A multi-station carbon brush spring assembly machine

Abstract

This invention provides a multi-station carbon brush spring assembly machine, which solves the technical problems of low automation and inapplicability to assembling multiple models in existing assembly machines. It includes a worktable, a vision-based feeding system, a robotic arm, a turntable mechanism, an angle adjustment mechanism, and a detection mechanism. The vision-based feeding system has a turntable mechanism on one side of its discharge end, with multiple workstations rotatably connected to the turntable and carbon brush fixtures placed on it. An angle adjustment mechanism is located below the turntable. A robotic arm, equipped with spring fixtures, is located between the vision-based feeding system and the turntable mechanism. A detection mechanism with position detection sensors is also located on the side of the turntable mechanism. This invention, by applying a vision-based feeding system in conjunction with multi-station fixtures, achieves the ability to assemble multiple models. Simultaneously, by combining automation with a robotic arm, and relying on the angle adjustment mechanism and detection mechanism for final detection and feedback adjustment, the overall assembly accuracy can be improved, making it widely applicable in the field of motor assembly technology.

Description

Technical Field

[0001] This invention relates to the field of motor assembly technology, and in particular to a multi-station carbon brush spring assembly machine. Background Technology

[0002] The carbon brushes of electric motors are generally mounted on brush holders. Considering the issues of replacement, fixation, and component fit, disc-type torsion springs or coil springs are generally used to laterally fix the carbon brushes to the brush holders. However, the existing carbon brush spring installation is completed by a spring installation machine, and one spring installation machine is only suitable for one type of spring and corresponding brush holder. For example, Chinese patent CN209970046U - an automatic installation machine for automotive carbon brush torsion springs, discloses a vibratory feeder mechanism, a spring-carrying disc mechanism, a robot assembly, a spring-picking assembly, a brush holder assembly, and a worktable. The vibratory feeder mechanism has a vibratory feeder chassis and a vibratory feeder. The spring-carrying disc mechanism has a first servo motor, a first reducer, a spring-carrying disc bracket, and a spring-carrying disc. The spring-picking assembly has two spring pickers, namely a first spring picker and a second spring picker, each equipped with a rotary cylinder, a torque sensor, a rotation mechanism, a spring positioner, and a rotary pin. The brush holder assembly has a second servo motor, a second reducer, a brush holder bracket, and a brush holder.

[0003] Although the above technical solution has a high degree of automation and solves the problem that traditional process equipment requires a lot of manual intervention, it cannot work properly if different models of workpieces are changed. Generally, it is necessary to stop the machine for tooling replacement, zero-position calibration and other preparatory work.

[0004] In summary, a complete machine suitable for rapid switching between multiple models and automatic identification for carbon brush spring assembly still needs to be designed. Summary of the Invention

[0005] The present invention aims to overcome the shortcomings of the aforementioned background technology by providing a multi-station carbon brush spring assembly machine that is adaptable to various workpiece models.

[0006] To this end, the present invention provides a multi-station carbon brush spring assembly machine, which mainly includes a worktable, a vision feeding system, a robot arm, a turntable mechanism, an angle adjustment mechanism, and a detection mechanism; the vision feeding system, the robot arm, the turntable mechanism, the angle adjustment mechanism, and the detection mechanism are all installed on the worktable;

[0007] The visual feeding system has a turntable mechanism on one side of the discharge end; the main body of the turntable mechanism is a turntable, and multiple workstations are evenly distributed along the circumference of the turntable, each of which is rotatably connected to a carbon brush fixture; the angle adjustment mechanism is provided below the turntable.

[0008] The angle adjustment mechanism is provided with a lifting mechanism at its lower part, and the movable end of the lifting mechanism is provided with a rotary mechanism; the movable end of the rotary mechanism and the carbon brush tool are provided with a split connection structure;

[0009] The robotic arm is provided between the vision loading system and the turntable mechanism. The movable end of the robotic arm is provided with a spring fixture for clamping and torsion springs.

[0010] The detection mechanism is also provided on the side of the turntable mechanism. The main body is a multi-axis moving platform, and a position detection sensor is installed on the moving end of the platform.

[0011] Preferably, the vision feeding system includes a hopper, a machine vision component, and a flexible vibrating plate; a linear vibrator is provided at the bottom of the hopper, and the discharge port is located above the flexible vibrating plate; the machine vision component is also provided above the flexible vibrating plate.

[0012] Preferably, the machine vision component includes a smart camera and a light source; the smart camera and the light source are mounted above the flexible vibrating plate via a cantilever bracket.

[0013] Preferably, a photoelectric switch is provided on the side of the turntable; each carbon brush fixture is provided with a zero-position plate on its side.

[0014] Preferably, a workstation detection sensor is provided between the turntable and the fixed end of the turntable mechanism.

[0015] Preferably, the split connection structure is a face gear pair, and both the movable end face of the rotary mechanism and the lower end face of the carbon brush tool are provided with face gears; after the lifting mechanism rises, the face gears at the two corresponding positions mesh.

[0016] Preferably, the robotic arm is a multi-axis industrial robotic arm, and the movable end is provided with a tooling mounting base.

[0017] Preferably, the upper part of the spring fixture is provided with a rotating mechanism, and the end of the rotating shaft is coaxially connected to the spring positioning pin through a spring return mechanism; a pin is fixedly installed at the lower part of the spring fixture, and the pin is located to the side of the spring positioning pin.

[0018] Preferably, a torque sensor is connected in series on the rotating shaft.

[0019] Preferably, the main body of the detection mechanism is a two-dimensional moving platform; the position detection sensor is a laser displacement sensor.

[0020] This invention provides a multi-station carbon brush spring assembly machine, which has the following beneficial effects:

[0021] This invention achieves the ability to assemble multiple models by applying a vision-based material feeding system in conjunction with multi-station tooling. At the same time, by combining robotic arms to enhance automation, and relying on angle adjustment mechanisms and detection mechanisms for end-point detection and feedback adjustment, the overall assembly accuracy can be improved. Attached Figure Description

[0022] Figure 1 This is an overall perspective view of a specific embodiment of the present invention;

[0023] Figure 2 This is a perspective view of the silo in a specific embodiment of the present invention;

[0024] Figure 3 This is a three-dimensional view of the machine vision component in a specific embodiment of the present invention;

[0025] Figure 4 This is a perspective view of the turntable mechanism in a specific embodiment of the present invention;

[0026] Figure 5 This is a half-sectional view of the turntable mechanism in a specific embodiment of the present invention;

[0027] Figure 6 This is a perspective view of the angle adjustment mechanism in a specific embodiment of the present invention;

[0028] Figure 7 This is a perspective view of the robotic arm in a specific embodiment of the present invention;

[0029] Figure 8 This is a front view of the spring tooling in a specific embodiment of the present invention;

[0030] Figure 9 for Figure 8 Sectional view of AA;

[0031] Figure 10 This is a perspective view of the detection mechanism in a specific embodiment of the present invention;

[0032] Figure 11 This is a perspective view of the spring in this invention;

[0033] Figure 12 This is a schematic diagram of the spring mounting position in this invention;

[0034] The diagram shows the following components: 1. Workbench, 2. Hopper, 3. Machine vision component, 4. Flexible vibratory feeder, 5. Turntable mechanism, 6. Angle adjustment mechanism, 7. Robot arm, 8. Detection mechanism, 9. Spring, 10. Brush holder, 201. Material box, 202. Linear vibrator, 203. Vibrator mounting plate, 204. Fixed screw, 301. Base, 302. Support column, 303. Reinforcing beam, 304. Monitor bracket, 305. Display screen, 306. Bracket, 307. Camera mount, 308. 309. Camera base, 310. Smart camera, 311. Light source, 501. Turntable, 502. Carbon brush fixture, 503. First zero-position plate, 504. First photoelectric switch, 505. Sensor support column, 506. Sensor base, 507. Support column, 508. Station identification plate, 509. Locking nut, 510. Upper tooth, 511. Photoelectric sensor, 512. First bearing, 513. Turntable mounting plate, 514. Bearing with seat, 601. Ejection cylinder, 602. Coupling, 603. Linear bearing, 604. Slide plate, 605. Positioning screw, 606. Lower gear, 607. Second bearing, 608. Double-layer bracket, 609. Ejector rod, 610. Buffer, 611. Servo motor, 701. Robot arm mounting base, 702. Rotary arm, 703. Tooling mounting base, 704. Spring tooling, 801. Platform base, 802. Second photoelectric switch, 803. First lead screw, 804. Second lead screw, 805. Second lead screw motor, 806. Laser 807. Displacement sensor; 808. Sensor bracket; 809. First lead screw motor; 7041. Second zero-position plate; 7042. Rotary cylinder; 7043. Cylinder connecting plate; 7044. Rotary shaft mounting base; 7045. Needle mounting base; 7046. Needle; 7047. Upper coupling; 7048. Torque sensor; 7049. Lower coupling; 70410. Compression nut; 70411. Tooling bearing; 70412. Lower rotating shaft; 70413. Compression spring; 70414. Spring locating pin. Detailed Implementation

[0035] The present invention will be further described below with reference to the accompanying drawings and specific embodiments to aid in understanding its content. Unless otherwise specified, the methods used in this invention are conventional methods; the raw materials and apparatus used, unless otherwise specified, are conventional commercially available products.

[0036] It should be noted that, in this embodiment of the invention, a coil spring is used as an example for illustration; for specific structure, please refer to [reference needed]. Figure 11 As shown, the protruding part at the end of the curled section has an S-shaped structure.

[0037] This invention provides a multi-station carbon brush spring assembly machine, such as... Figure 1As shown, it mainly includes a worktable 1, a vision-based feeding system, a robotic arm 7, a turntable mechanism 5, an angle adjustment mechanism 6, and a detection mechanism 8. Among them, the vision-based feeding system, the robotic arm 7, the turntable mechanism 5, the angle adjustment mechanism 6, and the detection mechanism 8 are all installed on the worktable 1.

[0038] Preferred, combined Figure 1-3 As shown, the vision-based material handling system includes a hopper 2, a machine vision component 3, and a flexible vibrating feeder 4. The hopper 2 is located on the left side of the worktable 1, as shown below. Figure 2 As shown, the main body of the hopper 2 is a rectangular material box 201 with a discharge port on the right side. A linear vibrator 202 is also located below it, with the discharge port positioned above the flexible vibrating plate 4. The linear vibrator 202 is mounted on a vibrator mounting plate 203, which is placed on the workbench 1 surface via four corner fixing screws 204 (or threaded rods). A machine vision component 3 is also located above the flexible vibrating plate 4. Figure 3 As shown, the machine vision component includes a smart camera 310 and a light source 311. The smart camera 310 captures images of the workpiece and provides them to the image analysis module in the system. Specifically, it can use a commercially available intelligent workpiece recognition system. After image training, it can distinguish the workpiece model and its position in the vibratory feeder. The light source 311 can be an LED backlight or a combination of a supplementary light and a reflector. The light source 311 is mounted above the flexible vibratory feeder 4 via a cantilever bracket 306. The bracket 306 is fixed to the worktable 1 via four pillars 302 and corresponding bases 301. The upper part of the bracket 306 is fixed to the camera base 309 via a camera mounting bracket 307 and a camera mounting beam 308, and then the smart camera 310 is connected to it. The middle part of the bracket 306 is fixed to a display screen 305 via a reinforcing crossbeam 303 and a display bracket 304. This display screen is used to display the shooting status and corresponding annotation information, providing reference for the operator and providing a corresponding human-machine interface.

[0039] The flexible vibratory feeder 4 has a turntable mechanism 5 on its right side, such as... Figure 4 , 5 As shown, the main body of the turntable mechanism 5 is a turntable, with a turntable 501 on top. It is rotatably connected to the turntable mounting plate 513 via a first bearing 512. The turntable mounting plate 513 is fixed to the table surface of the workbench 1 by multiple support columns 507 evenly distributed on its lower surface. In this embodiment, the turntable 501 has 6 workstations evenly distributed along its circumference. Each workstation has a corresponding through hole, and a bearing 514 with a seat is installed at the through hole. A carbon brush fixture 502 is rotatably connected to the through hole via a rotating shaft. Each carbon brush fixture 502 has a positioning structure and corresponds to a type of brush holder 10.

[0040] Preferably, to increase positioning accuracy, a first photoelectric switch 504 is provided on the side of the turntable 501, and is fixedly installed on the table surface of the workbench 1 via a sensor support 505 and a sensor base 506. Correspondingly, a first zero-position plate 503 is provided on the side of each carbon brush fixture 502. Furthermore, multiple station identification plates 508 are vertically installed on the lower surface of the turntable 501, and a photoelectric sensor 511 is provided at the center of the turntable mounting plate 513. The photoelectric sensor 511, together with the station identification plates 508, serves as a station detection component to identify the angular position of the turntable 501. Combined with the zero-position identification of the fixture, the specific position of the brush holder 10 in the fixture can be confirmed.

[0041] Accordingly, in order to adjust the angle of the brush holder 10 in the tooling and make its assembly more precise, an angle adjustment mechanism 6 is provided below the turntable 501. Figure 6 As shown, the lower part of the angle adjustment mechanism 6 is equipped with a lifting mechanism, specifically a double-layer bracket 608 with opposing supports. The upper edge is fixed to the opening of the workbench 1 surface by bolts, and ejector cylinders 601 are symmetrically installed at the bottom of the bracket. The ejector rods 609 are fixedly connected to both ends of the slide plate 604 by linear bearings 603. The slide plate 604 is also equipped with positioning screws 605, and a buffer 610 is installed at the corresponding position in the middle layer of the double-layer bracket 608. Its head is coaxial with the positioning screws 605, which is used to limit the downward movement range of the slide plate 604 and to provide a buffering effect. The movable end of the lifting mechanism is equipped with a rotary mechanism, specifically including a servo motor 611. The output shaft is connected to a rotating shaft through a coupling 602. The rotating shaft is rotatably connected to the center hole of the slide plate 604 through a second bearing 607, and a circumferential limiting mechanism is provided on the side of the servo motor 611.

[0042] A separate connection structure is provided between the shaft end of the servo motor 611 and the carbon brush fixture 502; preferably, combined with Figure 4 , 6 As shown, the split connection structure is a face gear pair. The lower part of the rotating shaft of the carbon brush fixture 502 is restricted to axial movement by two locking nuts 509, and an upper tooth 510 is provided at the end of the rotating shaft. A lower tooth 606 is provided at the upper end of the rotating shaft of the servo motor 611. In this way, when the turntable 501 rotates to the position, the angle adjustment mechanism rises, the two face gears mesh, and then the angle of the carbon brush fixture 502 is finely adjusted by rotating the servo motor 611.

[0043] A robotic arm 7 is installed between the vision-based loading system and the turntable mechanism 5, such as... Figure 7 As shown, in this embodiment, a four-axis industrial robot is specifically used. The lower part is fixed to the table surface of the workbench 1 via a robot mounting base 701. The rotating arm 702 is connected to the movable end of the robot 7. The movable end is also equipped with a lifting mechanism and a rotating mechanism, and a tooling mounting base 703 is provided at the end, through which a spring tooling 704 is connected for clamping and torsion springs; preferably, combined with Figure 8 , 9 As shown, the spring fixture 704 has a rotary cylinder 7041 on its upper part, and a hollowed-out cylinder connecting plate 7042 in the middle connecting the lower rotating shaft mounting seat 7043 and the pin mounting seat 7044. Figure 9 As shown, the end of the rotating shaft of the rotary cylinder 7041 is coaxially connected to the torque sensor 7047 via an upper coupling 7046, and the lower part of the torque sensor 7047 is coaxially connected to the lower rotating shaft 70411 via a lower coupling 7048; a rotating structure is formed in the middle by a clamping nut 7049, a tooling bearing 70410, and a lower flange, maintaining the axial position of the lower rotating shaft 70411 and ensuring smooth rotation. Furthermore, the lower rotating shaft 70411 has a hollow structure with a rebound mechanism inside, specifically a compression spring 70412, the lower end of which abuts against a spring positioning pin 70413. The pin's head has a fork-shaped structure, which can be inserted into the center of the coil spring in this embodiment (e.g., ...). Figure 11 (As shown). A circumferential limiting structure is provided between the spring positioning pin 70413 and the lower rotating shaft 70411, so that it can only extend and retract axially. A shift pin 7045 is vertically mounted on the lower part of the shift pin mounting seat 7044, which is located to the side of the spring positioning pin 70413. The main function is that, guided by the vision system, the robot arm 7 drives the spring fixture 704 to pick up the spring 9 in the correct state from the flexible vibrating plate 4. During the picking, the spring positioning pin 70413 is inserted into the center of the coil spring, and at the same time, the rotating pin 7045 is inserted into the S-shaped structure at the front of the extended end of the coil spring. The robot arm moves up, the rotary cylinder 7041 rotates, and then drives the picked spring to tighten. The robot arm moves to the brush holder 10 of the turntable mechanism 5 and installs the spring 9 on the column of the brush holder 10. During the installation, the robot arm 7 adjusts the angle and moves down. During the downward movement, the compression spring 70412 is compressed, and the spring positioning pin 70413 is pushed out by the column of the brush holder 10. After it is in place, the robot arm 7 moves up, the rotary cylinder 7041 returns to its original position, and the assembly of the spring 9 and the brush holder 10 is completed.

[0044] Combination Figure 1 , 10 As shown, a detection mechanism 8 is also provided on the side of the turntable mechanism 5 (right side of the workbench 1). Its main body is a multi-axis moving platform, and a position detection sensor is installed at the moving end of the platform. Preferably, the main body of the detection mechanism 8 is a two-dimensional moving platform, which is mounted on the platform base 801. The first lead screw motor 808 drives the first lead screw 803 to rotate, driving the first slider to move laterally. A second lead screw motor 805 and a second lead screw 804 are also fixed on it, which can drive the second slider to move vertically. A sensor bracket 807 is fixed on the second slider, and a position detection sensor is installed thereon; in this embodiment, a laser displacement sensor 806 is selected. To ensure the accuracy of the movement, a second zero-position plate 809 is installed on each slider, and a second photoelectric switch 802 is installed at both ends of the lead screw. The main function is to address the differences in the positions of the four columns of the same brush holder 10 (e.g., ...). Figure 12 As shown, during the installation of spring 9, the displacement difference of each brush holder column is measured by laser displacement sensor 806 to compensate for the position of the spring installed by the robot arm 7. Since the height of the spring columns of the six brush holders 10 and their positions on the brush holders 10 differ in this embodiment, the position of laser displacement sensor 806 needs to be adjusted by first lead screw motor 808 and second lead screw motor 805.

[0045] In the description of this invention, it should be understood that the terms "left", "right", "up", "down", "top", "bottom", "front", "back", "inner", "outer", "back", "middle", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0046] However, the above description is merely a specific embodiment of the present invention and should not be construed as limiting the scope of the present invention. Therefore, any substitution of equivalent components or equivalent changes and modifications made in accordance with the scope of protection of the present invention should still fall within the scope of the claims of the present invention.

Claims

1. A multi-station carbon brush spring assembly machine, characterized in that, It includes a worktable, a vision-based feeding system, a robotic arm, a turntable mechanism, an angle adjustment mechanism, and a detection mechanism; the vision-based feeding system, the robotic arm, the turntable mechanism, the angle adjustment mechanism, and the detection mechanism are all mounted on the worktable; The turntable mechanism is provided on one side of the discharge end of the vision feeding system; the main body of the turntable mechanism is a turntable, and multiple workstations are evenly distributed along the circumference of the turntable. Each workstation is rotatably connected to a carbon brush fixture. Each carbon brush fixture is provided with a positioning structure and corresponds to a type of brush holder; the angle adjustment mechanism is provided below the turntable. The angle adjustment mechanism is provided with a lifting mechanism at its lower part, and the movable end of the lifting mechanism is provided with a rotary mechanism; the movable end of the rotary mechanism and the carbon brush tool are provided with a split connection structure; The robotic arm is provided between the vision loading system and the turntable mechanism. The movable end of the robotic arm is provided with a spring fixture for clamping and torsion springs. The detection mechanism is also provided on the side of the turntable mechanism. The main body is a multi-axis moving platform. A position detection sensor is installed on the movable end of the platform. The position detection sensor measures the displacement difference of each brush holder column to compensate for the position of the spring installed on the robot arm. The vision-based feeding system includes a hopper, a machine vision component, and a flexible vibrating plate; a linear vibrator is provided at the bottom of the hopper, and the discharge port is located above the flexible vibrating plate; the machine vision component is also provided above the flexible vibrating plate. A photoelectric switch is provided on the side of the turntable; a zero-position plate is provided on the side of each carbon brush fixture; multiple station identification plates are vertically installed on the lower surface of the turntable; and a photoelectric sensor is provided at the center of the turntable mounting plate. Together with the station identification plates, they serve as a station detection component to identify the angular position of the turntable. Combined with the zero-position identification of the fixture, the specific position of the brush holder in the fixture can be confirmed.

2. The multi-station carbon brush spring assembly machine according to claim 1, characterized in that, The machine vision component includes a smart camera and a light source; the smart camera and the light source are mounted above the flexible vibrating plate via a cantilever bracket.

3. The multi-station carbon brush spring assembly machine according to claim 1, characterized in that, The split connection structure is a face gear pair, and face gears are provided on the movable end face of the rotary mechanism and the lower end face of the carbon brush tool; after the lifting mechanism rises, the face gears at the two corresponding positions mesh.

4. A multi-station carbon brush spring assembly machine according to claim 1, characterized in that, The robotic arm is a multi-axis industrial robotic arm, and its movable end is equipped with a tooling mounting base.

5. A multi-station carbon brush spring assembly machine according to claim 1, characterized in that, The upper part of the spring fixture is provided with a rotating mechanism, and the end of the rotating shaft is coaxially connected to the spring positioning pin through a spring return mechanism; a pin is fixedly installed at the lower part of the spring fixture, and the pin is located to the side of the spring positioning pin.

6. A multi-station carbon brush spring assembly machine according to claim 5, characterized in that, A torque sensor is connected in series on the rotating shaft.

7. A multi-station carbon brush spring assembly machine according to claim 1, characterized in that, The main body of the detection mechanism is a two-dimensional moving platform; the position detection sensor is a laser displacement sensor.

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