Full-automatic Insulation Withstand Voltage Test System and Test Method for Rail Transit Widget Products

Abstract

The present invention discloses a fully automatic insulation withstand voltage test system and test method for rail transit small component products. This test system includes a feeding unit, a buffer unit, a vision inspection unit, a docking unit, a test unit, and a discharging unit that are connected in sequence. The feeding unit is used to transport the product to be tested from the tray to the placement position of the buffer unit. The buffer unit is used to sequentially transport the products to the vision inspection unit. The vision inspection unit is used to perform vision inspection on the products. The docking unit is used to automatically wire the products transported to the test position. The test unit is used to perform a fully automatic insulation withstand voltage test on the wired products and transport the products to the discharging unit after the test. The discharging unit is used to transport the products to different tracks for discharging according to the test results. The present invention has the advantages of high automation degree, high test efficiency, high test consistency, etc.

Description

Technical Field

[0001] The present invention mainly relates to the technical field of product testing, and particularly relates to a fully automatic insulation withstand voltage testing system and testing method for small parts products in rail transit. Background Art

[0002] Most products in the rail transit industry have achieved process automation testing, among which unmanned testing and fully automatic testing technologies are increasingly used, and the application of full automation will be more extensive. The unmanned factory is a future trend. Therefore, the feeding before product testing, the wiring during the testing process, and the unloading after the testing machine finishes testing are all problems that need to be solved urgently.

[0003] Traditional insulation withstand voltage testing of small parts requires manual intervention and has the following problems:

[0004] 1. Low testing efficiency: Currently, only manual wiring can be carried out, and one small part product is tested at a time. On average, it takes more than 6 minutes to test one small part product, resulting in low efficiency. When testing a large number of product productions, the problem of low efficiency becomes more prominent, seriously hindering the product delivery process.

[0005] 2. Unable to automatically distinguish whether the product is aged: There are no pre-aging and post-aging processes, and it is impossible to physically distinguish the placement areas automatically. Among them, the aged products cannot be subjected to insulation withstand voltage testing.

[0006] 3. Loading and unloading problems: There is no fully automated production line, and product testing requires manual intervention or operation, making it impossible to achieve fully automated production. Summary of the Invention

[0007] The technical problem to be solved by the present invention lies in: aiming at the technical problems existing in the prior art, the present invention provides a fully automatic insulation withstand voltage testing system and testing method for small parts products in rail transit with high automation degree and high testing efficiency.

[0008] To solve the above technical problems, the technical solution proposed by the present invention is:

[0009] A fully automatic insulation withstand voltage testing system for small parts products in rail transit, including a feeding unit, a buffer unit, a vision detection unit, a docking unit, a testing unit, and a discharging unit that are connected in sequence;

[0010] The feeding unit is used to transport the product to be tested from the tray to the placement position of the buffer unit;

[0011] The buffer unit is used to sequentially transport the products into the vision detection unit;

[0012] The vision detection unit is used to perform vision detection on the products;

[0013] The docking unit is used to automatically wire the products delivered to the testing unit;

[0014] The testing unit is used to perform a full-automatic insulation withstand voltage test on the wired products and deliver the products to the discharging unit after the test;

[0015] The discharging unit is used to deliver the products to different tracks for discharging according to the test results.

[0016] Preferably, the loading unit consists of a manipulator and a tray positioning device controlled thereby; the buffer unit includes a buffer controller, a track movement motor, a track width adjustment control motor, a cylinder, a sensor and a code scanning device; the vision detection unit consists of a camera and an illumination system; the docking unit includes a servo pressing motor, a pressing platform, a positioning device, an upper fixture and a lower fixture; the testing unit includes a temperature and humidity sensor, a test controller, an insulation withstand voltage test device and a PC; the discharging unit includes an NG track, an OK track, a transfer device and a blanking mechanism.

[0017] The present invention also discloses a testing method based on the full-automatic insulation withstand voltage test system for rail transit small parts products as described above, including the steps of:

[0018] S1. The loading unit transports the product to be tested from the tray to the placement position of the buffer unit;

[0019] S2. The buffer unit sequentially transports the products into the vision detection unit;

[0020] S3. The vision detection unit performs vision detection on the products;

[0021] S4. The docking unit automatically wires the products transported to the test position;

[0022] S5. The testing unit performs a full-automatic insulation withstand voltage test on the wired products and delivers the products to the discharging unit after the test;

[0023] S6. The discharging unit transports the products to different tracks for discharging according to the test results.

[0024] Preferably, the specific process of step S1 is as follows:

[0025] S11. Detect the tray on the loading unit;

[0026] S12. Press the start button;

[0027] S13. Confirm whether there are people or other interfering objects within the predetermined range of the loading unit. If not, proceed to the next step;

[0028] S14. Send the tray to the designated position;

[0029] S15. Automatically pull out the tray and position it at a fixed location;

[0030] S16. After taking a photo to confirm the product model, replace the gripper according to the model, and at the same time collect the gripper information and product information and send them to the server;

[0031] S17. The manipulator on the buffer area requires the product model. The manipulator feeds the material and informs the buffer unit of the model of the fed material;

[0032] S18. After the manipulator finishes feeding the material, notify the buffer unit that the feeding is completed. The buffer unit sends the product at the feeding position into the buffer area;

[0033] S19. The buffer area requests the product from the manipulator and repeats steps S17 - S18;

[0034] S110. When there is no product in the feeding area, the manipulator fails, or there are other abnormalities, notify the buffer unit and the server of the status and wait for the server's instruction.

[0035] Preferably, the specific process of step S2 is as follows:

[0036] S21. The PLC controller of the buffer area obtains the product model to be placed at the placement position;

[0037] S22. The PLC controller of the buffer area adjusts the corresponding track width according to the product model;

[0038] S23. The PLC controller of the buffer area requests the product from the manipulator and sends out a product request signal;

[0039] S24. After the PLC controller of the buffer area waits for the manipulator to place the product at the placement position, monitor the product supply signal of the manipulator;

[0040] S25. After the PLC controller of the buffer area monitors the product supply signal of the manipulator, confirm the product placement status;

[0041] S26. After the product status is normal, the PLC controller of the buffer area moves the product from the placement position to the #1 position;

[0042] S27. After the product reaches the #1 position, the PLC controller of the buffer area starts the cylinder to block the movement of the product;

[0043] S28. The PLC controller of the buffer area sends a product request signal to the manipulator again and repeats steps S23 - S27;

[0044] S29. The PLC controller of the buffer area checks whether there is a product at the #2 position. If there is a product, keep the product at the #1 position stationary; if there is no product, move the product at the #1 position to the #2 position;

[0045] S210. The buffer area PLC controller checks if there is a product at position 3#. If there is a product, it keeps the product at position 2# unmoved. If there is no product, it moves the product at position 2# to position 3#.

[0046] S211. The buffer area PLC controller checks if there is a product at position 4#. If there is a product, it keeps the product at position 3# unmoved. If there is no product, it moves the product at position 3# to position 4#.

[0047] S212. The buffer area PLC controller checks if there is a product at position 5#. If there is a product, it keeps the product at position 4# unmoved. If there is no product, it moves the product at position 4# to position 5#.

[0048] S213. The buffer area PLC controller checks if there is a product at position 6#. If there is a product, it keeps the product at position 5# unmoved. If there is no product, it moves the product at position 5# to position 6#.

[0049] S214. Scan the code and transfer the serial number to the vision detection unit and the testing unit.

[0050] S215. The vision detection unit notifies the buffer area PLC controller that the product at position 6# is to be visually inspected.

[0051] S216. After the vision detection is completed, if it fails, it is directly moved to the NG area and the operator is notified to take it out. If it passes, it notifies the buffer area PLC controller that the product at position 6# can be moved.

[0052] S217. The buffer area PLC controller checks if there is a product at position 8#. If there is a product, it keeps the product at position 6# unmoved. If there is no product and an approval instruction is obtained, it moves the product at position 6# to position 8#.

[0053] S218. Repeat steps S27 - S217.

[0054] S219. The buffer area PLC controller checks if there is a product at position 7#. If there is a product, it keeps the product at position 6# unmoved. If there is no product and an approval instruction is obtained, it moves the product at position 6# to the test position 7#.

[0055] Preferably, the specific process of step S3 is as follows:

[0056] S31. Confirm if there is a product at position 6#.

[0057] S32. If there is a product at position 6#, it notifies the buffer area PLC controller that the product at position 6# is being inspected and cannot be moved. If there is no product at position 6#, it continues to wait.

[0058] S33. After the visual inspection is completed, if the inspection passes, notify the buffer area PLC controller to continue moving; if the inspection fails, notify the buffer area PLC controller to move to the NG area.

[0059] Preferably, the specific process of step S4 is as follows:

[0060] S41. Read the product barcode information;

[0061] S42. Check whether the upper fixture number and the lower fixture number are correct according to the barcode information; if correct, allow the product to enter from the 6# position; if incorrect, do not allow the product to enter from the 6# position;

[0062] S43. Send the product to the test position at 8#, and block the product to stop on the track;

[0063] S44. Send the product to the test position at 7#, and block the product to stop on the track;

[0064] S45. The track expands to both sides and moves down at the same time, the track is disengaged from the product, and the product is accurately positioned;

[0065] S46. Clamp the product, detect whether the product is placed in place, if placed in place, continue to execute; if not placed in place, alarm and stop;

[0066] S47. The positioning post of the upper fixture is first pressed into the lower fixture to achieve precise positioning; when the upper fixture presses down and contacts the product, the product is automatically introduced into the housing positioning device, and the entire housing positioning device moves freely in the X / Y direction; detect whether the downward pressure exceeds the standard at the moment of contact, if it exceeds the standard, it is considered that the docking is abnormal, alarm and stop; if there is no abnormality, continue to press down;

[0067] S48. The relative positions of the connectors on the upper fixture and the product are fixed, the upper fixture connector moves freely in the X / Y direction, and preliminary positioning is carried out through the positioning pins added on the connector and the positioning holes on the product. After the positioning pins are inserted into the positioning holes of the product, detect whether the downward pressure exceeds the standard at the moment of contact, if it exceeds the standard, it is considered that the docking is abnormal, alarm and stop; if there is no abnormality, continue to press down;

[0068] S49. The connector on the upper fixture is accurately introduced into the socket of the product by moving freely in the X / Y direction to achieve automatic docking of the connectors. Detect whether the downward pressure exceeds the standard during the pressing process. If it exceeds the standard, it is considered that the docking is abnormal, alarm and stop; if there is no abnormality, continue to press down until it contacts in place.

[0069] Preferably, the specific process of step S5 is as follows:

[0070] S51. Automatically call the product test program according to the product model and serial number;

[0071] S52. The test program reads the coding information of the upper and lower jigs and the verification information of the server. If there is any inconsistency, it stops and alarms; if they are consistent, it continues to execute.

[0072] S53. The test program reads the temperature and humidity information. If the temperature and humidity meet the requirements, it continues the test; if they do not meet the requirements, it alarms for prompt, and after manual confirmation, it continues the test.

[0073] S54. The test program calls the insulation withstanding voltage test equipment to automatically perform insulation resistance tests on the products at test positions 8# and 7#. If it fails, it moves the product to the NG area; if it passes, it continues to execute the test.

[0074] S55. The test program calls the insulation withstanding voltage test equipment to automatically perform a discharging operation on the products at test positions 8# and 7#, and waits for a period of time.

[0075] S56. The test program calls the insulation withstanding voltage test equipment to automatically perform power frequency withstanding voltage tests on the products at test positions 8# and 7#. If it fails, it moves the product to the NG area; if it passes, it continues to execute the test.

[0076] S57. The test program calls the insulation withstanding voltage test equipment to automatically perform a discharging operation on the products at test positions 8# and 7#, and waits for a period of time.

[0077] S58. The test program calls the insulation withstanding voltage test equipment to automatically perform insulation resistance tests on the products at test positions 8# and 7#. If it fails, it moves the product to the NG track; if it passes, it moves the product to the OK track.

[0078] Preferably, the specific process of step S6 is as follows:

[0079] S61. Confirm whether there are products on the NG track and the OK track. If there are products, clear the materials.

[0080] S62. After the track is cleared, read the information of the product to be entered and receive the product.

[0081] S63. After receiving the product, send it to the entrance of the NG track or the OK track.

[0082] S64. The NG track or the OK track receives the product.

[0083] S65. Confirm whether there are products on the NG track and the OK track. If there are products, take away the products.

[0084] S66. Read the information of the next station. If a feeding signal is obtained, feed the materials; if not, wait.

[0085] S67. Repeat steps S62 - S66.

[0086] Compared with the prior art, the advantages of the present invention are as follows:

[0087] The present invention improves efficiency by adopting parallel testing and automated testing means, connects testing with the production line, uses a manipulator for automatic feeding, and completes product wiring and disconnection through an automatic docking technology. The testing process equipment can be docked with the assembly process equipment to form a fully automated production line, truly achieving the goal of unmanned operation; realizing fully automated and unmanned testing of products, and simultaneously performing parallel testing, improving production efficiency, reducing costs, and enhancing the production competitiveness of products in the rail transit industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0088] Figure 1 is a block structure diagram of the system of the present invention in an embodiment.

[0089] Figure 2 is a specific block structure diagram of the system of the present invention in an embodiment.

[0090] Figure 3 is a flowchart of the method of the present invention in an embodiment. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0091] The present invention will be further described below in conjunction with the accompanying drawings of the specification and specific embodiments.

[0092] As Figure 1 shown, the fully automatic insulation withstand voltage testing system for rail transit small parts products in this embodiment includes a feeding unit, a buffer unit, a vision inspection unit, a docking unit, a testing unit, and a discharging unit that are connected in sequence; among them, the feeding unit is used to transport the product to be tested from the tray to the placement position of the buffer unit; the buffer unit is used to sequentially transport the products into the vision inspection unit; the vision inspection unit is used to perform vision inspection on the products; the docking unit is used to automatically wire the products transported to the testing position; the testing unit is used to perform a full-automatic insulation withstand voltage test on the wired products and transport the products to the discharging unit after the test; the discharging unit is used to transport the products to different tracks for discharging according to the test results.

[0093] In a specific embodiment, the feeding unit includes a manipulator and a tray positioning device controlled by it; the buffer unit includes a buffer controller, a track movement motor, a track width adjustment control motor, a cylinder, a sensor, and a code scanning device; the vision inspection unit includes a camera and an illumination system; the docking unit includes a servo pressing motor, a pressing platform, a positioning device, an upper fixture, and a lower fixture; the testing unit includes a temperature and humidity sensor, a test controller, an insulation withstand voltage test device, and a PC; the discharging unit includes an NG track, an OK track, a transfer device, and a blanking mechanism.

[0094] The present invention improves efficiency by adopting parallel testing and automated testing methods, connects testing with production lines, adopts automatic loading by robots and completes product wiring and disconnection through automatic docking technology. The testing process equipment can be docked with the assembly process equipment to form a fully automated line, truly realizing the purpose of unmanned operation; it realizes fully automated and unmanned testing of products, and performs parallel testing at the same time, thereby improving production efficiency, reducing costs, and enhancing the production competitiveness of products in the rail transit industry.

[0095] The present invention also discloses a testing method based on the fully automatic insulation withstand voltage testing unit for rail transit widgets as described above, comprising the steps of:

[0096] S1. The loading unit moves the tested product from the tray to the placement position of the buffer unit;

[0097] S2, the buffer unit transports the products to the visual inspection unit in sequence;

[0098] S3, the visual inspection unit performs visual inspection on the product;

[0099] S4, the docking unit automatically connects the products delivered to the test position;

[0100] S5. The testing unit performs a fully automatic insulation withstand voltage test on the wired products and transports the products to the discharging unit after the test;

[0101] S6. The discharging unit transports the product to different tracks for discharging according to the test results.

[0102] In a specific embodiment, a cylinder, a sensor and an infrared light curtain are installed on the feeding unit. After the system is started normally, the specific process of step S1 is as follows:

[0103] S11, the sensor detects the material tray on the loading unit;

[0104] S12, press the start button;

[0105] S13, the infrared light curtain is activated and it is confirmed whether there are people or other interfering objects within the range of the feeding unit. If not, it proceeds to the next step;

[0106] S14, the loading unit delivers the material tray to the designated position;

[0107] S15, the automation mechanism automatically pulls out the tray and positions it to a fixed position;

[0108] S16, after the robot guides the camera to take a photo to confirm the product model, the gripper is replaced according to the model, and the gripper information and product information are collected and sent to the server;

[0109] S17. The manipulator on the buffer requires the product model, loads the product, and notifies the buffer PLC of the loaded model.

[0110] S18. After the manipulator finishes loading, it notifies the buffer that the loading is complete, and the buffer sends the product at the loading position into the buffer.

[0111] S19. The buffer requests the product from the manipulator and repeats the operations in steps 7 and 8.

[0112] S110. When there is no product in the loading area, the manipulator malfunctions, or there are other abnormalities, the status is notified to the buffer and the server, and it waits for the server's instructions.

[0113] In a specific embodiment, a cylinder, a sensor, a track movement motor, a track width adjustment motor, and a code scanning device are installed on the buffer. After the system is normally started, the specific process of step S2 is as follows:

[0114] S21. The buffer PLC controller requests the product model to be placed at the 0# position from the server.

[0115] S22. The buffer PLC controller starts the track width adjustment motor to adjust the corresponding track width according to the product model.

[0116] S23. The buffer PLC controller requests the product from the manipulator and sends a product request signal.

[0117] S24. After the buffer PLC controller waits for the manipulator to place the product at the 0# position, it monitors the product supply signal from the manipulator.

[0118] S25. After the buffer PLC controller monitors the product supply signal from the manipulator, it reads the sensor information at the 0# position to confirm the product placement status.

[0119] S26. After the product status is normal, the buffer PLC controller starts the track movement motor to move the product from the 0# position to the 1# position.

[0120] S27. The buffer PLC controller reads the sensor information at the 1# position. After the product reaches the 1# position, it starts the cylinder to block the product from moving.

[0121] S28. The buffer PLC controller sends a product request signal to the manipulator again and repeats steps 3 to 7.

[0122] S29. The buffer PLC controller checks whether there is a product at the 2# position. If there is a product, the product at the 1# position is kept stationary; if there is no product, the product at the 1# position is moved to the 2# position.

[0123] S210. The buffer PLC controller checks if there is a product at position 3#. If there is a product, it keeps the product at position 2# stationary; if there is no product, it moves the product at position 2# to position 3#.

[0124] S211. The buffer PLC controller checks if there is a product at position 4#. If there is a product, it keeps the product at position 3# stationary; if there is no product, it moves the product at position 3# to position 4#.

[0125] S212. The buffer PLC controller checks if there is a product at position 5#. If there is a product, it keeps the product at position 4# stationary; if there is no product, it moves the product at position 4# to position 5#.

[0126] S213. The buffer PLC controller checks if there is a product at position 6#. If there is a product, it keeps the product at position 5# stationary; if there is no product, it moves the product at position 5# to position 6#.

[0127] S214. The barcode scanner scans the code and transmits the serial number to the vision inspection unit and the test line system.

[0128] S215. The vision inspection unit notifies the buffer PLC controller to perform a vision inspection on the product at position 6#.

[0129] S216. After the vision inspection is completed, if it fails, it is directly moved to the NG area and the operator is notified to take it out; if it passes, it notifies the buffer PLC controller that the product at position 6# can be moved.

[0130] S217. The buffer PLC controller checks if there is a product at the test position 1 (8#). If there is a product, it keeps the product at position 6# stationary; if there is no product and an approval instruction is obtained, it moves the product at position 6# to the test position 1 (8#).

[0131] S218. Repeat steps 7 to 17.

[0132] S219. The buffer PLC controller checks if there is a product at the test position 2 (7#). If there is a product, it keeps the product at position 6# stationary; if there is no product and an approval instruction is obtained, it moves the product at position 6# to the test position 2 (7#).

[0133] In a specific embodiment, the vision inspection unit mainly consists of a camera. After normal startup, the specific process of step S3 is as follows:

[0134] S31. Take the sensor at position 6# and confirm if there is a product.

[0135] S32. If there is a product at position 6#, notify the buffer area PLC controller that the product at position 6# is being inspected and cannot be moved; if there is no product at position 6#, continue to wait.

[0136] S33. After the visual inspection is completed, if the inspection passes, notify the buffer area PLC controller to continue moving; if the inspection fails, notify the buffer area PLC controller to move to the NG area.

[0137] In a specific embodiment, the product docking unit is composed of a servo down-press motor, a down-press platform jig, a positioning device, an upper jig, and a lower jig. After normal startup, the specific process of step S4 is as follows:

[0138] S41. Read the barcode information of the barcode scanner.

[0139] S42. Check whether the upper jig number and the lower jig number are correct according to the barcode information. If they are correct, allow the product to enter from position 6#; if they are incorrect, do not allow the product to enter from position 6#.

[0140] S43. The product is sent to the test position 1 (8#), and the lower mold stops and rises to block the product to stop on the track.

[0141] S44. The product is sent to the test position 2 (7#), and the lower mold stops and rises to block the product to stop on the track.

[0142] S45. The track expands to both sides and moves down at the same time, the track is separated from the product under test, and the lower jig holds the product under test and moves to the positioning holes (the four diagonal mounting holes enter the positioning holes of the lower mold at the same time), and the product falls onto the lower jig for precise positioning.

[0143] S46. The lower jig clamps the product, and the leveling sensor detects whether the product is placed in place. If it is placed in place, continue to execute; if it is not placed in place, alarm and stop.

[0144] S47. The servo down-press motor drives the down-press platform to move down along the guide rail. The positioning post of the upper jig first presses into the lower jig to achieve precise positioning, and the upper and lower molds are precisely positioned. When the upper jig presses down and contacts the product, the guiding device automatically guides the product into the housing positioning device, and the entire housing positioning device can move freely in the X / Y directions. When contacting, the pressure sensor detects whether the downward pressure exceeds the standard. If it exceeds the standard, it is considered that the docking is abnormal, alarm and stop; if there is no abnormality, continue to execute the down-press.

[0145] S48. The relative positions of the connectors on the upper fixture and the product are fixed. The connector on the upper fixture can move freely in the X / Y directions. Preliminary positioning is carried out by adding positioning pins on the connector and positioning holes on the product. After the positioning pins are inserted into the positioning holes of the product under test, the pressure sensor at the moment of contact detects whether the downward pressure exceeds the standard. If it exceeds the standard, it is considered that the docking is abnormal, and an alarm is given and the operation stops; if there is no abnormality, the downward pressure continues to be applied.

[0146] S49. The connector on the upper fixture is accurately inserted into the socket of the product under test by moving freely in the X / Y directions to achieve automatic docking of the connectors. During the downward pressure application process, the pressure sensor detects whether the downward pressure exceeds the standard. If it exceeds the standard, it is considered that the docking is abnormal, and an alarm is given and the operation stops; if there is no abnormality, the downward pressure continues to be applied until the contact is in place.

[0147] In a specific embodiment, the insulation withstanding voltage test unit mainly consists of a temperature and humidity sensor, a PLC controller, an insulation withstanding voltage test device, and a PC. After the system is normally started, the specific process of step S5 is as follows:

[0148] S51. Automatically call the product test program according to the model and serial number obtained by the barcode scanner.

[0149] S52. The test program reads the coding information of the upper fixture and the lower fixture and the verification information of the server. If there is an inconsistency, it stops and gives an alarm; if they are consistent, it continues to execute.

[0150] S53. The test program reads the temperature and humidity sensor information. If the temperature and humidity meet the requirements, the test continues; if the temperature and humidity do not meet the requirements, an alarm is given for prompt, and after manual confirmation, the test continues.

[0151] S54. The test program calls the insulation withstanding voltage test device to automatically perform insulation resistance tests on the products at test position 1 (8#) and test position 2 (7#). If it fails, the product is moved to the NG area; if it passes, the test continues.

[0152] S55. The test program calls the insulation withstanding voltage test device to automatically perform a discharging operation on the products at test position 1 (8#) and test position 2 (7#), and waits for 5 s.

[0153] S56. The test program calls the insulation withstanding voltage test device to automatically perform power frequency withstanding voltage tests on the products at test position 1 (8#) and test position 2 (7#). If it fails, the product is moved to the NG area; if it passes, the test continues.

[0154] S57. The test program calls the insulation withstanding voltage test device to automatically perform a discharging operation on the products at test position 1 (8#) and test position 2 (7#), and waits for 5 s.

[0155] S58. The test program calls the insulation voltage withstand test equipment to automatically perform insulation resistance tests on the products at test position 1 (8#) and test position 2 (7#). If the test fails, the products are moved to the NG track; if the test passes, the products are moved to the OK track.

[0156] In a specific embodiment, the discharging unit mainly consists of a PLC controller, an NG track, an OK track, a transfer device, and a blanking mechanism. After initialization is completed, step S6 operates as follows:

[0157] S61. The PLC controller reads the sensor information of the NG track and the OK track. If there are products, it notifies the operator to clear the materials.

[0158] S62. After the tracks are cleared, the PLC controller reads the information of the products to enter and notifies the transfer machine to pick up the products.

[0159] S63. After the transfer machine picks up the products, it delivers them to the entrance of the NG track or the OK track.

[0160] S64. The NG track or the OK track receives the products.

[0161] S65. The PLC controller reads the sensor information of the NG track and the OK track. If the products are full, it notifies the operator to take away the products.

[0162] S66. The PLC controller reads the information of the next station. If a feeding signal is obtained, it feeds the materials; if not, it waits.

[0163] S67. Repeat steps S62 to S66.

[0164] During the product testing process, the automatic docking fixture adopts the method of guiding and positioning for rough positioning + floating combination for precise positioning for automatic docking. At the same time, pressure detection is carried out during the docking process to prevent product or equipment damage caused by inaccurate positioning. When designing the docking fixture / equipment, the positioning accuracy of the structural parts should be ensured. The positioning mechanism should not deform after being stressed, and at the same time, it should be wear-resistant to avoid affecting the accuracy due to the use time. The robot realizes the function of replacing manual feeding. The robot vision guidance and motion control are very important. The design and automatic replacement of the gripper need to strictly control the accuracy to avoid unstable operation caused by cumulative errors.

[0165] Such as Figure 3As shown in the figure, before starting the test after power-on, the device first initializes the test system, checks whether the startup status of the PC and the test software is normal. At the same time, the manipulator initialization, buffer initialization, vision detection unit initialization, and docking structure initialization are carried out simultaneously; after the PC and the manipulator communicate and confirm the mutual interaction status, the manipulator initialization is completed; the manipulator gives an IO interaction signal to the buffer and completes the handshake, and the buffer initialization is completed; the buffer interacts with the vision detection unit and completes the handshake, and the vision detection unit initialization is completed; the vision detection unit interacts with the docking unit and completes the handshake, and the docking unit initialization is completed; the docking unit gives an IO interaction signal to the discharging unit and completes the handshake, and the discharging unit initialization is completed; the device connects to the server for connection server verification, obtains the model of the product to be tested, MES verification information, and downloads the test program from the server to the local. After confirmation, the server verification is completed; the device automatically calls the test program according to the product model information obtained from the server and loads it. After loading, it is compared with the MES verification information. After checking, it automatically calls the program to complete; the test program performs fixture ID verification, and after verification, it starts to execute the test; the product starts to enter the device. After scanning the code, the test program will compare whether the current program, the current fixture, and the product match. If they do not match, an alarm will be issued. If they match, automatic docking wiring will be executed, and then the test unit will automatically test. After the test, the test result will be uploaded to the server, the device will automatically disconnect the wiring, and the product will enter the discharging area and wait for the entry instruction of the next process.

[0166] The present invention is compatible with different products, designs an automatic width adjustment function, and can automatically adjust the widths of the buffer, docking unit, transfer machine, and discharging area according to the model of the product to be tested to suit different products. The test of the present invention has strong flexibility and can be compatible with a variety of different models of products to be tested.

[0167] The present invention adds a manipulator, designs an automatic gripper replacement and gripper self-adaptive width of the manipulator to meet different products; when the product model is changed, the manipulator can automatically adjust the gripper width or replace the gripper according to the product model.

[0168] The automated test unit of the present invention designs an automatic program call logic, interactive IO and interactive logic between components, and can ensure that the manipulator program, manipulator gripper, device test program, device fixture, and width automatic adjustment avoid errors.

[0169] The automatic docking method in the test process of the present invention can realize the automatic connection between the test resources and the external interface of the UUT; the servo motor in the docking unit drives the downward pressure platform to drive the upper fixture to press down and cooperate with the limited free floating connector to dock with the product under test. A variety of positioning technologies are used in the docking process, such as product positioning + leveling technology, and the application of comprehensive guidance (guidance of the downward pressure platform + precise guidance of the upper fixture + limited free floating connector + precise positioning pin of the connector). At the same time, the downward force at a specific position is limited during the docking process to ensure that the product under test can be successfully docked with the upper fixture, thereby avoiding damage to the product or equipment due to accuracy problems.

[0170] The present invention adopts two insulation withstand voltage testers to perform parallel testing, thereby improving the testing efficiency.

[0171] The present invention greatly improves the test efficiency, adopts a parallel test mode, and the average test time for testing a tested product is ≤3 minutes, meeting the cycle time requirement of the automated production line.

[0172] The present invention is integrated with the automated production line and the server for interactive integration, and automatically collects, verifies and uploads data to realize automated information management. The testing process does not require human intervention, and adopts a robot loading + fully automated parallel testing mode to achieve unmanned operation.

[0173] The docking unit of the present invention can realize automatic wiring and disconnection of product testing. The application of product positioning + leveling + comprehensive guidance (guidance of the lower pressure platform + precise guidance of the upper fixture + limited free floating connector + precise positioning pin of the connector) ensures smooth wiring of complex products.

[0174] The above are only preferred embodiments of the present invention, and the protection scope of the present invention is not limited to the above embodiments. All technical solutions under the concept of the present invention belong to the protection scope of the present invention. It should be pointed out that for ordinary technicians in this technical field, some improvements and modifications without departing from the principle of the present invention should be regarded as the protection scope of the present invention.

Claims

1. A testing method for a fully automatic insulation withstand voltage testing system of rail transit small parts products, characterized in that, the fully automatic insulation withstand voltage testing system of rail transit small parts products includes a feeding unit, a buffer unit, a vision inspection unit, a docking unit, a testing unit and a discharging unit which are connected in sequence; the feeding unit is used to carry products from the tray to the placement position of the buffer unit; the buffer unit is used to convey products to the vision inspection unit in sequence; the vision inspection unit is used to conduct vision inspection on products; the docking unit is used to automatically wire the products conveyed to the testing position; the testing unit is used to conduct a fully automatic insulation withstand voltage test on the wired products and convey the products to the discharging unit after the test; the discharging unit is used to convey products to different tracks for discharging according to the test results; the testing method includes the steps: S1. The feeding unit carries products from the tray to the placement position of the buffer unit; S2. The buffer unit conveys products to the vision inspection unit in sequence; S3. The vision inspection unit conducts vision inspection on products; S4. The docking unit automatically wires the products conveyed to the testing position; S5. The testing unit conducts a fully automatic insulation withstand voltage test on the wired products and conveys the products to the discharging unit after the test; S6. The discharging unit conveys products to different tracks for discharging according to the test results; The specific process of step S1 is as follows: S11. Detect the tray on the feeding unit; S12. Press the start button; S13. Confirm whether there are people or other interfering objects within the predetermined range of the feeding unit. If not, proceed to the next step; S14. Send the tray to the designated position; S15. Automatically pull out the tray and position it at a fixed position; S16. After taking a photo to confirm the product model, replace the gripper according to the model, and at the same time collect the gripper information and product information and send them to the server; S17. The manipulator on the buffer area requires the product model. The manipulator feeds the material and informs the buffer unit of the feeding model; S18. After the manipulator finishes feeding, notify the buffer unit that the feeding is completed. The buffer unit sends the product at the feeding position into the buffer area; S19. The buffer area asks the manipulator for the product and repeats steps S17 - S18; S110. When there is no product in the feeding area, the manipulator fails or there are other abnormalities, notify the buffer unit and the server of the status and wait for the server's instruction; The specific process of step S2 is as follows: S21. The PLC controller of the buffer area obtains the product model to be placed at the placement position; S22. The PLC controller of the buffer area adjusts the corresponding track width according to the product model; S23. The PLC controller of the buffer area asks the manipulator for the product and sends out the signal for asking for the product; S24. After the PLC controller of the buffer area waits for the manipulator to place the product at the placement position, monitor the signal for giving the product by the manipulator; S25. After the PLC controller of the buffer area monitors the signal for giving the product by the manipulator, confirm the product placement status; S26. After the product status is normal, the PLC controller of the buffer area moves the product from the placement position to the No. 1 position; S27. After the product reaches the 1# position, the buffer area PLC controller starts the cylinder to block the movement of the product; S28. The buffer area PLC controller sends a signal to the manipulator to request the product again, and repeats steps S23 - S27; S29. The buffer area PLC controller checks if there is a product at the 2# position. If there is a product, it keeps the product at the 1# position stationary; if there is no product, it moves the product at the 1# position to the 2# position; S210. The buffer area PLC controller checks if there is a product at the 3# position. If there is a product, it keeps the product at the 2# position stationary; if there is no product, it moves the product at the 2# position to the 3# position; S211. The buffer area PLC controller checks if there is a product at the 4# position. If there is a product, it keeps the product at the 3# position stationary; if there is no product, it moves the product at the 3# position to the 4# position; S212. The buffer area PLC controller checks if there is a product at the 5# position. If there is a product, it keeps the product at the 4# position stationary; if there is no product, it moves the product at the 4# position to the 5# position; S213. The buffer area PLC controller checks if there is a product at the 6# position. If there is a product, it keeps the product at the 5# position stationary; if there is no product, it moves the product at the 5# position to the 6# position; S214. Scan the code and transfer the serial number to the vision inspection unit and the testing unit; S215. The vision inspection unit notifies the buffer area PLC controller that the product at the 6# position is to be visually inspected; S216. After the visual inspection is completed, if it fails, it directly moves to the NG area and notifies the operator to take it out; if it passes, it notifies the buffer area PLC controller that the product at the 6# position can be moved; S217. The buffer area PLC controller checks if there is a product at the 8# position. If there is a product, it keeps the product at the 6# position stationary; if there is no product and it receives the permission instruction, it moves the product at the 6# position to the 8# position; S218. Repeat steps S27 - S217; S219. The buffer area PLC controller checks if there is a product at the 7# position. If there is a product, it keeps the product at the 6# position stationary; if there is no product and it receives the permission instruction, it moves the product at the 6# position to the test position at the 7# position; The specific process of step S3 is as follows: S31. Confirm if there is a product at the 6# position; S32. If there is a product at the 6# position, notify the buffer area PLC controller that the product at the 6# position is being inspected and cannot be moved; if there is no product at the 6# position, continue to wait; S33. After the visual inspection is completed, if the inspection passes, notify the buffer area PLC controller to continue moving; if the inspection fails, notify the buffer area PLC controller to move to the NG area; The specific process of step S4 is as follows: S41. Read the product barcode information; S42. Check if the upper fixture number and the lower fixture number are correct according to the barcode information. If they are correct, allow the product to enter from the 6# position; if they are incorrect, do not allow the product to enter from the 6# position; S43. Send the product to the test position at the 8# position and block the product to stop on the track; S44. Send the product to the test position at the 7# position and block the product to stop on the track; S45. The track expands to both sides and moves downward simultaneously, disengaging from the product to precisely position the product. S46. Clamp the product and detect whether the product is properly placed. If it is properly placed, continue; if not, alarm and stop. S47. The positioning post of the upper fixture is first pressed into the lower fixture for precise positioning. During the downward pressing of the upper fixture, when it contacts the product, the product is automatically guided into the housing positioning device. The entire housing positioning device can move freely in the X / Y directions. At the moment of contact, detect whether the downward pressure exceeds the standard. If it does, it is considered that the docking is abnormal, alarm and stop; if there is no abnormality, continue to press downward. S48. The relative positions of the connectors on the upper fixture and the product are fixed. The connector on the upper fixture can move freely in the X / Y directions. Preliminary positioning is carried out by adding positioning pins on the connector and positioning holes on the product. After the positioning pins are inserted into the product positioning holes, at the moment of contact, detect whether the downward pressure exceeds the standard. If it does, it is considered that the docking is abnormal, alarm and stop; if there is no abnormality, continue to press downward. S49. The connector on the upper fixture is precisely inserted into the product socket through the free movement in the X / Y directions to achieve automatic docking of the connectors. During the downward pressing process, detect whether the downward pressure exceeds the standard. If it does, it is considered that the docking is abnormal, alarm and stop; if there is no abnormality, continue to press downward until the contact is in place.

2. The test method according to claim 1, wherein, the specific process of step S5 is as follows: S51. Automatically call the product test program according to the product model and serial number. S52. The test program reads the coding information of the upper fixture and the lower fixture and the verification information of the server. If there is inconsistency, stop and alarm; if consistent, continue to execute. S53. The test program reads the temperature and humidity information. If the temperature and humidity meet the requirements, continue the test; if the temperature and humidity do not meet the requirements, alarm and prompt, and continue the test after manual confirmation. S54. The test program calls the insulation and withstand voltage test equipment to automatically perform insulation resistance tests on the products at test positions 8# and 7#. If it fails, move the product to the NG area; if it passes, continue the test. S55. The test program calls the insulation and withstand voltage test equipment to automatically perform discharge operations on the products at test positions 8# and 7#, and wait for a period of time. S56. The test program calls the insulation and withstand voltage test equipment to automatically perform power frequency withstand voltage tests on the products at test positions 8# and 7#. If it fails, move the product to the NG area; if it passes, continue the test. S57. The test program calls the insulation and withstand voltage test equipment to automatically perform discharge operations on the products at test positions 8# and 7#, and wait for a period of time. S58. The test program calls the insulation and withstand voltage test equipment to automatically perform insulation resistance tests on the products at test positions 8# and 7#. If it fails, move the product to the NG track; if it passes, move the product to the OK track.

3. The test method according to claim 2, wherein, the specific process of step S6 is as follows: S61. Confirm whether there are products on the NG track and the OK track. If there are products, clear the materials. After the track is cleared, read the information of the product to be entered and receive the product; After receiving the product, send it to the entrance of the NG track or the OK track; The NG track or the OK track receives the product; Confirm whether there is a product on the NG track and the OK track; if there is a product, take it away; Read the information of the next station. If a feeding signal is obtained, feed the material; if not, wait; Repeat steps S62 to S66.

4. The test method according to claim 1, characterized in that, The loading unit consists of a manipulator and a tray positioning device controlled by it; the buffer unit includes a buffer controller, a track movement motor, a track width adjustment control motor, a cylinder, a sensor and a code scanning device; the vision detection unit consists of a camera and an illumination system; the docking unit includes a servo pressing motor, a pressing platform, a positioning device, an upper fixture and a lower fixture; the test unit includes a temperature and humidity sensor, a test controller, an insulation withstand voltage test device and a PC; the discharging unit includes an NG track, an OK track, a transfer device and a blanking mechanism.

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