Automatic Assembly Device for Junction Box

Abstract

An automatic assembly device for a junction box, comprising a frame. A turntable mechanism is rotatably arranged above the frame. A plurality of box body positioning jigs are arranged around the circumference of the turntable mechanism. A resistance welding mechanism, a wire pressing block feeding mechanism, an ultrasonic mechanism, a testing mechanism, and a blanking mechanism are sequentially arranged around the turntable mechanism. In the working state, the box body positioning jig loaded with the junction box is conveyed to the resistance welding mechanism, and the resistance welding mechanism welds the cable of the junction box and the module diode together. The wire pressing block feeding mechanism positions the wire pressing block on the cable of the junction box, and the ultrasonic mechanism fuses the wire pressing block and the junction box together. The testing mechanism tests the electrical characteristics of the junction box, and the blanking mechanism removes the assembled junction box from the box body positioning jig. The present invention is a new type of non-standard automation equipment integrating feeding, processing, detection, and blanking, and mainly solves problems such as slow production efficiency and small production site.

Description

Technical Field

[0001] The present invention relates to an automatic assembly device for junction boxes. Background Art

[0002] In the production operation of photovoltaic modules, manual operation is usually adopted for assembly line processing. Therefore, there is a need for automated production and processing equipment to solve problems such as slow production efficiency and small production space. Summary of the Invention

[0003] In order to overcome the problems encountered in the existing production process, the purpose of the present invention is to provide an automatic assembly device for junction boxes with a relatively small volume and high production and processing efficiency.

[0004] To achieve the above object, the present invention provides an automatic assembly device for junction boxes, which includes a frame. A turntable mechanism is rotatably arranged above the frame. A plurality of box positioning jigs are arranged around the circumference of the turntable mechanism. A resistance welding mechanism, a pressure block feeding mechanism, an ultrasonic mechanism, a testing mechanism, and a blanking mechanism are sequentially arranged around the turntable mechanism. In the working state, the box positioning jig loaded with the junction box is conveyed to the resistance welding mechanism. The resistance welding mechanism welds the cable of the junction box and the module diode together. The pressure block feeding mechanism positions the pressure block on the cable of the junction box. The ultrasonic mechanism fuses the pressure block and the junction box together. The testing mechanism tests the electrical characteristics of the junction box. The blanking mechanism removes the assembled junction box from the box positioning jig.

[0005] Preferably, the turntable mechanism includes a motor, a divider, and a reducer.

[0006] Preferably, the resistance welding mechanism includes a base. An upper air cylinder is sequentially arranged above the base. An upper insulating plate is installed at the output end of the upper air cylinder. A concave electrode mounting plate is connected below the upper insulating plate. An upper transfer rod is connected horizontally to the concave electrode mounting plate. An upper water injection copper rod is vertically inserted through the upper transfer rod. A concave electrode is fixed at the lower end of the upper water injection copper rod. A lower air cylinder is sequentially arranged below the base. A lower insulating plate is installed at the output end of the lower air cylinder. A flat electrode mounting plate is connected above the lower insulating plate. A lower transfer rod is connected horizontally to the flat electrode mounting plate. A lower water injection copper rod is vertically inserted through the lower transfer rod. A flat electrode is fixed at the upper end of the lower water injection copper rod. In the working state, the lower air cylinder drives the flat electrode to move upward to a fixed position, and the upper air cylinder drives the concave electrode to approach the flat electrode to discharge.

[0007] Preferably, the concave electrode and the flat electrode are forged from a titanium zirconium molybdenum material.

[0008] Preferably, the end of the concave electrode has a positioning hole with a radius of.mm to.mm.

[0009] Preferably, the wire pressing block feeding mechanism includes a base, a rotary cylinder arranged on the base, a suction nozzle installed on the rotary cylinder for picking and placing the wire pressing block, and a vacuum valve for controlling the suction nozzle.

[0010] Preferably, the ultrasonic mechanism includes an ultrasonic controller, a base, a vibrator, and an ultrasonic upper and lower mold.

[0011] Preferably, the testing mechanism includes a bracket, a testing cylinder arranged at the top of the bracket, and a probe board connected to the output end of the testing cylinder. When the turntable mechanism rotates to the position where the box body positioning fixture is located below the probe board, the testing cylinder drives the probe board to descend and connect to the junction box for testing.

[0012] Preferably, the testing mechanism further includes a scanning module. The scanning module obtains the number of the junction box and matches it with the test result of the testing mechanism. The discharging mechanism removes the junction box from the box body positioning fixture according to the test result and classifies and collects it.

[0013] Preferably, it further includes a feeding station for placing the junction box in the box body positioning fixture.

[0014] Due to the adoption of the above technical solutions, the present invention is a new non-standard automatic device integrating feeding, processing, detection, and discharging, mainly solving problems such as slow production efficiency and small production site. Description of the Drawings

[0015] Attached Figure 1 is a schematic diagram of the junction box automatic assembly device of the present invention;

[0016] Attached Figure 2 is a three-dimensional view of the resistance welding mechanism of the junction box automatic assembly device of the present invention;

[0017] Attached Figure 3 is an enlarged view of the resistance welding mechanism of the junction box automatic assembly device of the present invention;

[0018] Attached Figure 4 is a front view of the concave electrode of the resistance welding mechanism of the junction box automatic assembly device of the present invention;

[0019] Attached Figure 5 is a front view of the flat electrode of the resistance welding mechanism of the junction box automatic assembly device of the present invention;

[0020] Attached Figure 6 is a three-dimensional view of the testing mechanism of the junction box automatic assembly device of the present invention. Detailed Embodiments

[0021] In the following text, the terms used in the specification will be briefly described, and the embodiments will be described in detail. All terms used herein, including descriptive or technical terms, should be construed as having the meanings understood by those of ordinary skill in the art. However, depending on the intention of those of ordinary skill in the art, precedents, or the emergence of new technologies, these terms may have different meanings.

[0022] In addition, some terms may be selected by the applicant, and in such cases, the meanings of the selected terms will be described in detail in the detailed description of the embodiments. Therefore, the terms used herein must be defined based on the meanings of the terms together with the descriptions throughout the specification. In addition, when a component "includes" or "contains" an element, unless there is a specific description to the contrary, the component may also include other elements without excluding other elements. In the following description, terms such as "component" and "module" indicate units for processing at least one function or operation, where the units and modules can be implemented as hardware or software or by combining hardware and software.

[0023] The embodiments will now be described more fully with reference to the accompanying drawings. However, the embodiments can be implemented in many different forms and should not be construed as limited to the embodiments set forth herein. On the contrary, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the embodiments to those of ordinary skill in the art. In the following description, well-known functions or structures will not be described in detail because they will obscure the embodiments with unnecessary details, and throughout the specification, like reference numerals in the drawings denote the same or similar elements.

[0024] Attached Figure 1 is a schematic diagram of the automatic assembly device for the junction box of the present invention. An automatic assembly device for a junction box in this embodiment includes a frame 1, and a turntable mechanism 2 is rotatably arranged above the frame 1. The turntable mechanism 2 includes a motor, a divider, and a reducer. A plurality of box body positioning fixtures 3 are arranged around the circumference of the turntable mechanism 2, and a resistance welding mechanism 4, a pressure block feeding mechanism 5, an ultrasonic mechanism 6, a testing mechanism 7, and a blanking mechanism 8 are sequentially arranged around the turntable mechanism 2. The electrical part mainly includes an air switch, a PLC, a relay, a relay module, a 37-pin adapter card, a three-color lamp, a button, a human-machine interface, an industrial computer, etc.

[0025] The pressure block feeding mechanism 5 includes a base 51, a rotary cylinder 52 arranged on the base 51, a suction nozzle 53 installed on the rotary cylinder 52 for picking and placing the pressure block, and a vacuum valve for controlling the suction nozzle 53. The ultrasonic mechanism 6 includes an ultrasonic controller, a base, a vibrator, and an ultrasonic upper and lower die.

[0026] In the working state, the box body positioning fixture 3 loaded with the junction box is conveyed to the resistance welding mechanism 4. The resistance welding mechanism 4 welds the cable of the junction box and the module diode together. The pressing block feeding mechanism 5 positions the pressing block on the cable of the junction box. The ultrasonic mechanism 6 fuses the pressing block and the junction box together. The testing mechanism 7 tests the electrical characteristics of the junction box. The unloading mechanism 8 removes the assembled junction box from the box body positioning fixture 3.

[0027] Attached Figure 2 is a perspective view of the resistance welding mechanism of the automatic assembly device of the junction box of the present invention. Attached Figure 3 is an enlarged view of the resistance welding mechanism of the automatic assembly device of the junction box of the present invention. The resistance welding mechanism 4 includes a base 41. Above the base 41, an upper air cylinder 411, an upper insulating plate 412 installed at the output end of the upper air cylinder 411, a concave electrode mounting plate 413 connected below the upper insulating plate 412, an upper transfer rod 414 connected to the concave electrode mounting plate 413 horizontally, an upper water injection copper rod 415 vertically passing through the upper transfer rod 414, and a concave electrode 416 fixed at the lower end of the upper water injection copper rod 415 are sequentially arranged. Below the base 41, a lower air cylinder 417, a lower insulating plate 418 installed at the output end of the lower air cylinder 417, a flat electrode mounting plate 419 connected above the lower insulating plate 418, a lower transfer rod 420 connected to the flat electrode mounting plate 419 horizontally, a lower water injection copper rod 421 vertically passing through the lower transfer rod 420, and a flat electrode 422 fixed at the upper end of the lower water injection copper rod 415 are sequentially arranged. In the working state, the lower air cylinder 417 drives the flat electrode 422 to move upward to a fixed position, and the upper air cylinder 411 drives the concave electrode 416 to approach the flat electrode 422 to discharge.

[0028] Attached Figure 4 is a front view of the concave electrode of the resistance welding mechanism of the automatic assembly device of the junction box of the present invention. Attached Figure 5 is a front view of the flat electrode of the resistance welding mechanism of the automatic assembly device of the junction box of the present invention. The concave electrode 416 and the flat electrode 422 are forged from titanium zirconium molybdenum material. The end of the concave electrode 416 has a positioning hole 423 with a radius of 2.3 mm to 2.5 mm. Since the cable uses lead-free solder sheets with a low melting point and metal resistance welding relies on heat, in order to avoid the melting of the solder sheets affecting the heat and process, the welding uses a compression ratio of 70 - 90 and a welding tensile force of 360 - 400 mpa.

[0029] Attached Figure 6It is a perspective view of the test mechanism of the automatic assembly device for the junction box of the present invention. The test mechanism 7 includes a bracket 71, a test cylinder 72 arranged at the top of the bracket 71, and a probe board 73 connected to the output end of the test cylinder 72. When the turntable mechanism 2 rotates to the position where the box body positioning fixture 3 is below the probe board 73, the test cylinder 72 drives the probe board 73 to descend and connect to the junction box for testing. The test mechanism 7 further includes a scanning module 74. The scanning module 74 obtains the number of the junction box and matches it with the test result of the test mechanism 7. The blanking mechanism 8 removes the junction box from the box body positioning fixture 3 and classifies and collects it according to the test result.

[0030] In another embodiment, it further includes a feeding station for placing the junction box in the box body positioning fixture 3.

[0031] The present invention is a new type of non-standard automation equipment integrating feeding, processing, detection, and blanking, which mainly solves problems such as slow production efficiency and small production site. It has high efficiency (up to more than 600 pieces per hour), small floor area (about 9 square meters per unit), and few labor requirements (one person can operate multiple units).

[0032] It should be understood that the embodiments described herein should be considered only in a descriptive sense and not for the purpose of limitation. The description of the features or aspects within each embodiment should generally be considered applicable to other similar features or aspects in other embodiments. Although one or more embodiments have been described with reference to the drawings, those of ordinary skill in the art will understand that various changes in form and detail can be made therein without departing from the spirit and scope defined by the appended claims.

Claims

1. An automatic assembly device for a junction box, characterized in that: It includes a frame (1), above which a turntable mechanism (2) is rotatably arranged. A plurality of box positioning jigs (3) are arranged around the circumference of the turntable mechanism (2). In sequence around the turntable mechanism (2), there are a resistance welding mechanism (4), a pressure block feeding mechanism (5), an ultrasonic mechanism (6), a testing mechanism (7), and a discharging mechanism (8). The turntable mechanism (2) includes a motor, a divider, and a speed reducer. It also includes a loading station for placing the junction box in the box positioning jig (3). In the working state, the box positioning jig (3) loaded with the junction box is conveyed to the resistance welding mechanism (4), and the resistance welding mechanism (4) welds the cable of the junction box and the module diode together. The pressure block feeding mechanism (5) positions the pressure block on the cable of the junction box. The ultrasonic mechanism (6) fuses the pressure block and the junction box together. The testing mechanism (7) tests the electrical characteristics of the junction box. The discharging mechanism (8) removes the assembled junction box from the box positioning jig (3).

2. The automatic assembly device for a junction box according to claim 1, wherein: The resistance welding mechanism (4) includes a resistance welding base (41). Above the resistance welding base (41), there are sequentially arranged an upper air cylinder (411), an upper insulating plate (412) installed at the output end of the upper air cylinder (411), a concave electrode mounting plate (413) connected to the lower part of the upper insulating plate (412), an upper transfer rod (414) connected horizontally to the concave electrode mounting plate (413), an upper water injection copper bar (415) vertically passing through the upper transfer rod (414), and a concave electrode (416) fixed at the lower end of the upper water injection copper bar (415). Below the resistance welding base (41), there are sequentially arranged a lower air cylinder (417), a lower insulating plate (418) installed at the output end of the lower air cylinder (417), a flat electrode mounting plate (419) connected to the upper part of the lower insulating plate (418), a lower transfer rod (420) connected horizontally to the flat electrode mounting plate (419), a lower water injection copper bar (421) vertically passing through the lower transfer rod (420), and a flat electrode (422) fixed at the upper end of the lower water injection copper bar (421). In the working state, the lower air cylinder (417) drives the flat electrode (422) to move upward to a fixed position, and the upper air cylinder (411) drives the concave electrode (416) to approach the flat electrode (422) to discharge.

3. The automatic assembly device for the junction box according to claim 2, wherein: The concave electrode (416) and the flat electrode (422) are forged from titanium zirconium molybdenum material.

4. The automatic assembly device for junction boxes according to claim 2, wherein: The end of the concave electrode (416) has a positioning hole (423) with a radius of 2.3 mm to 2.5 mm.

5. The automatic assembly device for junction boxes according to claim 1, characterized in that: The pressure block feeding mechanism (5) includes a pressure block feeding base (51), a rotary air cylinder (52) arranged on the pressure block feeding base (51), a suction nozzle (53) installed on the rotary air cylinder (52) for picking and placing the pressure block, and a vacuum valve for controlling the suction nozzle (53).

6. The automatic assembly device for junction boxes according to claim 1, characterized in that: The ultrasonic mechanism (6) includes an ultrasonic controller, an ultrasonic base, a vibrator, and an ultrasonic upper and lower mold.

7. The automatic assembly device for junction boxes according to claim 1, characterized in that: The testing mechanism (7) includes a bracket (71), a testing cylinder (72) arranged at the top of the bracket (71), and a probe board (73) connected to the output end of the testing cylinder (72). When the turntable mechanism (2) rotates to a position where the box positioning fixture (3) is located below the probe board (73), the testing cylinder (72) drives the probe board (73) to move downward to connect to the junction box for testing.

8. The automatic assembly device for junction boxes according to claim 7, characterized in that: The testing mechanism (7) further includes a scanning module (74). The scanning module (74) obtains the number of the junction box and matches it with the test result of the testing mechanism (7). The blanking mechanism (8) removes the junction box from the box positioning fixture (3) according to the test result and classifies and collects it.

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