A single-board full-automatic test production line integrated with a manipulator and a test method

Abstract

The present invention discloses a single-board full-automatic test production line integrated with a manipulator and a test method. This production line includes: a board loading machine for sending the product to be tested from the rack to a predetermined position; an insulation withstanding voltage test bench for performing insulation withstanding voltage tests on the circuit board; an ICT test bench for performing ICT tests on the circuit board; a function test bench for performing function tests on the circuit board; a board unloading machine for transferring the circuit board to an AGV trolley; a manipulator for realizing the transfer of the circuit board; the board loading and unloading machine and each test bench are arranged around the manipulator, and a safety fence forms a working area; a central control cabinet for being responsible for supervising the operation of the entire system, product and program switching, and data acquisition, and monitoring that the safety fence is in a closed state. The present invention can achieve fully automatic and unmanned testing of products, improve production efficiency, reduce the test cycle, realize automatic data acquisition and traceability, and enhance the production competitiveness of products in the rail transit industry.

Description

Technical Field

[0001] The present invention mainly relates to the technical field of circuit board testing, and in particular to a single-board fully automatic testing production line and a testing method integrated with a manipulator. Background Art

[0002] The testing of circuit boards in industries such as automotive electronics is basically automated or unmanned, and the application of automated lines will be more extensive. Unmanned factories are a future trend, so the loading of products before testing, wiring during testing, and offline testing after the testing machine is completed are all urgent problems to be solved. Therefore, the insulation withstand voltage, ICT and functional testing of single boards are fully automated at the circuit board stage, and the single board is transferred between different testing processes through a manipulator. Automatic loading is achieved by docking the AGV trolley with the automatic loading and unloading machine, and artificial intelligence is integrated in the central control cabinet to assist technicians in intelligent diagnosis and analysis of single board defects.

[0003] At present, traditional circuit board testing requires manual intervention, such as wiring and disconnection, manual confirmation of test process information, etc., and only one product can be tested at a time, which is inefficient. The use of automated testing methods is the main way to improve efficiency. At the same time, the test is connected with the production line, and automatic loading is done by a robot. The automatic fixture and automatic board loader are connected with the AGB to truly realize unmanned automatic testing.

[0004] In addition, traditional circuit board testing requires insulation withstand voltage testing, online testing, and functional testing to ensure that the functions of the circuit board meet the requirements of the technical specifications. The technical problems that need to be solved in the existing technology are:

[0005] 1) Unmanned fully automatic testing. The insulation withstand voltage test, online test and functional test of the circuit board are distributed in different areas. Each station requires an operator to place the board, manually measure some signals and take the board, which has a very high labor cost.

[0006] 2) Shorten the production cycle. The insulation withstand voltage test, online test and functional test of the circuit board are distributed in different areas. Each station needs half a day of buffer time to ensure the continuity of test production, resulting in a production cycle of 2 days for the circuit board test process, which seriously affects product delivery.

[0007] 3) The problem of automatic loading and unloading. The insulation and withstand voltage test, online test and functional test equipment of the circuit board each require an operator to place and take the board. Occasionally, the board is placed abnormally, resulting in the board being crushed, or the operator is not skilled, resulting in the board being damaged when placing the board.

[0008] 4) Solve the problem of low test efficiency. The insulation withstand voltage test and function test of the circuit board require manual operation, which has problems such as long wiring time, poor consistency of manual testing and low test efficiency.

[0009] 5) Problem of automatic acquisition of test data. The insulation withstand voltage test and functional test data of the circuit board are not fully automatically acquired, and data traceability cannot be achieved, which brings problems to subsequent data analysis. Summary of the Invention

[0010] The technical problem to be solved by the present invention lies in: aiming at the problems existing in the prior art, the present invention provides a single-board full-automatic test production line and test method of an integrated manipulator that can achieve full automation and unmanned testing of products, improve production efficiency, reduce operators, shorten the test cycle, realize automatic data acquisition and traceability, and enhance the production competitiveness of products in the rail transit industry.

[0011] To solve the above technical problems, the technical solution proposed by the present invention is:

[0012] A single-board full-automatic test production line of an integrated manipulator, comprising:

[0013] A loading machine for sending the product to be tested from the rack to a predetermined position;

[0014] An insulation withstand voltage test bench for performing insulation withstand voltage test on the circuit board;

[0015] An ICT test bench for performing ICT test on the circuit board;

[0016] A functional test bench for performing functional test on the circuit board;

[0017] An unloading machine for transferring the circuit board to the AGV trolley;

[0018] A manipulator for realizing the transfer of the circuit board among the loading machine, the insulation withstand voltage test bench, the ICT test bench, the functional test bench and the unloading machine;

[0019] A safety fence for forming a working area to accommodate each component;

[0020] The loading machine, the insulation withstand voltage test bench, the ICT test bench, the functional test bench and the unloading machine are arranged around the manipulator;

[0021] A central control cabinet for supervising the operation of the entire system, product and program switching and data acquisition, and monitoring that the safety fence is in a closed state.

[0022] The present invention also discloses a test method based on the single-board full-automatic test production line of the integrated manipulator as described above, including a full-automatic test method, and the specific steps are:

[0023] The loading machine, the insulation withstand voltage test bench, the ICT test bench, the functional test bench, the unloading machine, the manipulator and the central control cabinet in the single-board full-automatic test production line perform self-inspection;

[0024] The central control cabinet downloads the test program from the file server according to the drawing number, verifies the file to ensure the integrity of the downloaded file, and then distributes the program to the board loading machine, insulation withstand voltage test bench, ICT test bench, function test bench, manipulator, and board unloading machine respectively; each test bench executes the program automatic loading and verifies the test program number, test program version, test equipment ID, and test fixture ID with the MES system; after the loading is completed, the upper covers of the fixtures on the insulation withstand voltage test bench, ICT test bench, and function test bench are opened, and the manipulator performs coordinate calibration. First, it determines that there is no circuit board on the gripper by shooting the features on the gripper with a fixed camera, and then it shoots the feature points on the insulation withstand voltage test fixture, ICT test fixture, and function test fixture respectively with a moving camera, calibrates and updates the coordinates of the three fixtures in the manipulator coordinate system, and eliminates the installation error of the fixtures;

[0025] The board loading machine sends out the circuit board in the rack to the adaptive board receiving device. After detecting the circuit board, it notifies the manipulator that the board loading of the board loading machine is completed; after receiving the signal, the manipulator moves above the adaptive board receiving device to shoot the feature points of the circuit board to calibrate the coordinates of the circuit board and complete the positioning of the circuit board; after the positioning of the circuit board is completed, the manipulator moves the camera to scan the QR code on the circuit board and parse the serial number and drawing number, confirms the current serial number of the circuit board, and completes the scanning of the serial number; the manipulator grabs the circuit board to the position of the fixed camera to perform secondary positioning of the circuit board to avoid coordinate deviation caused by the moment of the gripper grabbing the board and completes the secondary positioning of grabbing the board;

[0026] The manipulator takes out the circuit board in the withstand voltage fixture with the 1# position of the gripper and then places the circuit board on the 2# position of the gripper into the withstand voltage fixture, completes the board taking and placing of the withstand voltage fixture and sends a signal to the insulation withstand voltage test bench; after receiving the signal that the board taking and placing of the withstand voltage fixture is completed, the insulation withstand voltage test bench closes the upper cover of the withstand voltage fixture and performs the withstand voltage test. After the test is completed, it judges the withstand voltage test result. If the test result fails, it executes the NG tray board placement; if the test result passes, it completes the board taking and placing of the withstand voltage fixture and sends a signal to the insulation withstand voltage test bench;

[0027] The manipulator takes out the circuit board in the ICT fixture with the 1# position of the gripper and then places the circuit board on the 2# position of the gripper into the ICT fixture, completes the board taking and placing of the ICT fixture and sends a signal to the ICT test bench; after receiving the signal that the board taking and placing of the ICT fixture is completed, the ICT test bench closes the upper cover of the ICT fixture and performs the ICT test. After the test is completed, it judges the ICT test result. If the test result fails, it executes the NG tray board placement; if the test result passes, it completes the board taking and placing of the ICT fixture and sends a signal to the ICT test bench;

[0028] The gripper of the robotic arm takes out the circuit board from the fixture at the 1# position, then places the circuit board at the 2# position of the gripper onto the fixture, completes the board picking and placing of the fixture, and sends a signal to the functional test bench. After receiving the signal indicating that the board picking and placing of the fixture is completed, the functional test bench closes the upper cover of the fixture and performs a functional test. After the test is completed, it judges the functional test result. If the test result fails, it executes the action of placing the board on the NG tray. If the test result passes, it completes the board picking and placing of the fixture and sends a signal to the functional test bench. The robotic arm grabs the circuit board to the fixed camera position for secondary positioning of the circuit board to avoid coordinate deviation caused by the moment when the gripper grabs the board, and completes the secondary positioning of the placed board.

[0029] The robotic arm moves the circuit board to the adaptive board receiving device of the board placer, completes the board placing to the lower board machine, and the test ends.

[0030] As a further improvement of the above technical solution:

[0031] It also includes an automatic test program calling process, specifically: after the software starts, it is necessary to select the drawing number of the product to be tested, and check with the production program database to obtain the program path and program package verification information. After the software obtains the program path, it automatically accesses the program package under the specified path and executes the action of downloading the program package. After the program package is downloaded locally, it executes the program package verification action. If the program verification result fails, it directly ends and reports an error. If the program verification result passes, the central control software will decompress the program package and distribute the test program to the upper board machine, insulation withstand voltage test bench, ICT test bench, functional test bench, robotic arm, and lower board machine. The upper board machine, insulation withstand voltage test bench, ICT test bench, functional test bench, robotic arm, and lower board machine will automatically load the test program and perform device ID verification. If the device verification result fails, it directly ends and reports an error. If the device verification result passes, it will connect to the MES system to perform MES verification. If the MES verification result fails, the program will directly end. If the MES verification result passes, it will read the fixture ID used by the test program from the MES. After the test program obtains the fixture ID, it performs fixture ID verification. If the fixture verification result fails, the program will directly end. If the fixture verification result passes, it means the program is okay, and it executes sensor verification according to the logic preset in the program to check whether the states of each cylinder, motion device, and detection device meet the test requirements. If the sensor verification result fails, the program will directly end. If the sensor verification result passes, it starts the product test program, and the test program automatically calls the software to execute and ends.

[0032] It also includes the execution process of the expert diagnosis program, specifically: after starting the expert diagnosis software, scan the serial number on the software interface, and then the expert diagnosis program finds the test report of the current serial number in the test database and obtains the test report; sort by time to find the names of the items that failed the test in the latest test report, and find the same test names in the fault tree of the expert diagnosis program to compare with the expert experience database; if the comparison results are different, generate a new expert experience task; if the comparison results are the same, directly retrieve all the expert experiences under the fault tree and display them on the expert diagnosis program interface, troubleshoot faults through interactive problem-solving and compare with the actual product faults for verification. After troubleshooting, perform expert experience evaluation, put forward modification or optimization opinions for the current expert experience, and continuously update the content of the expert database.

[0033] The central control cabinet includes a main control PLC, HMI, server, UPS, industrial computer and switch. After the cabinet starts up normally, it works according to the following steps:

[0034] 1.1. Log in with the work number to automatically obtain the program and log in to the industrial computer, server and HMI;

[0035] 1.2. Open the central control monitoring software and automatically establish connections with the production line server, company MES server, company program server, and company DDCS server;

[0036] 1.3. The main control PLC establishes connections with the board loading machine, insulation withstand voltage test bench cabinet and fixture, ICT cabinet and fixture, function test bench cabinet and fixture, manipulator, board unloading machine, and safety interlock device;

[0037] 1.4. Before the test starts, select the operation mode through the manual / automatic switch. After each device self-checks normally without alarm information, the safety interlock device sensor has no alarm, and the product test program passes the verification, it enters the full-automatic mode; otherwise, it enters the manual mode;

[0038] 1.5. Select the drawing number of the product to be tested, automatically call the product test program from the company program server and send the program to the board loading machine, insulation withstand voltage test bench cabinet and fixture, ICT cabinet and fixture, function test bench cabinet and fixture, manipulator, and board unloading machine; after each device obtains the program, it parses the parameters and automatically verifies them with the MES server;

[0039] 1.6. Product error prevention verification. If the verification passes, it is allowed to go online and start the test; if it fails, it cannot go online;

[0040] 1.7. Automatically obtain and upload test data to the company DDCS server during the test;

[0041] 1.8. During the test, the position of the circuit boards with each serial number is automatically detected and each circuit board is controlled to complete the corresponding test according to the program requirements;

[0042] 1.9. Re-launch NG products and track test results, and automatically find, analyze and locate faults through the fault expert database;

[0043] 1.10. Record log information;

[0044] 1.11. Repeat steps 1.4 to 1.10 during the test.

[0045] The board loading machine includes a PLC, a feeding / discharging mechanism, an adaptive board pushing device, an adaptive board receiving device, an AGV docking device and an error prevention device. After the board loading machine is started normally, it works according to the following steps:

[0046] 2.1. The equipment will power on for self-test. If the self-test is normal, it will proceed to the next step. If the self-test is abnormal, an alarm message will be output;

[0047] 2.2. The manual / automatic switch status of the equipment. If it is in automatic status, obtain the operation mode of the central control monitoring software;

[0048] 2.3. PLC controls and initializes each device and sensor information of the equipment;

[0049] 2.4. Obtain the drawing number information and product program parameters issued by the central control monitoring software on the central control cabinet, and adjust the SMT rack in / out mechanism, adaptive push plate device and adaptive board receiving device to the specified position according to the program parameters, such as the travel of the push plate device, the position of the support block of the board receiving device, and the lifting height parameters;

[0050] 2.5. The AGV transports the product from the front end, docks with the AGV docking device of the loader, and sends the SMT rack on the AGV to the interface of the infeed / outfeed mechanism;

[0051] 2.6. Scan the product QR code and pass it to the central control to confirm whether to allow entry into the board loader. Allow the board loader's error prevention device to retract and allow the SMT rack to enter. If not allowed, the board loader's error prevention device remains in the error prevention position;

[0052] 2.7. After the feeding and unloading mechanism sends the SMT rack to the designated position, the PLC control sensor detects the position of the circuit board and drives the adaptive push device to push the circuit board out of the SMT rack;

[0053] 2.8. After the circuit board is pushed out by the adaptive board pushing device, the adaptive board receiving device receives the circuit board and notifies the central controller that the circuit board is ready and can be grasped by the robot;

[0054] 2.9. Repeat steps 2.7 to 2.8 to complete the upper plate.

[0055] The insulation voltage withstand test bench cabinet includes an insulation voltage withstand tester, an industrial control computer, a PLC, and test jigs. After the insulation voltage withstand test bench cabinet is normally started, the work process is as follows:

[0056] 3.1. The device powers on and performs self-check. After the self-check is normal, it proceeds to the next step. If the self-check is abnormal, an alarm message is output.

[0057] 3.2. Check the device's manual / automatic switch status. If it is in the automatic state, obtain the operation mode of the central control monitoring software.

[0058] 3.3. The PLC controls and initializes the information of each device and sensor of the device.

[0059] 3.4. The industrial control computer obtains the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet and downloads the program from the central control cabinet to the local.

[0060] 3.5. The industrial control computer automatically starts the test program and verifies the test program name and version number through MES.

[0061] 3.6. The industrial control computer's test program self-checks the ID of the insulation voltage withstand tester, the sensors controlled by the PLC, and the jigs.

[0062] 3.7. After the self-check is completed, the PLC automatically opens the upper cover of the jig and sends a self-check normal signal to the central control cabinet through the industrial control computer, waiting for the manipulator to place the circuit board.

[0063] 3.8. The industrial control computer's test program sends a signal indicating no board in the jig, and the manipulator places the circuit board.

[0064] 3.9. After the manipulator leaves the jig range and reaches the specified position, it sends a signal indicating that the circuit board has been placed on the insulation voltage withstand test bench.

[0065] 3.10. The PLC controls the in-position sensor to detect that the circuit board is in the specified position, and the leveling sensor detects that the circuit board is level, and sends a waiting-for-test signal to the industrial control computer.

[0066] 3.11. The industrial control computer's test program starts the test. After the test is completed, it notifies the manipulator of the test result through the industrial control computer to the central control cabinet. After the manipulator removes the circuit board, it places another circuit board to be tested.

[0067] 3.12. Repeat steps 3.8 - 3.11 to complete the test.

[0068] The ICT test bench includes an industrial control computer, a channel card, a measurement card, a module power supply, and test jigs. After the ICT test bench is normally started, the work process is as follows:

[0069] 4.1. The device performs a power-on self-check. After the self-check is normal, it proceeds to the next step. If the self-check is abnormal, it outputs an alarm message.

[0070] 4.2. When the device is in the automatic state, it obtains the operating mode of the central control monitoring software.

[0071] 4.3. The industrial control computer controls and initializes each device and sensor information of the device.

[0072] 4.4. The industrial control computer obtains the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet and downloads the program from the central control cabinet to the local.

[0073] 4.5. The industrial control computer automatically starts the test program and verifies the test program name and version number through MES.

[0074] 4.6. The industrial control computer test program self-checks the absolute channel card, measurement board, module power supply, sensors of the test fixture, and the ID of the fixture.

[0075] 4.7. After the self-check is completed, the industrial control computer automatically opens the upper cover of the fixture and sends a self-check normal signal to the central control cabinet, waiting for the manipulator to place the circuit board.

[0076] 4.8. The industrial control computer test program sends a signal indicating no board in the fixture, and the manipulator places the circuit board.

[0077] 4.9. After the manipulator leaves the fixture range and reaches the specified position, it sends a signal indicating that the ICT board placement is completed.

[0078] 4.10. The industrial control computer controls the in-position sensor to detect that the circuit board is in the specified position, and the leveling sensor to detect that the circuit board is leveled, and sends a waiting-for-test signal to the industrial control computer.

[0079] 4.11. The industrial control computer test program starts the test. After the test is completed, it notifies the manipulator of the test result through the industrial control computer to the central control cabinet. After the manipulator removes the circuit board, it places another circuit board to be tested.

[0080] 4.12. Repeat steps 4.8 - 4.11 to complete the test.

[0081] The function test bench includes an oscilloscope, a multimeter, a signal generator, a power supply, a matrix, an industrial control computer, a PLC, and a test fixture. After the function test bench starts normally, the work process is as follows:

[0082] 5.1. The device performs a power-on self-check. After the self-check is normal, it proceeds to the next step. If the self-check is abnormal, it outputs an alarm message.

[0083] 5.2. The hand / automatic switch state of the device. If it is in the automatic state, it obtains the operating mode of the central control monitoring software.

[0084] 5.3. The PLC controls and initializes the information of each device and sensor of the equipment;

[0085] 5.4. The industrial control computer obtains the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet and downloads the program from the central control cabinet to the local;

[0086] 5.5. The industrial control computer automatically starts the test program and verifies the test program name and version number through MES;

[0087] 5.6. The industrial control computer test program self-checks the oscilloscope, multimeter, signal generator, power supply, matrix, sensors controlled by PLC, and the ID of the fixture;

[0088] 5.7. After the self-check is completed, the PLC automatically opens the upper cover of the fixture and sends a normal self-check signal to the central control cabinet through the industrial control computer, waiting for the manipulator to place the circuit board;

[0089] 5.8. The industrial control computer test program sends a signal indicating no board in the fixture, and the manipulator places the circuit board;

[0090] 5.9. After the manipulator leaves the fixture range and reaches the specified position, it sends a signal indicating that the circuit board has been placed on the functional test bench;

[0091] 5.10. The PLC controls the in-position sensor to detect that the circuit board is in the specified position, and the leveling sensor detects that the circuit board is leveled, and sends a waiting test signal to the industrial control computer;

[0092] 5.11. The industrial control computer test program starts the test. After the test is completed, it notifies the manipulator of the test result through the industrial control computer to the central control cabinet. After the manipulator takes out the circuit board, it places another circuit board to be tested;

[0093] 5.12. Repeat steps 5.8 - 5.11 to complete the test.

[0094] The unloading machine includes a PLC, a feeding / discharging mechanism, an adaptive pushing plate device, an adaptive receiving plate device, an AGV docking device, and an anti-mistake device. After the unloading machine is normally started, it works according to the following steps:

[0095] 6.1. The equipment performs a power-on self-check. If the self-check is normal, it proceeds to the next step. If the self-check is abnormal, it outputs an alarm message;

[0096] 6.2. The equipment's manual / automatic switch status. If it is in the automatic state, it obtains the operating mode of the central control monitoring software;

[0097] 6.3. The PLC controls and initializes the information of each device and sensor of the equipment;

[0098] 6.4. Obtain the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet, and adjust the in / out feeding mechanism of the SMT rack, the adaptive push plate device, and the adaptive board receiving device to the specified positions according to the program parameters, such as the stroke of the push plate device, the position of the support block of the board receiving device, and the lifting height parameter;

[0099] 6.5. The manipulator places the circuit board on the adaptive board receiving device;

[0100] 6.6. After the manipulator leaves the fixture range and reaches the specified position, send out the signal indicating that the lower board machine has finished placing the board;

[0101] 6.7. After the circuit board is pushed out by the adaptive push plate device, the circuit board is sent into the SMT rack;

[0102] 6.8. Repeat steps 6.5 - 6.7 to complete unloading the board;

[0103] 6.9. The AGV docks with the AGV docking device of the upper board machine, and the SMT rack is taken out from the in / out feeding mechanism interface and sent to the next process.

[0104] Compared with the prior art, the advantages of the present invention are as follows:

[0105] The single - board full - automatic test production line and test method of the integrated manipulator of the present invention can realize fully automated and unmanned testing of products, improve production efficiency, reduce the number of operators, shorten the test cycle, realize automatic data acquisition and traceability, and enhance the production competitiveness of products in the rail transit industry.

[0106] The present invention realizes the acquisition of the program package, the distribution of device programs by the central control cabinet, the status of each device program, and the verification of the fixture ID, and realizes the automation of program call in the test production line. The present invention greatly improves the test efficiency. Through the methods of automatic loading and unloading and full - automatic testing, the average test time of the circuit board is reduced to 105 s, and the test cycle is shortened by 2 days, meeting the requirements of the production line beat time. The present invention is integrated and interacted with the program server, MES server, and test data server, automatically collecting, verifying, and uploading data to realize the automatic operation of information. The test process of the present invention does not require manual intervention, adopts the test mode of AGV feeding + upper and lower board machine in / out feeding + manipulator handling + full - automation, realizes unmanned operation, and saves 3 operators. The full - automatic docking platform of the test fixture of the present invention is designed. The fixture platform realizes precise positioning and automatic locking of the fixture through fixture rough positioning, limited free - floating connection, connector guidance, and cylinder pushing the fixture, and realizes the automatic docking of the test fixture, improving the installation efficiency of the fixture and reducing the change - over time by more than 50%. The device of the present invention has strong test flexibility and can be compatible with a variety of different models of products to be tested. Description of the Drawings

[0107] Figure 1Schematic structural diagram of the production line of the present invention in the embodiment.

[0108] Figure 2 Block structure diagram of the production line of the present invention in the embodiment.

[0109] Figure 3 Flowchart of the method embodiment of the present invention.

[0110] Figure 4 Flowchart of the automatic call and execution of the test program of the present invention.

[0111] Figure 5 Flowchart of the execution of the expert diagnosis program of the present invention.

[0112] Legend: 1. Board loading machine; 2. Insulation withstanding voltage test bench; 3. ICT test bench; 4. Function test bench; 5. Manipulator; 6. Board unloading machine; 7. Central control cabinet; 8. Safety fence. Detailed implementation manners

[0113] The present invention will be further described below in conjunction with the accompanying drawings of the specification and specific embodiments.

[0114] As Figure 1 shown, the single-board full-automatic test production line of the integrated manipulator in this embodiment includes:

[0115] Board loading machine 1, used to send the product to be tested from the rack to a predetermined position;

[0116] Insulation withstanding voltage test bench 2, used to perform insulation withstanding voltage test on the circuit board;

[0117] ICT test bench 3, used to perform ICT test on the circuit board;

[0118] Function test bench 4, used to perform function test on the circuit board;

[0119] Board unloading machine 6, used to transfer the circuit board to the AGV trolley;

[0120] Manipulator 5, used to realize the transfer of the circuit board among the board loading machine 1, the insulation withstanding voltage test bench 2, the ICT test bench 3, the function test bench 4 and the board unloading machine 6;

[0121] Safety fence 8, used to form a working area to accommodate each component;

[0122] The board loading machine 1, the insulation withstanding voltage test bench 2, the ICT test bench 3, the function test bench 4 and the board unloading machine 6 are arranged around the manipulator 5;

[0123] Central control cabinet 7, used to be responsible for supervising the operation of the whole system, product and program switching and data acquisition, and monitoring that the safety fence 8 is in a closed state.

[0124] Specifically, the AGV is responsible for transporting the circuit board to the board loading machine 1. Then, the material rack is transferred from the AGV to the in / out feeding device of the board loading machine 1, and the product to be tested is sent from the material rack to the adaptive board receiving device; after the manipulator 5 takes out the circuit board from the board loading machine 1, it sends the circuit board to the test fixture of the insulation withstanding voltage test bench 2 for testing and waits for the completion of the insulation withstanding voltage test; after the manipulator 5 takes out the circuit board from the insulation withstanding voltage test bench 2, it sends the circuit board to the test fixture of the ICT test bench 3 for testing and waits for the completion of the ICT test; after the manipulator 5 takes out the circuit board from the ICT test bench 3, it sends the circuit board to the test fixture of the functional test bench 4 for testing and waits for the completion of the ICT test; after the manipulator 5 takes out the circuit board from the functional test bench 4, it sends the circuit board into the board unloading machine 6, and then the in / out feeding device of the board unloading machine 6 is transferred to the AGV, and the product enters the next process step.

[0125] The single-board full-automatic test production line with the integrated manipulator 5 of the present invention can achieve fully automated and unmanned testing of products, improve production efficiency, reduce operators, shorten the test cycle, realize automatic data collection and traceability, and enhance the production competitiveness of products in the rail transit industry.

[0126] The present invention also discloses a testing method for a single-board full-automatic testing production line based on the integrated manipulator as described above, including a full-automatic testing method. The specific steps are as follows: After power-on and starting the test, click "Start". The central control cabinet 7 performs self-check on the communication status of the industrial control computer, server, PLC and its controlled sensors, switch, and safety fence 8 to confirm that each part starts normally and data is transmitted normally. After the self-check of the central control cabinet 7 is completed, the safety fence 8 performs self-check on the emergency stop status, door safety switch status, manipulator 5 emergency stop, etc. to confirm that each safety circuit is normal. For the self-check of each device, the loading machine 1 confirms that there is no material rack on the feeding / discharging device, no material rack on the lifting device, and no circuit board on the adaptive board receiving device; the insulation withstanding voltage test bench 2 confirms normal startup and normal initialization of each instrument; the ICT test bench 3 confirms normal startup and normal initialization of each board card; the function test bench 4 confirms normal startup and normal initialization of each instrument; the unloading machine confirms that there is no material rack on the feeding / discharging device, no material rack on the lifting device, and no circuit board on the adaptive board receiving device; the manipulator 5 is initialized normally and each robotic arm is in a safe position. After the self-check is judged to be normal, select the product drawing number to be tested. If the self-check is judged to be abnormal, stop running, wait for troubleshooting, and restart the system. The central control cabinet 7 downloads the test program from the file server according to the drawing number and verifies the file to ensure the integrity of the downloaded file, and then distributes the program to the loading machine 1, insulation withstanding voltage test bench 2, ICT test bench 3, function test bench 4, manipulator 5, and unloading machine 6 respectively; each test bench executes the program to automatically load and verify the test program number, test program version, test equipment ID, and test fixture ID with the MES system. After the loading is completed, the upper covers of the fixtures of the insulation withstanding voltage test bench 2, ICT test bench 3, and function test bench 4 are opened, and the manipulator 5 performs coordinate calibration. First, a fixed camera is used to photograph the features on the gripper to determine that there is no circuit board on the gripper, and then a moving camera is used to photograph the feature points on the insulation withstanding voltage test fixture, ICT test fixture, and function test fixture respectively to calibrate and update the coordinates of the three fixtures in the coordinate system of the manipulator 5, eliminating the installation error of the fixture. When the loading machine 1 discharges the board, the circuit board in the material rack on the feeding / discharging device is sent to the adaptive board receiving device, and after the sensor detects the circuit board, it notifies the manipulator 5 that the discharging of the loading machine 1 is completed. After receiving the signal, the manipulator 5 moves above the adaptive board receiving device to photograph the feature points of the circuit board to calibrate the circuit board coordinates and complete the circuit board positioning. After the circuit board positioning is completed, the manipulator 5 moves the camera to scan the QR code on the circuit board and parses the serial number and drawing number to confirm the current circuit board serial number and complete the serial number scanning. The manipulator 5 grabs the circuit board to the position of the fixed camera for secondary circuit board positioning to avoid coordinate offset caused by the moment when the gripper grabs the board, and completes the secondary positioning of grabbing the board. The manipulator 5 first takes out the circuit board in the withstanding voltage fixture with the 1# position of the gripper and then places the circuit board on the 2# position of the gripper into the withstanding voltage fixture, completes the taking and placing of the board in the withstanding voltage fixture, and sends a signal to the insulation withstanding voltage test bench 2.After the insulation withstand voltage test bench 2 receives the signal indicating that the plate placing and removing plate of the withstand voltage fixture is completed, it closes the upper cover of the withstand voltage fixture and performs the withstand voltage test. After the test is completed, it judges the withstand voltage test result. If the test result fails, it performs plate placing on the NG tray; if the test result passes, it completes the plate placing and removing plate of the withstand voltage fixture and sends a signal to the insulation withstand voltage test bench 2. The manipulator 5 first takes out the circuit board in the ICT fixture at the 1# position of the gripper and then places the circuit board at the 2# position of the gripper on the ICT fixture, completes the plate placing and removing plate of the ICT fixture and sends a signal to the ICT test bench 3. After the ICT test bench 3 receives the signal indicating that the plate placing and removing plate of the ICT fixture is completed, it closes the upper cover of the ICT fixture and performs the ICT test. After the test is completed, it judges the ICT test result. If the test result fails, it performs plate placing on the NG tray; if the test result passes, it completes the plate placing and removing plate of the ICT fixture and sends a signal to the ICT test bench 3. The manipulator 5 first takes out the circuit board in the function fixture at the 1# position of the gripper and then places the circuit board at the 2# position of the gripper on the function fixture, completes the plate placing and removing plate of the function fixture and sends a signal to the function test bench 4. After the function test bench 4 receives the signal indicating that the plate placing and removing plate of the function fixture is completed, it closes the upper cover of the function fixture and performs the function test. After the test is completed, it judges the function test result. If the test result fails, it performs plate placing on the NG tray; if the test result passes, it completes the plate placing and removing plate of the function fixture and sends a signal to the function test bench 4. The manipulator 5 grabs the circuit board to the fixed camera position for secondary positioning of the circuit board to avoid coordinate offset caused by the moment when the gripper grabs the board, and completes the secondary positioning of plate placing. The manipulator 5 moves the circuit board to the adaptive board receiving device of the plate placing machine, completes plate placing to the lower plate machine 6, and the test ends.

[0127] In a specific embodiment, such as Figure 4As shown in the figure, it also includes the execution process of the test program automatically called by the software. Specifically: after the software starts, it is necessary to select the drawing number of the product to be tested, and check it with the production program database to obtain the path of the program and the program package verification information. After the software obtains the program path, it automatically accesses the program package under the specified path and executes the action of downloading the program package. After the program package is downloaded locally, the program package verification action is executed. If the program verification result fails, it will directly end and report an error; if the program verification result passes, the central control software will decompress the program package and distribute the test program to the upper board machine 1, the insulation withstand voltage test bench 2, the ICT test bench 3, the function test bench 4, the manipulator 5 and the lower board machine 6. The upper board machine 1, the insulation withstand voltage test bench 2, the ICT test bench 3, the function test bench 4, the manipulator 5 and the lower board machine 6 will automatically load the test program and perform the device ID verification. If the device verification result fails, it will directly end and report an error; if the device verification result passes, it will connect to the MES system to perform the MES verification. If the MES verification result fails, the program will directly end; if the MES verification result passes, the fixture ID used by the test program will be read from the MES. After the test program obtains the fixture ID, it performs the fixture ID verification. If the fixture verification result fails, the program will directly end; if the fixture verification result passes, it means that the program is okay, and the sensor verification will be performed according to the logic preset in the program to check whether the states of each cylinder, motion device, and detection device meet the test requirements. If the sensor verification result fails, the program will directly end; if the sensor verification result passes, the product test program will start, and the execution of the test program automatically called by the software will end. The MES system and the production program database are public systems and are not within the scope of the present invention.

[0128] In a specific embodiment, as Figure 5 shown, it also includes the execution process of the expert diagnosis program. Specifically: after starting the expert diagnosis software, after scanning the serial number on the software interface, the expert diagnosis program finds the test report of the current serial number in the test database and obtains the test report. Sort by time to find the names of the items that failed the test in the latest test report, and find the same test name in the fault tree in the expert diagnosis program, and compare it with the expert experience database. If the comparison results are different, a new expert experience task will be generated; if the comparison results are the same, all the expert experiences under this fault tree will be directly retrieved and displayed on the expert diagnosis program interface, and the troubleshooting will be carried out through interactive troubleshooting and compared with the actual product faults for verification. After the troubleshooting is completed, the expert experience evaluation will be executed, and modification / optimization opinions for the current expert experience will be put forward to continuously update the content of the expert library.

[0129] In a specific embodiment, as Figure 2 shown, the central control cabinet 7 mainly includes devices such as the main control PLC and HMI, server, UPS, industrial computer, switch, etc. After the cabinet starts normally, it works according to the following steps:

[0130] 1.1. Enter the work number to log in and automatically obtain the program to log in to the industrial computer, server and HMI;

[0131] 1.2. Open the central control monitoring software and automatically establish connections with the production line server, company MES server, company program server, and company DDCS server;

[0132] 1.3. The main control PLC establishes connections with the upper board machine 1, the insulation and withstand voltage test bench 2 cabinet and fixture, the ICT cabinet and fixture, the function test bench 4 cabinet and fixture, the manipulator 5, the lower board machine 6, and the safety interlock device;

[0133] 1.4. Before the test begins, select the operation mode (manual mode or fully automatic mode) through the manual / automatic switch. After the self-test of each device is normal without alarm information, the safety interlocking device sensor has no alarm, and the product test program is verified and passed, enter the fully automatic mode, otherwise enter the manual mode;

[0134] 1.5. Select the drawing number of the product to be tested, automatically call the product test program from the company's program server and send the program to the upper board machine 1, insulation and withstand voltage test bench 2 cabinet and fixture, ICT cabinet and fixture, function test bench 4 cabinet and fixture, manipulator 5, lower board machine 6; each device obtains the program and parses the parameters and automatically verifies it with the company's MES server;

[0135] 1.6. Error proofing of the product. If the product passes the verification, it is allowed to go online and start testing. If it fails, it cannot go online.

[0136] 1.7. Automatically obtain and upload test data to the company's DDCS server during the test;

[0137] 1.8. During the test, the position of the circuit boards with each serial number is automatically detected and each circuit board is controlled to complete the corresponding test according to the program requirements;

[0138] 1.9. Re-launch NG products and track test results, and automatically find, analyze and locate faults through the fault expert database;

[0139] 1.10. Record log information. Repeat steps 1.4 to 1.10 during the test.

[0140] In a specific embodiment, if Figure 2 As shown, the board loading machine 1 mainly includes a PLC, a feeding / discharging mechanism, an adaptive board pushing device, an adaptive board receiving device, an AGV docking device and an error prevention device. After the board loading machine 1 is started normally, it works according to the following steps:

[0141] 2.1. The equipment will power on for self-test. If the self-test is normal, it will proceed to the next step. If the self-test is abnormal, an alarm message will be output;

[0142] 2.2. Status of the equipment's manual / automatic switch. If it is in the automatic state, obtain the operating mode of the central control monitoring software.

[0143] 2.3. The PLC controls and initializes the information of each device and sensor of the equipment.

[0144] 2.4. Obtain the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet 7, and adjust the SMT rack in / out feeding mechanism, adaptive push plate device, and adaptive board receiving device to the specified positions according to the program parameters, such as parameters like the stroke of the push plate device, the position of the support block of the board receiving device, and the lifting height.

[0145] 2.5. The AGV transports the product from the front end, docks with the AGV docking device of the board loading machine 1, and sends the SMT rack on the AGV to the in / out feeding mechanism interface.

[0146] 2.6. Scan the product QR code and transmit the product QR code to the central control to confirm whether it is allowed to enter the board loading machine 1. If allowed, the anti-mistake device of the board loading machine 1 retracts and allows the SMT rack to enter. If not allowed, the anti-mistake device of the board loading machine 1 remains in the anti-mistake position.

[0147] 2.7. After the in / out feeding mechanism sends the SMT rack to the specified position, the PLC controls the sensor to detect the position of the circuit board and drives the adaptive push plate device to push the circuit board out of the SMT rack.

[0148] 2.8. After the circuit board is pushed out by the adaptive push plate device, the adaptive board receiving device catches the circuit board and notifies the central controller that the circuit board is ready and can be grabbed by the manipulator 5.

[0149] 2.9. Repeat steps 2.7 - 2.8 to complete board loading.

[0150] In a specific embodiment, as Figure 2 shown, the cabinet of the insulation withstanding voltage test bench 2 mainly consists of an insulation withstanding voltage tester, an industrial control computer, a PLC, and a test fixture. After the cabinet of the insulation withstanding voltage test bench 2 is normally started, the working process is as follows:

[0151] 3.1. The equipment performs a power-on self-check. After the self-check is normal, proceed to the next step. If the self-check is abnormal, output an alarm message.

[0152] 3.2. Status of the equipment's manual / automatic switch. If it is in the automatic state, obtain the operating mode of the central control monitoring software.

[0153] 3.3. The PLC controls and initializes the information of each device and sensor of the equipment.

[0154] 3.4. The industrial control computer obtains the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet 7 and downloads the program from the central control cabinet 7 to the local.

[0155] 3.5. The industrial control computer test program starts automatically and verifies the test program name and version number through MES.

[0156] 3.6. The industrial control computer test program self-checks the ID of the insulation withstand voltage tester, the sensors controlled by PLC, and the fixture.

[0157] 3.7. After the self-check is completed, the PLC automatically opens the upper cover of the fixture and sends a normal self-check signal to the central control cabinet 7 through the industrial control computer, waiting for the manipulator 5 to place the circuit board.

[0158] 3.8. The industrial control computer test program sends a signal indicating no board in the fixture, and the manipulator 5 places the circuit board.

[0159] 3.9. After the manipulator 5 leaves the fixture range and reaches the specified position, it sends a signal indicating that the circuit board has been placed on the insulation withstand voltage test bench 2.

[0160] 3.10. The PLC controls the in-position sensor to detect that the circuit board is in the specified position, and the leveling sensor detects that the circuit board is leveled, and sends a waiting-for-test signal to the industrial control computer.

[0161] 3.11. The industrial control computer test program starts the test. After the test is completed, it notifies the manipulator 5 of the test result through the industrial control computer to the central control cabinet 7. After the manipulator 5 takes out the circuit board, it places another circuit board to be tested.

[0162] 3.12. Repeat steps 3.8 - 3.11 to complete the test.

[0163] In a specific embodiment, as Figure 2 shown, the ICT test bench 3 mainly consists of an industrial control computer, a channel card, a measurement card, a module power supply, and a test fixture. After the ICT test bench 3 starts normally, the working process is as follows:

[0164] 4.1. The device powers on and self-checks. If the self-check is normal, it proceeds to the next step; if the self-check is abnormal, it outputs an alarm message.

[0165] 4.2. In the automatic state of the device, it obtains the operating mode of the central control monitoring software.

[0166] 4.3. The industrial control computer controls and initializes the information of each device and sensor of the device.

[0167] 4.4. The industrial control computer obtains the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet 7 and downloads the program from the central control cabinet 7 to the local.

[0168] 4.5. The industrial control computer test program starts automatically and verifies the test program name and version number through MES.

[0169] 4.6. The industrial control computer test program self-checks the absolute channel card, measurement board card, module power supply, sensors of the test fixture, and the ID of the fixture;

[0170] 4.7. After the self-check is completed, the industrial control computer automatically opens the upper cover of the fixture and sends a self-check normal signal to the central control cabinet 7, waiting for the manipulator 5 to place the circuit board;

[0171] 4.8. The industrial control computer test program sends a signal indicating no circuit board in the fixture, and the manipulator 5 places the circuit board;

[0172] 4.9. After the manipulator 5 leaves the fixture range and reaches the specified position, it sends a signal indicating that the circuit board has been placed in the ICT;

[0173] 4.10. The industrial control computer controls the in-position sensor to detect that the circuit board is in the specified position, and the leveling sensor to detect that the circuit board is leveled, and sends a waiting-for-test signal to the industrial control computer;

[0174] 4.11. The industrial control computer test program starts the test. After the test is completed, it notifies the manipulator 5 of the test result through the industrial control computer to the central control cabinet 7. After the manipulator 5 takes out the circuit board, it places another circuit board to be tested;

[0175] 4.12. Repeat steps 4.8 - 4.11 to complete the test.

[0176] In a specific embodiment, as Figure 2 shown, the functional test bench 4 mainly consists of an oscilloscope, a multimeter, a signal generator, a power supply, a matrix, an industrial control computer, a PLC, and a test fixture. After the functional test bench 4 is normally started, the working process is as follows:

[0177] 5.1. The device performs a power-on self-check. If the self-check is normal, it proceeds to the next step; if the self-check is abnormal, it outputs an alarm message;

[0178] 5.2. Check the hand / auto switch status of the device. If it is in the auto state, obtain the operation mode of the central control monitoring software;

[0179] 5.3. The PLC controls and initializes the information of each device and sensor of the device;

[0180] 5.4. The industrial control computer obtains the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet 7 and downloads the program from the central control cabinet 7 to the local;

[0181] 5.5. The industrial control computer test program automatically starts and verifies the test program name and version number through MES;

[0182] 5.6. The industrial control computer test program self-checks the oscilloscope, multimeter, signal generator, power supply, matrix, sensors controlled by the PLC, and the ID of the fixture;

[0183] 5.7 After the self-check is completed, the PLC automatically opens the upper cover of the fixture and sends a normal self-check signal to the central control cabinet 7 through the industrial control computer, waiting for the manipulator 5 to place the circuit board;

[0184] 5.8 The industrial control computer test program sends out a signal indicating no board in the fixture, and the manipulator 5 places the circuit board;

[0185] 5.9 After the manipulator 5 leaves the fixture range and reaches the specified position, it sends out a signal indicating that the board has been placed on the function test bench 4;

[0186] 5.10 The PLC controls the in-position sensor to detect that the circuit board is in the specified position, and the leveling sensor detects that the circuit board is leveled, and sends a waiting-for-test signal to the industrial control computer;

[0187] 5.11 The industrial control computer test program starts the test. After the test is completed, the industrial control computer notifies the manipulator 5 of the test result to the central control cabinet 7. After the manipulator 5 takes out the circuit board, it places another circuit board to be tested;

[0188] 5.12 Repeat steps 5.8 - 5.11 to complete the test.

[0189] In a specific embodiment, as Figure 2 shown, the lower board machine 6 mainly includes a PLC, a feeding / discharging mechanism, an adaptive push plate device, an adaptive board receiving device, an AGV docking device, and an anti-mistake device. After the lower board machine 6 is normally started, it works according to the following steps:

[0190] 6.1 Power on the device for self-check. After the self-check is normal, proceed to the next step. If the self-check is abnormal, output an alarm message;

[0191] 6.2 Check the manual / automatic switch status of the device. If it is in the automatic state, obtain the operation mode of the central control monitoring software;

[0192] 6.3 The PLC controls and initializes the information of each device and sensor of the device;

[0193] 6.4 Obtain the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet 7, and adjust the SMT rack feeding / discharging mechanism, the adaptive push plate device, and the adaptive board receiving device to the specified positions according to the program parameters, such as parameters like the stroke of the push plate device, the position of the support block of the board receiving device, and the lifting height;

[0194] 6.5 The manipulator 5 places the circuit board on the adaptive board receiving device;

[0195] 6.6 After the manipulator 5 leaves the fixture range and reaches the specified position, it sends out a signal indicating that the board has been placed on the lower board machine 6;

[0196] 6.7 After the circuit board is pushed out by the adaptive push plate device, the circuit board is sent into the SMT rack;

[0197] 6.8. Repeat steps 6.5 - 6.7 to complete the lower board;

[0198] 6.9. The AGV docks with the AGV docking device of the upper board machine 1, and the SMT rack is taken out from the inlet / outlet mechanism interface and sent to the next process.

[0199] In a specific embodiment, as Figure 2 shown, the manipulator 5 mainly consists of a manipulator 5 and a gripper. The manipulator 5 can automatically replace the gripper and the gripper has a self - adapting width to meet different products; when the product model is changed, the manipulator 5 can automatically adjust the gripper width or replace the gripper according to the product model; during the process of replacing the gripper, ID verification, gripper status detection, visual inspection and error prevention functions are added. After the manipulator 5 is normally started, it works according to the following steps:

[0200] 7.1. Power on the equipment for self - inspection. After the self - inspection is normal, proceed to the next step. If the self - inspection is abnormal, an alarm message is output;

[0201] 7.2. Check the hand / auto switch status of the equipment. If it is in the auto state, obtain the operation mode of the central control monitoring software;

[0202] 7.3. Obtain the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet 7 and obtain the gripper ID, and automatically replace the corresponding gripper according to the ID;

[0203] 7.4. The manipulator 5 takes pictures of the visual calibration points of each fixture to correct the specific coordinates of the fixture;

[0204] 7.5. When each device enters the self - inspection normal and enters the waiting test state, the manipulator 5 moves to the adaptive board receiving device of the upper board machine 1 and takes pictures to correct the position of the circuit board;

[0205] 7.6. The manipulator 5 takes pictures to obtain the circuit board serial number and sends it to the central control cabinet 7. After receiving the signal allowing the board to be grabbed, it starts to grab the board at the gripper 1# position;

[0206] 7.7. After the manipulator 5 grabs the circuit board at the gripper 1# position, it takes pictures at the fixed camera to correct the position of the circuit board;

[0207] 7.8. The manipulator 5 takes out the circuit board with the 2# position of the gripper and puts the circuit board at the 1# position into the fixture of the insulation withstand voltage test bench 2. If there is no circuit board in the ICT fixture, repeat steps 5 - 7;

[0208] 7.9. When the circuit board is in the test fixture of the insulation withstand voltage test bench 2, after each sensor detects normally, the test starts until the test is completed. After the upper cover of the test fixture is opened, the industrial control computer of the insulation withstand voltage test bench 2 cabinet sends the signal that the upper cover of the test fixture is opened in place to the central control cabinet 7;

[0209] 7.10. The manipulator 5 takes out the circuit board at the 2# position of the gripper and puts the circuit board at the 1# position into the ICT fixture to start the test; if there is no circuit board in the fixture of the functional test bench 4, repeat steps 5 to 9;

[0210] 7.11. When the circuit board is in the ICT test fixture and all sensors detect normally, start the test until the test is completed. After the upper cover of the test fixture is opened, the industrial control computer of the ICT cabinet sends the signal that the upper cover of the test fixture is opened in place to the central control cabinet 7;

[0211] 7.12. The manipulator 5 takes out the circuit board at the 1# position of the gripper and puts the circuit board at the 2# position into the test fixture of the functional test bench 4 to start the test;

[0212] 7.13. When the circuit board is in the test fixture of the functional test bench 4 and all sensors detect normally, start the test until the test is completed. The industrial control computer of the functional test bench 4 cabinet sends the signal that the upper cover of the test fixture is opened in place to the central control cabinet 7;

[0213] 7.14. The manipulator 5 takes a photo of the circuit board at the 1# position of the gripper at the fixed camera to correct the position, and then puts the circuit board on the lower trigger adaptive board receiving device.

[0214] The present invention realizes the acquisition of the program package, the distribution of the programs of each device by the central control cabinet 7, the status of the programs of each device and the verification of the fixture ID, and realizes the automation of the program call of the test production line. The present invention greatly improves the test efficiency. By means of automatic loading and unloading and full-automatic testing, the average test time of the circuit board is reduced to 105 s, and the test cycle is reduced by 2 days, meeting the requirements of the beat time of the automatic production line. The present invention is integrated and interacted with the program server, the MES server and the test data server, and automatically collects, verifies and uploads data to realize the automatic operation of information. The test process of the present invention does not require manual intervention, adopts the test mode of AGV feeding + the 6 in-out board machine for loading and unloading + the manipulator 5 for handling + full-automatic, realizes unmanned operation, and saves 3 operators. The full-automatic docking platform of the test fixture of the present invention is designed. The fixture platform realizes fine positioning and automatic locking and realizes the automatic docking of the test fixture through fixture rough positioning, limited free floating connection, connector guiding, and the cylinder pushing the fixture, improves the installation efficiency of the fixture, and reduces the line change time by more than 50%. The device of the present invention has strong test flexibility and can be compatible with a variety of different models of products to be tested.

[0215] The above is only the preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments. All technical solutions falling within the idea of the present invention belong to the protection scope of the present invention. It should be noted that for those of ordinary skill in the art in this technical field, several improvements and refinements made 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 single-board full-automatic testing production line based on an integrated manipulator, characterized in that, the single-board full-automatic testing production line of the integrated manipulator includes: a loading machine (1), which is used to send the product to be tested from the rack to a predetermined position; an insulation withstanding voltage test bench (2), which is used to perform insulation withstanding voltage tests on the circuit board; an ICT test bench (3), which is used to perform ICT tests on the circuit board; a function test bench (4), which is used to perform function tests on the circuit board; an unloading machine (6), which is used to transfer the circuit board to an AGV trolley; a manipulator (5), which is used to realize the transfer of the circuit board among the loading machine (1), the insulation withstanding voltage test bench (2), the ICT test bench (3), the function test bench (4) and the unloading machine (6); a safety fence (8), which is used to form an operation area to accommodate each component; the loading machine (1), the insulation withstanding voltage test bench (2), the ICT test bench (3), the function test bench (4) and the unloading machine (6) are arranged around the manipulator (5); a central control cabinet (7), which is used to be responsible for supervising the operation of the whole system, product and program switching and data collection, and monitoring that the safety fence (8) is in a closed state; the testing method includes a full-automatic testing method, and the specific steps are as follows: the loading machine (1), the insulation withstanding voltage test bench (2), the ICT test bench (3), the function test bench (4), the unloading machine (6), the manipulator (5) and the central control cabinet (7) in the single-board full-automatic testing production line perform self-checks; the central control cabinet (7) downloads the test program from the file server according to the drawing number and verifies the file. After ensuring that the downloaded file is complete, the program is distributed to the loading machine (1), the insulation withstanding voltage test bench (2), the ICT test bench (3), the function test bench (4), the manipulator (5) and the unloading machine (6) respectively; each test bench executes program automatic loading and verifies the test program number, test program version, test equipment ID and test fixture ID with the MES system; after the loading is completed, the upper covers of the fixtures of the insulation withstanding voltage test bench (2), the ICT test bench (3) and the function test bench (4) are opened, and the manipulator (5) performs coordinate calibration. First, the fixed camera is used to shoot the features on the gripper to determine that there is no circuit board on the gripper, and then the moving camera is used to shoot the feature points on the insulation withstanding voltage test fixture, ICT test fixture and function test fixture respectively, and the coordinates of the three fixtures in the coordinate system of the manipulator (5) are calibrated and updated to eliminate the installation error of the fixtures; the loading machine (1) discharges the circuit board in the rack to the adaptive board receiving device. After detecting the circuit board, it notifies the manipulator (5) that the loading machine (1) has completed discharging; after receiving the signal, the manipulator (5) moves above the adaptive board receiving device to shoot the feature points of the circuit board to calibrate the circuit board coordinates and complete the circuit board positioning; after the circuit board positioning is completed, the manipulator (5) moves the camera to scan the QR code on the circuit board and parses the serial number and drawing number to confirm the current circuit board serial number and complete the serial number scanning; the manipulator (5) grabs the circuit board to the fixed camera position for secondary circuit board positioning to avoid coordinate offset caused by the moment when the gripper grabs the board and complete the secondary gripper positioning; The manipulator (5) takes out the circuit board in the pressure-resistant fixture at the 1# position of the gripper, and then places the circuit board at the 2# position of the gripper into the pressure-resistant fixture, completing the pick-and-place of the circuit board in the pressure-resistant fixture and sending a signal to the insulation withstand voltage test bench (2); after receiving the signal that the pick-and-place of the circuit board in the pressure-resistant fixture is completed, the insulation withstand voltage test bench (2) closes the upper cover of the pressure-resistant fixture and performs the withstand voltage test. After the test is completed, it judges the withstand voltage test result. If the test result fails, it performs the operation of placing the board on the NG tray; if the test result passes, it completes the pick-and-place of the circuit board in the pressure-resistant fixture and sends a signal to the insulation withstand voltage test bench (2); The manipulator (5) takes out the circuit board in the ICT fixture at the 1# position of the gripper, and then places the circuit board at the 2# position of the gripper into the ICT fixture, completing the pick-and-place of the circuit board in the ICT fixture and sending a signal to the ICT test bench (3); after receiving the signal that the pick-and-place of the circuit board in the ICT fixture is completed, the ICT test bench (3) closes the upper cover of the ICT fixture and performs the ICT test. After the test is completed, it judges the ICT test result. If the test result fails, it performs the operation of placing the board on the NG tray; if the test result passes, it completes the pick-and-place of the circuit board in the ICT fixture and sends a signal to the ICT test bench (3); The manipulator (5) takes out the circuit board in the function fixture at the 1# position of the gripper, and then places the circuit board at the 2# position of the gripper into the function fixture, completing the pick-and-place of the circuit board in the function fixture and sending a signal to the function test bench (4); after receiving the signal that the pick-and-place of the circuit board in the function fixture is completed, the function test bench (4) closes the upper cover of the function fixture and performs the function test. After the test is completed, it judges the function test result. If the test result fails, it performs the operation of placing the board on the NG tray; if the test result passes, it completes the pick-and-place of the circuit board in the function fixture and sends a signal to the function test bench (4); the manipulator (5) grabs the circuit board to the fixed camera position for secondary positioning of the circuit board to avoid coordinate offset caused by the moment when the gripper grabs the board, and completes the secondary positioning of placing the board; The manipulator (5) moves the circuit board to the adaptive board receiving device of the board placing machine, completes the board placing of the board discharging machine (6), and the test ends; After the manipulator (5) is normally started, it works according to the following steps: 7.

1. The device performs a power-on self-check. After the self-check is normal, it proceeds to the next step. If the self-check is abnormal, it outputs an alarm message; 7.

2. Check the manual / automatic switch state of the device. If it is in the automatic state, obtain the operation mode of the central control monitoring software; 7.

3. Obtain the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet (7) and obtain the gripper ID, and automatically replace the corresponding gripper according to the gripper ID; 7.

4. The manipulator (5) takes pictures of the visual calibration points of each fixture to correct the specific coordinates of the fixture; 7.

5. When each device enters the waiting test state after the self-check is normal, the manipulator (5) moves to the adaptive board receiving device of the board loading machine (1) and takes pictures to correct the position of the circuit board; 7.

6. The manipulator (5) takes pictures to obtain the circuit board serial number and sends it to the central control cabinet (7). After receiving the signal allowing the board to be grabbed, it starts to grab the board at the 1# position of the gripper; 7.

7. After the manipulator (5) grabs the circuit board at the 1# position of the gripper, it takes pictures at the fixed camera to correct the position of the circuit board; 7.

8. The manipulator (5) takes out the circuit board at the 2# position of the gripper and places the circuit board at the 1# position into the fixture of the insulation withstanding voltage test bench (2). If there is no circuit board in the ICT fixture, steps 7.5 - 7.7 are repeated; 7.

9. When the circuit board is in the test fixture of the insulation withstanding voltage test bench (2), after each sensor detects normally, the test starts until the test is completed. After the upper cover of the test fixture is opened, the industrial control computer of the cabinet of the insulation withstanding voltage test bench (2) sends the signal that the upper cover of the test fixture is opened in place to the central control cabinet (7); 7.

10. The manipulator (5) takes out the circuit board at the 2# position of the gripper and places the circuit board at the 1# position into the ICT fixture to start the test; If there is no circuit board in the fixture of the functional test bench (4), steps 7.5 - 7.9 are repeated; 7.

11. When the circuit board is in the ICT test fixture, after each sensor detects normally, the test starts until the test is completed. After the upper cover of the test fixture is opened, the industrial control computer of the ICT cabinet sends the signal that the upper cover of the test fixture is opened in place to the central control cabinet (7); 7.

12. The manipulator (5) takes out the circuit board at the 1# position of the gripper and places the circuit board at the 2# position into the test fixture of the functional test bench (4) to start the test; 7.

13. When the circuit board is in the test fixture of the functional test bench (4), after each sensor detects normally, the test starts until the test is completed. The industrial control computer of the cabinet of the functional test bench (4) sends the signal that the upper cover of the test fixture is opened in place to the central control cabinet (7); 7.

14. The manipulator (5) takes a photo of the circuit board at the 1# position of the gripper at the fixed camera to correct the position, and then places the circuit board on the lower trigger adaptive board receiving device.

2. The test method according to claim 1, characterized in that, It also includes the automatic call process of the test program, specifically as follows: After the software starts, it is necessary to select the drawing number of the product to be tested, verify it with the production program database, and obtain the program path and program package verification information; after the software obtains the program path, it automatically accesses the program package under the specified path and executes the action of downloading the program package; after the program package is downloaded locally, it executes the program package verification action; if the program verification result fails, it directly ends and reports an error; if the program verification result passes, the central control software will decompress the program package and distribute the test program to the loading machine (1), insulation withstanding voltage test bench (2), ICT test bench (3), function test bench (4), manipulator (5) and unloading machine (6); the loading machine (1), insulation withstanding voltage test bench (2), ICT test bench (3), function test bench (4), manipulator (5) and unloading machine (6) will automatically load the test program and perform device ID verification; if the device verification result fails, it directly ends and reports an error; if the device verification result passes, it will connect to the MES system to perform MES verification; if the MES verification result fails, the program will directly end; if the MES verification result passes, it will read the fixture ID used by the test program from the MES; after the test program obtains the fixture ID, it executes the fixture ID verification; if the fixture ID verification result fails, the program will directly end; if the fixture ID verification result passes, it means the program is okay, and it will execute the sensor verification according to the logic preset in the program to check whether the states of each cylinder, motion device, and detection device meet the test requirements; if the sensor verification result fails, the program will directly end; if the sensor verification result passes, the product test program will start, and the test program will automatically call the software to execute and end.

3. The test method according to claim 2, characterized in that it also includes the execution process of the expert diagnosis program, specifically as follows: After starting the expert diagnosis software, after scanning the serial number on the software interface, the expert diagnosis program finds the test report of the current serial number in the test database and obtains the test report; sorts by time to find the names of the items that failed the test in the latest test report, and finds the same test name in the fault tree in the expert diagnosis program, and compares it with the expert experience library; if the comparison result is different, a new expert experience task will be generated; if the comparison result is the same, all the expert experiences under this fault tree will be directly retrieved and displayed on the expert diagnosis program interface, and the faults will be investigated and eliminated interactively and compared with the actual product faults for verification. After the faults are eliminated, an expert experience evaluation will be performed, and modification or optimization opinions for the current expert experience will be put forward to continuously update the content of the expert library.

4. The test method according to claim 1 or 2 or 3, characterized in that the central control cabinet (7) includes a main control PLC, HMI, server, UPS, industrial computer and switch. After the cabinet starts normally, it works according to the following steps: 1.

1. Log in with the work number to automatically obtain the program to log in to the industrial computer, server and HMI; 1.

2. Open the central control monitoring software and automatically establish connections with the production line server, company MES server, company program server, and company DDCS server; 1.

3. The main control PLC establishes connections with the upper board machine (1), the insulation withstand voltage test bench (2) cabinet and fixture, the ICT cabinet and fixture, the functional test bench (4) cabinet and fixture, the manipulator (5), the lower board machine (6), and the safety interlock device; 1.

4. Before the test begins, select the operation mode through the manual / automatic switch. If the self-check of each device is normal and there is no alarm information, the sensor of the safety interlocking device has no alarm, and the product test program is verified and passed, enter the full-automatic mode, otherwise enter the manual mode; 1.

5. Select the drawing number of the product to be tested, automatically call the product test program from the company's program server and send the program to the board loading machine (1), insulation and withstand voltage test bench (2) cabinet and fixture, ICT cabinet and fixture, functional test bench (4) cabinet and fixture, manipulator (5), and board unloading machine (6); each device obtains the program and parses the parameters and automatically verifies it with the MES server; 1.

6. Error proofing of the product. If the product passes the verification, it is allowed to go online and start testing. If it fails, it cannot go online. 1.

7. Automatically obtain and upload test data to the company's DDCS server during the test; 1.

8. During the test, the position of the circuit boards with each serial number is automatically detected, and each circuit board is controlled to complete the corresponding test according to the program requirements; 1.

9. Re-launch NG products and track test results, and automatically find, analyze and locate faults through the fault expert database; 1.

10. Record log information; 1.

11. Repeat steps 1.4 to 1.10 during the test.

5. The test method according to claim 1, 2 or 3, It is characterized in that The board loading machine (1) comprises a PLC, a feeding / discharging mechanism, an adaptive board pushing device, an adaptive board receiving device, an AGV docking device and an error prevention device. After the board loading machine (1) is started normally, it works according to the following steps: 2.

1. The equipment will power on for self-test. If the self-test is normal, it will proceed to the next step. If the self-test is abnormal, an alarm message will be output; 2.

2. The manual / automatic switch status of the equipment. If it is in automatic status, obtain the operation mode of the central control monitoring software; 2.

3. PLC controls and initializes each device and sensor information of the equipment; 2.

4. Obtain the drawing number information and product program parameters issued by the central control monitoring software on the central control cabinet (7), and adjust the SMT material rack in / out mechanism, the adaptive push plate device and the adaptive board receiving device to the specified position according to the program parameters, specifically the stroke of the push plate device, the position of the support block of the board receiving device, and the lifting height parameters; 2.

5. The AGV transports the product from the front end, docks with the AGV docking device of the loader (1), and delivers the SMT rack on the AGV to the interface of the infeed / outfeed mechanism; 2.

6. Scan the product QR code and transmit it to the central control to confirm whether to allow entry into the board loading machine (1). If allowed, the error prevention device of the board loading machine (1) will retract and allow the SMT material rack to enter. If not allowed, the error prevention device of the board loading machine (1) will remain in the error prevention position; 2.7 After the feeding and discharging mechanism delivers the SMT rack to the designated position, the PLC controls the sensor to detect the position of the circuit board and drives the adaptive push plate device to push the circuit board out of the SMT rack; 2.8 After the adaptive push plate device pushes out the circuit board, the adaptive board receiving device catches the circuit board and notifies the central controller that the circuit board is ready and can be grabbed by the manipulator (5); 2.9 Repeat steps 2.7 - 2.8 to complete loading the board.

6. According to the test method described in claim 1 or 2 or 3, characterized in that the cabinet of the insulation withstand voltage test bench (2) includes an insulation withstand voltage tester, an industrial computer, a PLC, and test jigs. After the cabinet of the insulation withstand voltage test bench (2) is normally started, the working process is as follows: 3.1 The device performs a power-on self-check. After the self-check is normal, proceed to the next step. If the self-check is abnormal, an alarm message is output; 3.2 Check the device's manual / automatic switch status. If it is in the automatic state, obtain the operating mode of the central control monitoring software; 3.3 The PLC controls and initializes the information of each device and sensor of the device; 3.4 The industrial computer obtains the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet (7) and downloads the program from the central control cabinet (7) to the local; 3.5 The test program of the industrial computer is automatically started and the name and version number of the test program are verified through MES; 3.6 The test program of the industrial computer self-checks the ID of the insulation withstand voltage tester, the sensors controlled by the PLC, and the jigs; 3.7 After the self-check is completed, the PLC automatically opens the upper cover of the jig and sends a self-check normal signal to the central control cabinet (7) through the industrial computer, waiting for the manipulator (5) to place the circuit board; 3.8 The test program of the industrial computer sends a signal indicating that there is no board in the jig, and the manipulator (5) places the circuit board; 3.9 After the manipulator (5) leaves the jig range and reaches the designated position, it sends a signal indicating that the board has been placed on the insulation withstand voltage test bench (2); 3.10 The PLC controls the in-position sensor to detect that the circuit board is in the designated position, and the leveling sensor detects that the circuit board is leveled, and sends a waiting-for-test signal to the industrial computer; 3.11 The test program of the industrial computer starts the test. After the test is completed, the test result is notified to the manipulator (5) through the industrial computer to the central control cabinet (7). After the manipulator (5) takes out the circuit board, it places another circuit board to be tested; 3.12 Repeat steps 3.8 - 3.11 to complete the test.

7. According to the test method described in claim 1 or 2 or 3, characterized in that the ICT test bench (3) includes an industrial computer, a channel card, a measurement card, a module power supply, and test jigs. After the ICT test bench (3) is normally started, the working process is as follows: 4.1 The device performs a power-on self-check. After the self-check is normal, proceed to the next step. If the self-check is abnormal, an alarm message is output; 4.2 If the device is in the automatic state, obtain the operating mode of the central control monitoring software; 4.3 The industrial computer controls and initializes the information of each device and sensor of the device; 4.4 The industrial computer obtains the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet (7) and downloads the program from the central control cabinet (7) to the local; 4.

5. The industrial control computer test program starts automatically and verifies the test program name and version number through MES. 4.

6. The industrial control computer test program self-checks the channel card, measurement card, module power supply, sensors of the test fixture, and the ID of the fixture. 4.

7. After the self-check is completed, the industrial control computer automatically opens the upper cover of the fixture and sends a normal self-check signal to the central control cabinet (7), waiting for the manipulator (5) to place the circuit board. 4.

8. The industrial control computer test program sends out a signal indicating no board in the fixture, and the manipulator (5) places the circuit board. 4.

9. After the manipulator (5) leaves the fixture range and reaches the designated position, it sends out a signal indicating that the circuit board has been placed on the ICT. 4.

10. The industrial control computer controls the in-position sensor to detect that the circuit board is in the designated position, and the leveling sensor to detect that the circuit board is level, and sends a waiting-for-test signal to the industrial control computer. 4.

11. The industrial control computer test program starts the test. After the test is completed, the industrial control computer notifies the manipulator (5) of the test result through the central control cabinet (7). After the manipulator (5) removes the circuit board, it places another circuit board to be tested. 4.

12. Repeat steps 4.8 - 4.11 to complete the test.

8. According to the test method described in claim 1 or 2 or 3, characterized in that the functional test bench (4) includes an oscilloscope, a multimeter, a signal generator, a power supply, a matrix, an industrial control computer, a PLC, and a test fixture. After the functional test bench (4) starts up normally, the work flow is as follows: 5.

1. The device performs a power-on self-check. If the self-check is normal, proceed to the next step; if the self-check is abnormal, output an alarm message. 5.

2. Check the hand / auto switch status of the device. If it is in the auto state, obtain the operation mode of the central control monitoring software. 5.

3. The PLC controls and initializes the information of each device and sensor of the device. 5.

4. The industrial control computer obtains the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet (7), and downloads the program from the central control cabinet (7) to the local. 5.

5. The industrial control computer test program starts automatically and verifies the test program name and version number through MES. 5.

6. The industrial control computer test program self-checks the oscilloscope, multimeter, signal generator, power supply, matrix, sensors controlled by the PLC, and the ID of the fixture. 5.

7. After the self-check is completed, the PLC automatically opens the upper cover of the fixture and sends a normal self-check signal to the central control cabinet (7) through the industrial control computer, waiting for the manipulator (5) to place the circuit board. 5.

8. The industrial control computer test program sends out a signal indicating no board in the fixture, and the manipulator (5) places the circuit board. 5.

9. After the manipulator (5) leaves the fixture range and reaches the designated position, it sends out a signal indicating that the circuit board has been placed on the functional test bench (4). 5.

10. The PLC controls the in-position sensor to detect that the circuit board is in the designated position, and the leveling sensor to detect that the circuit board is level, and sends a waiting-for-test signal to the industrial control computer. 5.

11. The industrial control computer test program starts the test. After the test is completed, the industrial control computer notifies the manipulator (5) of the test result through the central control cabinet (7). After the manipulator (5) removes the circuit board, it places another circuit board to be tested. 5.

12. Repeat steps 5.8 - 5.11 to complete the test.

9. According to the test method described in claim 1 or 2 or 3, characterized in that The lower board machine (6) includes a PLC, a feeding / discharging mechanism, an adaptive pushing plate device, an adaptive receiving plate device, an AGV docking device, and an anti-misoperation device. After the lower board machine (6) is normally started, it works according to the following steps: 6.

1. The equipment powers on and performs self-check. After the self-check is normal, it proceeds to the next step. If the self-check is abnormal, an alarm message is output. 6.

2. Check the manual / automatic switch status of the equipment. If it is in the automatic state, obtain the operation mode of the central control monitoring software. 6.

3. The PLC controls and initializes the information of each device and sensor of the equipment. 6.

4. Obtain the drawing number information and product program parameters sent by the central control monitoring software on the central control cabinet (7), and adjust the SMT rack feeding / discharging mechanism, the adaptive pushing plate device, and the adaptive receiving plate device to the specified positions according to the program parameters. Specifically, the stroke of the pushing plate device, the position of the support block of the receiving plate device, and the lifting height parameters. 6.

5. The manipulator (5) places the circuit board on the adaptive receiving plate device. 6.

6. After the manipulator (5) leaves the fixture range and reaches the specified position, a signal indicating that the board has been placed is sent out by the lower board machine (6). 6.

7. After the circuit board is pushed out by the adaptive pushing plate device, the circuit board is sent into the SMT rack. 6.

8. Repeat steps 6.5 - 6.7 to complete the lower board operation. 6.

9. The AGV docks with the AGV docking device of the upper board machine (1) and takes out the SMT rack from the feeding / discharging mechanism interface and sends it to the next process.

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