection system software; The carrying clamping mechanism comprises a fourth motor, a fifth support plate driven by the fourth motor to move horizontally and linearly, a fifth motor fixed on the fifth support plate, a sixth support plate driven by the fifth motor to move up and down, a thirteenth air cylinder and a fourteenth air cylinder fixed on the sixth support plate, a clamping jaw driven by the thirteenth air cylinder to perform clamping or opening action, and a suction nozzle driven by the fourteenth air cylinder to move up and down.

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