A full-automatic production line for power modules

Abstract

A kind of power module full-automatic production line, including the power module full-automatic production line body for dispensing encapsulation to plastic shell and DBC, power module full-automatic production line body is by two first conveying mechanism and second conveying mechanism for conveying plastic shell and DBC workpiece, plastic shell processing equipment and DBC processing equipment, plastic shell processing equipment includes feeding mechanism, plastic shell cleaning mechanism, plastic shell dispensing mechanism and first detection mechanism, DBC processing equipment includes feeding mechanism, second detection mechanism and turnover mechanism, combination mechanism is arranged between two conveying mechanisms, plastic shell and DBC are continuously transported, processed and detected by two conveying mechanisms, then plastic shell and DBC are combined by combination mechanism.The application has adjacent plasma cleaning machine and full-automatic dispensing machine, can continuously clean and dispense plastic shell, and simultaneously with DBC processing equipment parallel operation, avoid the problem of low efficiency and high defective product caused by too large time interval of separate operation.

Description

Technical Field

[0001] This invention relates to a fully automated production line for power modules, belonging to the technical field of power module production equipment. Background Technology

[0002] Power modules are a type of product slightly larger than discrete devices, and are semiconductor devices used to construct basic electronic power units. These modules typically consist of power device chips such as IGBTs and diodes. These chips are arranged and combined into various basic circuit units, connected by aluminum wires of different diameters, and then protected by silicone and plastic casings to form the finished power module. Power modules are widely used in automobiles, frequency converters, and other fields.

[0003] In traditional power device packaging processes, loading, unloading, and plastic encapsulation are typically performed manually. Due to personnel changes and varying operator skill levels, rework and defects occur, leading to significant fluctuations in production efficiency and device yield. Furthermore, different operations require different equipment, necessitating multiple manual transfers, where unpredictable risks can result in product defects and rework. Therefore, a fully automated power module production process is designed to overcome these problems. Summary of the Invention

[0004] This invention provides a fully automated production line for power modules that is simple in structure, easy to use and operate, and highly efficient.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a fully automated production line for power modules, comprising a main body for dispensing and encapsulating plastic shells and DBCs, the main body of which consists of two parallel conveying mechanisms, a first conveying mechanism and a second conveying mechanism, respectively used for conveying plastic shells and DBCs, and plastic shell processing equipment and DBC processing equipment respectively disposed on one side of the first conveying mechanism and the second conveying mechanism, wherein the plastic shell processing equipment includes a feeding mechanism, a plastic shell cleaning mechanism, a plastic shell dispensing mechanism and a first detection mechanism, and the feeding mechanism is disposed at the inlet of the first conveying mechanism, and the plastic shell cleaning mechanism and the plastic shell dispensing mechanism... The DBC processing equipment includes a feeding mechanism, a second detection mechanism, and a tilting mechanism. The feeding mechanism is located at the inlet of the second conveyor, the second detection mechanism is located near the middle of the second conveyor, and the tilting mechanism is located near the outlet of the second conveyor. A combination mechanism is also provided on the side near the outlet between the first and second conveyors. After the plastic shell and the DBC are simultaneously conveyed, processed, and detected by the first and second conveyors, they are combined by the combination mechanism.

[0006] Preferably, the loading mechanism of the plastic shell processing equipment and the DBC processing equipment consists of multiple loading trays and conveyor trays placed on the conveying mechanism to support the plastic shell or DBC workpiece to be processed, a robotic arm set between the first conveying mechanism and the second conveying mechanism for transferring the plastic shell or DBC workpiece to be processed, and a motor for driving the robotic arm. After the robotic arm is driven by the motor to grab the plastic shell or DBC and place it on the tray, it is then transported by the two conveying mechanisms.

[0007] Preferably, the flipping mechanism of the DBC processing equipment consists of a standard mechanical electric gripper and a motor for driving the standard mechanical electric gripper. The standard mechanical electric gripper is used to flip the DBC from a chip-up state to a chip-down state. Then, a robotic arm set on one side of the mechanical electric gripper grips the DBC and the plastic shell onto the assembly mechanism for assembly.

[0008] Preferably, the first detection mechanism of the plastic shell processing equipment consists of a three-axis motion frame and a UV camera with a sensor mounted on the three-axis motion frame. The second detection mechanism consists of a three-axis motion frame and an optical camera with a sensor mounted on the three-axis motion frame. The UV camera of the first detection mechanism is a continuous UV light scanning recognition, while the optical camera of the second detection mechanism is a fixed-point camera for image recognition. The first and second detection mechanisms are also connected to an external computer to collect and display operating data and images, facilitating the viewing of the equipment's working status and timely detection of problems.

[0009] Preferably, the plastic shell cleaning mechanism of the plastic shell processing equipment consists of at least one plasma cleaner and an exhaust device. The plasma cleaner includes a three-axis motion module, a gas jet head, and a jet head controller. The gas jet head is controlled to spray air by the jet head controller. The exhaust device includes an exhaust pipe, a painted metal shield installed outside the exhaust pipe, and an external air extraction device connected to the exhaust pipe. The painted metal shield is used to prevent plastic debris from splashing to other workstations.

[0010] Preferably, the plastic shell dispensing mechanism of the plastic shell processing equipment consists of at least one standard fully automatic dispensing machine.

[0011] Compared to existing manual plastic shell packaging technology, the fully automated power module production line designed in this invention features adjacent plasma cleaners and fully automated dispensing machines, enabling continuous cleaning and dispensing of the plastic shells. It operates in parallel with the DBC processing equipment, avoiding the low efficiency and high defect rate issues caused by excessively long intervals between individual operations. This invention offers numerous advantages, including simple structure, convenient operation, and high efficiency. Attached Figure Description

[0012] Figure 1 This is an overall framework diagram of the present invention.

[0013] Figure 2 This is a schematic diagram of the DBC conveyor line tray in this invention.

[0014] Figure 3 This is a schematic diagram of the plastic shell conveyor line tray in this invention.

[0015] Figure 4 This is a schematic diagram of the plastic shell feeding tray structure in this invention.

[0016] Figure 5 This is a schematic diagram of the DBC loading tray structure in this invention. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0019] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but this is not intended to limit the invention. Figure 1As shown, a fully automated production line for power modules includes a main body for dispensing and encapsulating plastic shells and DBCs. The main body comprises two parallel conveying mechanisms 2 and 22 for respectively transporting the plastic shells and DBCs, a plastic shell processing device 3, and a DBC processing device 4. The plastic shell processing device 3 is located on one side of the first conveying mechanism 2, and the second conveying mechanism 22 is located on one side of the DBC processing device 4. The plastic shell processing device 3 includes a feeding mechanism, a plastic shell cleaning mechanism 5, a plastic shell dispensing mechanism 6, and a first detection mechanism 7. The feeding mechanism is located at the inlet of the first conveying mechanism 2. The plastic shell cleaning mechanism 5 and the plastic shell dispensing mechanism... The first detection mechanism 6 is located near the middle of the first conveying mechanism 2, and the first detection mechanism 7 is located near the discharge port of the first conveying mechanism 2. The DBC processing equipment 4 includes a feeding mechanism, a second detection mechanism 8, and a flipping mechanism 9. The feeding mechanism is located at the inlet of the second conveying mechanism 22, the second detection mechanism 8 is located near the middle of the second conveying mechanism 22, and the flipping mechanism 9 is located near the discharge port of the second conveying mechanism 22. A combination mechanism 10 is also provided on the side near the discharge port between the first and second conveying mechanisms. After the plastic shell and DBC are simultaneously conveyed, processed, and detected by the first and second conveying mechanisms, they are combined by the combination mechanism 10.

[0020] The loading mechanism of the plastic shell processing equipment 3 and the DBC processing equipment 4 consists of multiple loading trays 11 and conveyor trays 12 placed on the conveying mechanism to support the plastic shell or DBC workpiece to be processed, a robotic arm 13 for transferring the plastic shell or DBC workpiece to be processed, and a motor 20 for driving the robotic arm 13, which is set between the first conveying mechanism 2 and the second conveying mechanism 22. The robotic arm 13 is driven by the motor 20 to grab the plastic shell or DBC and place it on the tray, and then it is transported by the two conveying mechanisms.

[0021] The flipping mechanism 9 of the DBC processing equipment 4 consists of a standard mechanical electric gripper 14 and a motor for driving the standard mechanical electric gripper 14. The standard mechanical electric gripper 14 is used to flip the DBC from a chip-up state to a chip-down state. Then, the mechanical arm 21 set on one side of the mechanical electric gripper 14 grabs the DBC and the plastic shell onto the combination mechanism 10 for combination.

[0022] The first detection mechanism 7 of the plastic shell processing equipment 3 consists of a three-axis motion frame and a UV camera 15 with a sensor mounted on the three-axis motion frame. The second detection mechanism 8 consists of a three-axis motion frame and an optical camera 16 with a sensor mounted on the three-axis motion frame. The UV camera 15 of the first detection mechanism is a continuous UV light scanning recognition, while the optical camera 16 of the second detection mechanism 8 is a fixed-point camera for image recognition. The first detection mechanism 7 and the second detection mechanism 8 are also connected to an external computer to collect and display operating data and images, so as to facilitate the viewing of the working status of the equipment and facilitate the timely detection of problems.

[0023] The plastic shell cleaning mechanism 5 of the plastic shell processing equipment 3 consists of at least one plasma cleaner 17 and an exhaust device 18. The plasma cleaner 17 includes a three-axis motion module, a gas jet head, and a jet head controller. The gas jet head is controlled to spray air by the jet head controller. The exhaust device 18 includes an exhaust pipe, a painted metal shield installed outside the exhaust pipe, and an external air extraction device connected to the exhaust pipe. The painted metal shield is used to prevent plastic debris from splashing to other workstations.

[0024] The plastic shell processing equipment 3's plastic shell dispensing mechanism 6 consists of at least one standard fully automatic dispensing machine 19. The standard fully automatic dispensing machine is a standard component, and its structure and connection method are completely consistent with those of a general fully automatic dispensing machine.

[0025] The working process of this invention is as follows: Figure 1 This is an overall framework diagram of the present invention. The fully automated power module production line includes two conveying mechanisms (DBC conveying mechanism and plastic shell conveying mechanism) and multiple robotic arms (robotic arm 13, standard robotic gripper 14, and robotic arm 21). The processing equipment distributed on the plastic shell conveying mechanism includes a loading tray for placing plastic shells, a conveyor line tray, a plastic shell cleaning mechanism, a plastic shell dispensing mechanism, and a first inspection mechanism. The processing equipment distributed on the DBC conveying mechanism includes a loading tray for placing DBCs, a conveyor line tray, a second inspection mechanism, and a flipping mechanism. The structural schematic diagrams of the DBC conveyor line tray, plastic shell conveyor line tray, plastic shell loading tray, and DBC loading tray are shown below. Figure 2 , Figure 3 , Figure 4 and Figure 5 As shown.

[0026] It should be noted that the fully automated power module production line is also equipped with some functional modules, such as control systems and power distribution cabinets, to facilitate the control of the entire device and to enable or disable it; the DBC is a semi-finished module that has undergone chip soldering, aluminum wire soldering, cleaning and inspection, and PIN pin soldering; the plastic shell needs to have markings that meet the company's requirements printed on it using a marking machine, and the operator manually loads it onto the loading tray.

[0027] The main function of the fully automated power module production line is to seal the semi-finished DBC with the plastic shell together using sealant.

[0028] As described in the detailed function above, the plastic shell is picked up from the loading tray by a robotic arm and placed on the conveyor tray. The conveyor tray is then transported to the plastic shell cleaning mechanism via a plastic shell conveying mechanism. Upon detection by sensors, the plasma cleaner automatically starts, spraying flames to clean the plastic shell according to a pre-set program. Simultaneously, an exhaust system continuously extracts the generated waste gas through pipes, and a metal shield prevents plastic debris from splashing to other workstations. The cleaned plastic shell is then conveyed to the plastic shell dispensing mechanism. Upon detection by sensors within the dispensing mechanism, the dispensing machine automatically starts, applying sealant according to pre-set process parameters. After coating, the shell enters the first inspection mechanism, where a UV camera scans the sealant application. The camera sends the data to computer software, which automatically determines whether the sealant application is incomplete or misaligned according to the process parameters, thus ensuring product quality. Finally, the qualified plastic shells are conveyed to the assembly mechanism, awaiting assembly. After the robotic arm picks up the plastic shell, it simultaneously picks up a DBC from the loading tray and places it on the conveyor tray. The conveyor tray is then transported to the second inspection mechanism via the DBC conveyor mechanism. Upon detection by sensors in the second inspection mechanism, the camera automatically takes a picture according to the set program. The data is transmitted to the software via the controller. The software calculates according to the set process parameters and automatically determines whether the pin position and perpendicularity are up to standard. Qualified products are then transported to the flipping mechanism via the DBC conveyor mechanism. Upon detection, the flipping claw automatically grips the product, flips it 180°, and moves it to the designated position set by the equipment. The robotic arm then picks up the DBC from the flipping claw and places it at the assembly mechanism for assembly. Both conveyor mechanisms perform their respective processing simultaneously, ensuring that one DBC is assembled with one plastic shell. Data collection devices (the first and second inspection mechanisms, and external computers, etc.) can be connected to each module mechanism to read the equipment's operating status in real time, allowing administrators to quickly complete equipment inspection and maintenance by reviewing past records.

[0029] Compared with existing manual plastic shell packaging technology, the fully automated power module production line of this invention has adjacent plasma cleaning machines and fully automated dispensing machines, which can continuously clean and dispense plastic shells, and operate in parallel with DBC processing equipment, avoiding the problems of low efficiency and high defect rate caused by excessively long time intervals between individual operations.

[0030] The above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions or improvements within the spirit of the present invention are covered within the scope of the claims of the present invention.

[0031] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A fully automated production line for power modules, comprising a main body for dispensing and encapsulating plastic shells and DBCs, characterized in that: The fully automated power module production line body (1) consists of two parallel first conveyor mechanisms (2) and second conveyor mechanisms (22) used for conveying plastic shells and DBC workpieces respectively, and plastic shell processing equipment (3) and DBC processing equipment (4) respectively set on one side of the first conveyor mechanism (2) and the second conveyor mechanism (22). The plastic shell processing equipment (3) includes a feeding mechanism, a plastic shell cleaning mechanism (5), a plastic shell dispensing mechanism (6) and a first detection mechanism (7). The feeding mechanism is set at the inlet of the first conveyor mechanism (2), the plastic shell cleaning mechanism (5) and the plastic shell dispensing mechanism (6) are set in the middle position near the first conveyor mechanism (2), and the first detection mechanism (7) is set in the middle position of the first conveyor mechanism (2). The first conveying mechanism (2) is located near the discharge port. The DBC processing equipment (4) includes a feeding mechanism, a second detection mechanism (8) and a flipping mechanism (9). The feeding mechanism is located at the inlet of the second conveying mechanism (22). The second detection mechanism (8) is located near the middle of the second conveying mechanism (22). The flipping mechanism (9) is located near the discharge port of the second conveying mechanism (22). A combination mechanism (10) is also provided on the side near the discharge port between the first conveying mechanism and the second conveying mechanism. After the plastic shell and DBC are conveyed, processed and detected by the first conveying mechanism and the second conveying mechanism, they are combined by the combination mechanism (10).

2. The fully automated power module production line according to claim 1, characterized in that: The loading mechanism of the plastic shell processing equipment (3) and the DBC processing equipment (4) consists of multiple loading trays (11) and conveyor trays (12) placed on the conveying mechanism to support the plastic shell or DBC workpiece to be processed, a robot arm (13) set between the first conveying mechanism (2) and the second conveying mechanism (22) for transferring the plastic shell or DBC workpiece to be processed, and a motor (20) for driving the robot arm (13). After the robot arm (13) is driven by the motor (20) to grab the plastic shell or DBC and place it on the tray, it is then transported through the two conveying mechanisms.

3. The fully automated power module production line according to claim 2, characterized in that: The flipping mechanism (9) of the DBC processing equipment (4) consists of a standard mechanical electric gripper (14) and a motor for driving the standard mechanical electric gripper (14). The standard mechanical electric gripper (14) is used to flip the DBC from the chip-up state to the chip-down state. Then, the mechanical arm (21) set on one side of the mechanical electric gripper (14) grabs the DBC and the plastic shell onto the combination mechanism (10) for combination.

4. The fully automated power module production line according to claim 2, characterized in that: The first detection mechanism (7) of the plastic shell processing equipment (3) consists of a three-axis motion frame and a UV camera (15) with a sensor mounted on the three-axis motion frame. The second detection mechanism (8) consists of a three-axis motion frame and an optical camera (16) with a sensor mounted on the three-axis motion frame. The UV camera (15) of the first detection mechanism is a continuous UV light scanning recognition, and the optical camera (16) of the second detection mechanism (8) is a fixed-point camera for taking pictures and recognizing. The first detection mechanism (7) and the second detection mechanism (8) are also connected to an external computer to collect and display operating data and pictures, so as to facilitate the viewing of the working status of the equipment and facilitate timely detection of problems.

5. The fully automated production line for power modules according to claim 4, characterized in that: The plastic shell cleaning mechanism (5) of the plastic shell processing equipment (3) consists of at least one plasma cleaner (17) and an exhaust device (18). The plasma cleaner (17) includes a three-axis motion module, a gas jet head and a jet head controller. The gas jet head is controlled to spray gas through the jet head controller. The exhaust device (18) includes an exhaust pipe, a painted metal shield set outside the exhaust pipe, and an external air extraction device connected to the exhaust pipe. The painted metal shield is used to prevent plastic debris from splashing to other workstations.

6. The fully automated production line for power modules according to claim 5, characterized in that: The plastic shell processing equipment (3) has a plastic shell dispensing mechanism (6) consisting of at least one standard fully automatic dispensing machine (19).

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