A batch automatic welding system for network transformers

Abstract

A batch automatic welding system for network transformers includes multiple welding positions and a transformer absorber. The transformer absorber includes an absorption zone and a pair of handles at both ends of the absorption zone. The absorption zone has magnetic force. Each welding position includes a welding device and a conveyor belt arranged below the welding device. One end of the conveyor belt is a grabbing and positioning zone, and the other end is a loading and unloading zone. The conveyor belt is provided with an absorption zone carrier. The welding system also includes a mechanical arm capable of grabbing the transformer absorber and a mechanical arm control module. The present invention uses a magnetic transformer absorber to weld the network transformers after batch absorption. The mechanical arm, conveyor device, welding device, etc. only need to be operated on the transformer absorber, which simplifies the structure and operation process. Batch welding can be automatically performed during welding, which greatly improves production efficiency.

Description

Technical Field

[0001] The invention belongs to the field of electronic technology, relates to network transformer production equipment, and specifically relates to a network transformer batch automatic welding system. Background Art

[0002] The network transformer is an essential module for network equipment such as base stations, routers, switches, and digital network terminals. The main function of the easy-to-locate network transformer is to transmit data. It uses a differential mode coupled coil to couple and filter the differential signal sent by PHY to enhance the signal, and couples it to the other end of the network cable with different levels through the conversion of the electromagnetic field; at the same time, the network transformer also isolates the different levels between different network devices connected by the network cable to prevent different voltages from damaging the equipment through the transmission of the network cable. There are multiple magnetic cores inside the network transformer, and the wires are wound around the magnetic cores to form a signal transformer. The wires and the solder points on the outer shell of the network transformer need to be welded, and the solder points of the network transformer are usually located on the top surface of the outer shell.

[0003] Due to the small size and large output of network transformers, single welding mode is not suitable, and current automatic welding equipment is not suitable for batch welding of small components such as network transformers; although clamps can be set up to fix network transformers in batches, this method requires manual operation, which increases the workload, and the clamping process can easily disrupt the wire connection of the network transformer with wound wires, causing wrong welding during the welding process. Summary of the invention

[0004] In order to overcome the defects of the prior art, the present invention discloses a batch automatic welding system for network transformers.

[0005] The network transformer batch automatic welding system of the present invention comprises a plurality of welding positions and a plurality of transformer absorbers, wherein the transformer absorber comprises an absorption zone and a pair of handles at both ends of the absorption zone, and the absorption zone has magnetic force; each welding position comprises a welding device and a conveyor belt arranged below the welding device, wherein one end of the conveyor belt is a grabbing and positioning zone, and the other end is a loading and unloading zone, and an absorption zone carrier is arranged on the conveyor belt, and the absorption zone carrier comprises a lifting frame; the welding system also comprises a mechanical arm capable of grabbing the transformer absorber and a mechanical arm control module;

[0006] The robot control module can control the robot to grab the transformer absorber that has not been welded from the adsorption area carrier of the grabbing and positioning area of ​​different welding positions according to the preset welding method and send it to the welding device waiting area, and place the welded transformer absorber from the welding device waiting area to the adsorption area carrier of the grabbing and positioning area.

[0007] Preferably, the welding device comprises a solder tank, a welding additive tank and a fan located above the solder tank, wherein the solder tank and the welding additive tank;

[0008] The welding device also includes a conveying rack, which performs the following operations: the transformer adsorber is sent from the waiting area to the welding additive tank, then sent to the solder tank after soaking, and then sent back to the waiting area after welding.

[0009] Preferably, the grabbing and positioning area is provided with a sensor for detecting whether there is a carrier device in the adsorption area, and the sensor is connected to the robot arm control module signal.

[0010] Preferably, a spacing hole is provided in the center of the adsorption area of ​​the transformer adsorber.

[0011] Preferably, the conveyor belt includes a pair of slide rails and a conveyor rack arranged between the slide rails, the adsorption area carrying device is provided with a pair of lower arms and a dragging arm located between the lower arms, the pair of lower arms are respectively slidably mounted on the pair of slide rails, the lower end of the dragging arm is fixed on the conveyor rack, and the conveyor belt also includes a power gear set for driving the conveyor rack to rotate.

[0012] Preferably, the loading and unloading area is provided with a workbench, and buttons for controlling each conveyor belt are provided on the workbench.

[0013] Preferably, the adsorption area carriers on the conveyor belts at different welding positions are divided into two categories, unwelded and welded, according to different heights. The robot control module can control the robot arm to only grab the transformer absorber that has not been welded in the adsorption area carrier of the unwelded category and send it into the welding device, and place the welded transformer absorber from the welding device to the adsorption area carrier of the welded category.

[0014] The network transformer batch automatic welding system of the present invention utilizes the characteristics of the network transformer having a magnetic core inside and a flat distribution of external welding feet, and adopts a magnetic transformer absorber to weld the network transformers after batch absorption. The robot arm, the conveying device and the welding device only need to operate the transformer absorber, which simplifies the structure and the operation process. Batch welding can be automatically performed during welding, which greatly improves the production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 A schematic diagram of a specific implementation of the network transformer batch automatic welding system of the present invention;

[0016] Figure 2 A schematic diagram of a specific embodiment of the transformer adsorber of the present invention;

[0017] Figure 3A schematic diagram of a specific embodiment of the conveyor belt of the present invention;

[0018] Figure 4 A schematic side view of another specific embodiment of the network transformer batch automatic welding system of the present invention;

[0019] Figure 5 It is a side view schematic diagram of another specific implementation mode of the network transformer batch automatic welding system of the present invention;

[0020] The reference numerals in the figure are 1-welding device, 2-mechanical arm, 3-workbench, 4-transformer adsorber, 5-conveyor belt, 6-grabbing and positioning area, 7-loading and unloading area, 8-adsorption area carrier, 9-solder tank, 10-sensor, 11-handle, 12-adsorption area, 13-lower arm, 14-dragging arm, 15-slide rail, 16-transmission rack, 17-power gear set, and 18-spacer hole. DETAILED DESCRIPTION

[0021] The specific implementation modes of the present invention will be further described in detail below in conjunction with the accompanying drawings.

[0022] The network transformer batch automatic welding system of the present invention comprises a plurality of welding positions and a plurality of transformer absorbers 4, wherein the transformer absorber comprises an absorption area 12 and a pair of handles 11 located at both ends of the absorption area, and the absorption area has magnetic force; each welding position comprises a welding device 1 and a conveyor belt 5 arranged below the welding device, wherein one end of the conveyor belt is a grabbing and positioning area 6, and the other end is a loading and unloading area 7, and an absorption area carrier 8 is arranged on the conveyor belt; the welding system also comprises a mechanical arm capable of grabbing the transformer absorber and a mechanical arm control module;

[0023] The robot control module can control the robot to grab the transformer absorber that has not been welded from the adsorption area carrier of the grabbing and positioning area of ​​different welding positions according to a preset welding method and send it to the welding device, and place the welded transformer absorber from the welding device to the adsorption area carrier of the grabbing and positioning area.

[0024] like Figure 1 and Figure 2 As shown, during the operation of the present invention, a worker first arranges a plurality of network transformers in the adsorption area 12 of the transformer adsorber in the loading and unloading area 7. Since the network transformer is very light and has an iron core installed inside, it can be adsorbed by the adsorption area with magnetic force. The adsorption area can be made of a metal-wrapped permanent magnet or an electromagnet can be energized to generate magnetic force.

[0025] Workers place transformer absorbers filled with network transformers in the loading and unloading area 7 of each welding position. After the conveyor belt 5 transports the transformer absorbers to the grabbing and positioning area 6, the conveyor belt stops and waits. After detecting that a transformer absorber is transported from the loading and unloading area to the grabbing and positioning area, the robot arm 2 grabs the transformer absorber and sends it to the welding device 1 for welding. After welding is completed, the robot arm grabs back the welded transformer absorber and sends it back to the grabbing and positioning area; the conveyor belt transports the welded transformer absorber back to the loading and unloading area, and the worker removes the transformer absorber, removes the welded network transformer adsorbed on it, and then arranges new unwelded transformer absorbers on the transformer absorber.

[0026] Removing the transformer and arranging a new unwelded transformer absorber on the transformer absorber can be arranged automatically. When an electromagnet transformer absorber is used, the operation of removing the transformer absorber can be set to power off and shake.

[0027] It can also be arranged manually. In this case, a workbench 3 is provided in the loading and unloading area, and buttons for controlling each conveyor belt are provided on the workbench. After the worker rearranges the unwelded transformers on the transformer absorber, the transformer absorber is placed on the waiting carrier in the absorption area, and the button is pressed to send it back to the grabbing and positioning area.

[0028] The present invention adopts a transformer absorber with magnetic force. Compared with the previous clamps, it can not only load materials in batches, but also is suitable for transformers of different sizes. After the transformer absorber adopts magnetic force absorption, the complex control structure of the clamp is removed, the design is simplified, and the robot arm can grab the handles at both ends of the absorber for grabbing. Figure 2 As shown, a preferred embodiment is as follows: a spacing hole 18 is provided in the center of the adsorption area 12 of the transformer adsorber. The spacing hole can reduce the overall mass of the transformer adsorber on the one hand, and also forces the transformers to be arranged in the adsorption area not densely but around the spacing hole, so that there are no other transformers on both sides of a pair of parallel boundaries of each transformer, thereby avoiding cold welding and welding together during welding.

[0029] A specific embodiment of the welding device includes a solder tank 9, a welding additive tank and a fan located above the solder tank, wherein the solder tank and the welding additive tank;

[0030] The welding device also includes a conveyor frame, which performs the following operations: the transformer absorber is sent from the waiting area to the welding additive tank, and then sent to the solder tank after the immersion is completed, and then sent back to the waiting area after the welding is completed. The conveyor frame can be implemented by a two-dimensional cylinder, and the operation of immersion first and then welding is completed according to the set timing operation. After a welding cycle is completed, a signal is automatically sent to the robot arm to notify the robot arm to retrieve the welded transformer absorber. The automatic welding device of immersion first and then welding is a prior art in the field and will not be described in detail here.

[0031] The conveying frame and the adsorption zone carrier 8 may both include a pair of support arms for cooperating with the handles of the transformer adsorber, and the handles are placed on the support arms to achieve stable support for the transformer adsorber.

[0032] As for the grabbing timing of the robot arm, since the welding and transmission times can be precisely controlled, timing programming design can be adopted, for example, grabbing each workstation at a certain interval.

[0033] While a welding position is waiting for welding, the robotic arm can be used to grab the transformer absorber of other welding positions. Each robotic arm can generally operate 3-5 welding positions at the same time.

[0034] Figure 3 In the specific embodiment shown, the conveyor belt includes a pair of slide rails and a conveying rack arranged between the slide rails, the adsorption area carrier is provided with a pair of lower arms 13 and a dragging arm 14 located between the lower arms, the pair of lower arms are respectively slidably mounted on the pair of slide rails 15, the lower end of the dragging arm is fixed on the conveying rack 16, and the conveyor belt also includes a power gear set 17 for driving the conveying rack to rotate.

[0035] The power device drives the power gear set to rotate, so that the transmission rack engaged with the power gear set rotates and drives the dragging arm to move. The mutually sleeved slide rails and lower arms can make the adsorption area carrier device stably maintain a posture basically perpendicular to the transmission direction during transmission.

[0036] A preferred implementation of the robot arm control method is to set a sensor 10 for detecting whether there is a carrier in the suction area in the grabbing and positioning area, and the sensor is connected to the robot arm control module signal. The sensor is usually a laser sensor or other sensor that can detect whether there is an object in a specific position. When a transformer absorber is found in the grabbing and positioning area, the robot arm can grab it. Under this control method, whether the robot arm grabs or not can also be judged based on whether the most recent operation is for the same position. For example, the robot arm has just grabbed the welded transformer absorber to the grabbing and positioning area. At this time, although the sensor detects the existence of the transformer absorber, the correct operation at this time should be for the conveyor belt to be transmitted back to the loading and unloading area. Therefore, the robot arm can be controlled not to grab the transformer absorber at this position.

[0037] Another more preferred embodiment is as follows Figure 3 , 4 As shown in Figure 5, the adsorption zone carriers on the conveyor belts at different welding positions have two heights, high and low. For example, the higher adsorption zone carrier is set for the unwelded type, and the lower adsorption zone carrier is set for the welded type. The robot arm control module can control the robot arm to grab the transformer absorber that has not been welded and send it to the welding device only at the higher adsorption zone carrier of the unwelded type, and place the welded transformer absorber from the welding device to the adsorption zone carrier of the welded type. This setting method can effectively avoid the wrong grabbing of the robot arm, simplify the programming design of the control program and possible locking errors. At the same time, the staggered placement of adsorption zone carriers of different heights can also make the wider transformer absorber staggered in height transmission, reduce the gap between the conveyor belts, and reduce the equipment footprint.

[0038] The network transformer batch automatic welding system of the present invention utilizes the characteristics of the network transformer having a magnetic core inside and a flat distribution of external welding feet, and adopts a magnetic transformer absorber to weld the network transformers after batch absorption. The robot arm, the conveying device and the welding device only need to operate the transformer absorber, which simplifies the structure and the operation process. Batch welding can be automatically performed during welding, which greatly improves the production efficiency.

[0039] The foregoing describes various preferred embodiments of the present invention. Unless the preferred implementation modes in various preferred embodiments are obviously self-contradictory or based on a certain preferred implementation mode, various preferred implementation modes can be arbitrarily superimposed and used in combination. The embodiments and specific parameters in the embodiments are only for clearly describing the invention verification process of the inventor, and are not used to limit the patent protection scope of the present invention. The patent protection scope of the present invention shall still be based on its claims. All equivalent structural changes made using the contents of the description and drawings of the present invention should be included in the protection scope of the present invention.

Claims

1. A batch automatic welding system for network transformers, comprising a plurality of welding positions, characterized in that: It also includes a plurality of transformer absorbers (4), the transformer absorbers including an absorption area (12) and a pair of handles (11) located at both ends of the absorption area, the absorption area having magnetic force; each welding position includes a welding device (1) and a conveyor belt (5) arranged below the welding device, one end of the conveyor belt is a grabbing and positioning area (6), and the other end is a loading and unloading area (7), and an absorption area carrier (8) is arranged on the conveyor belt; the welding system also includes a mechanical arm (2) capable of grabbing the transformer absorber and a mechanical arm control module; The robot control module can control the robot to grab the transformer absorber that has not been welded from the absorption zone carrier of the grabbing and positioning zone of different welding positions according to the preset welding method and send it to the welding device waiting zone, and place the welded transformer absorber from the welding device waiting zone to the absorption zone carrier of the grabbing and positioning zone; The conveyor belt comprises a pair of slide rails (15) and a conveyor rack (16) arranged between the slide rails; the adsorption zone carrier device comprises a pair of lower arms (13) and a dragging arm (14) located between the lower arms; the pair of lower arms are respectively slidably mounted on the pair of slide rails (15); the lower end of the dragging arm is fixed on the conveyor rack (16); and the conveyor belt further comprises a power gear set (17) for driving the conveyor rack to rotate.

2. The network transformer batch automatic welding system according to claim 1, characterized in that: The welding device comprises a solder tank (9), a welding additive tank and a fan located above the solder tank; The welding device also includes a conveying rack, which performs the following operations: sending the transformer adsorber (4) from the waiting area into the welding additive tank, then into the solder tank after immersion is completed, and then returning to the waiting area after welding is completed.

3. The network transformer batch automatic welding system according to claim 1, characterized in that: The grabbing and positioning area is provided with a sensor (10) for detecting whether there is a carrier device in the adsorption area, and the sensor is connected to the robot arm control module by signal.

4. The network transformer batch automatic welding system according to claim 1, characterized in that: A spacing hole (18) is provided in the center of the adsorption area of ​​the transformer adsorber.

5. The network transformer batch automatic welding system according to claim 1, characterized in that: The loading and unloading area is provided with a workbench (3), and buttons for controlling each conveyor belt are provided on the workbench.

6. The network transformer batch automatic welding system according to claim 1, characterized in that: The adsorption zone carriers on the conveyor belts at different welding positions are divided into two categories, unwelded and welded, according to different heights. The robot arm control module can control the robot arm (2) to only grab the transformer absorber (4) that has not been welded and send it to the welding device (1) in the adsorption zone carrier of the unwelded category, and to place the welded transformer absorber (4) from the welding device to the adsorption zone carrier (8) of the welded category.

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