A fully automatic capacitor impregnation production line

Abstract

The application discloses a kind of full-automatic capacitor impregnation production line, including rack, feeding mechanism, discharging mechanism;Feeding mechanism includes transfer mechanism, transfer lifting mechanism and sequentially set in transfer mechanism between incoming work station, intermediate waiting work station, outgoing work station;Transfer mechanism reciprocates between incoming work station and outgoing work station;Transfer lifting mechanism drives transfer mechanism to make up-down lifting movement;After the trolley equipped with at least two groups of stacked racks enters incoming work station, transfer mechanism realizes simultaneously at least two groups of stacked racks from incoming work station to outgoing work station by left and right, up and down movement, then sequentially through chain type conveying mechanism enters the multiple impregnation work station and drying work station alternately arranged and processes, after completing impregnation processing, it is discharged by discharging mechanism.This application improves the feeding efficiency by overall structure design, especially the feeding mechanism can feed two groups of stacked racks at a time;Full automation is also realized in full production line operation.

Description

Technical Field

[0001] This invention relates to the field of capacitor processing equipment, and more particularly to a fully automated capacitor impregnation production line. Background Technology

[0002] A capacitor impregnation production line is a device used for impregnating capacitor workpieces with electrolyte. It improves the mechanical strength and insulation strength of the workpieces, and provides functions such as moisture resistance, mildew prevention, and noise reduction. In the impregnation process of electrolytic capacitors, the product containing the liner paper is immersed in the electrolyte, followed by drying. These two processes of "immersion" and "drying" are repeated multiple times to ensure that the liner paper can better absorb substances from different electrolytes.

[0003] However, existing impregnation production lines have the following drawbacks:

[0004] (1) In the prior art, the impregnation process generally requires manual labor combined with semi-automatic equipment. The reason is that in order to meet the multiple impregnation and drying processes in the impregnation production line, the carriers containing capacitors must be manually transported between multiple workstations, which results in high labor costs and high labor intensity. At the same time, manual transport of carriers can also easily lead to pollution of the working environment. If it is desired to achieve fully automated transport of workpieces, multiple robotic arms can be designed between different workstations to replace manual transport of carriers between workstations. However, the actual transfer efficiency is low and the cost is high.

[0005] (2) In the existing impregnation production line, capacitors and other impregnated materials are generally loaded on carriers. Multiple carriers are stacked on the material cart in a layered manner. Usually, only one set of stacked carriers can be loaded at a time. Each loading requires manual transportation of the carriers, which is inefficient. Moreover, during the production process, the material carts holding the carriers will also enter the impregnation production line along with the carriers. Since the rollers of the material carts are difficult to limit and fix, multiple material carts are prone to collision in the production line, which can cause the carriers to collapse and lead to production accidents.

[0006] Therefore, how to develop a high-efficiency, energy-saving, fully automated impregnation production line at a reasonable cost is a technical challenge that urgently needs to be solved. Summary of the Invention

[0007] To overcome the shortcomings of existing technologies, the present invention aims to provide a fully automated capacitor impregnation production line. This application, through its overall structural design, particularly its feeding mechanism which can simultaneously feed two sets of stacked carriers, significantly improves feeding efficiency. The entire production line, especially the feeding and discharging ends, achieves automated operation, forming a crucial foundation for fully automated impregnation production lines. No manual intervention is required, making it a highly efficient and energy-saving fully automated impregnation production line for feeding and transporting materials.

[0008] The objective of this invention is achieved through the following technical solution: a fully automatic capacitor impregnation production line, characterized in that it includes a frame, a loading mechanism and a unloading mechanism arranged sequentially on the frame; the loading mechanism includes a transfer mechanism, a transfer lifting mechanism that drives the transfer mechanism to move up and down, and a feeding station, an intermediate waiting station and an unloading station arranged sequentially between the transfer mechanisms; the transfer mechanism moves back and forth between the feeding station and the unloading station; the transfer lifting mechanism drives the transfer mechanism to move up and down; after a trolley equipped with at least two sets of stacked carriers enters the feeding station, the transfer mechanism simultaneously transfers at least two sets of stacked carriers from the feeding station to the unloading station by moving left and right and up and down, and then sequentially enters multiple impregnation stations and drying stations alternately arranged between the loading mechanism and the unloading mechanism for processing through a chain conveyor mechanism, and after the impregnation processing is completed, the material is unloaded through the unloading mechanism.

[0009] Furthermore, the transfer mechanism includes a loading and transfer frame, a sprocket assembly, and a carrier chain support plate; the sprocket assembly is installed inside the loading and transfer frame, and the carrier chain support plate is fixed on the chain of the sprocket assembly and moves back and forth with the chain to support and transfer the stacked carrier frame; when the sprocket assembly rotates, the chain on the sprocket assembly drives the carrier chain support plate to move back and forth left and right; wherein, there are two sets of sprocket assemblies, each set of sprocket assemblies includes a driving gear, a driven gear, a chain, and a sprocket motor; the chain is sleeved on the driving gear and the driven gear, and the sprocket motor is driven by the driving gear; the carrier chain support plates are correspondingly and symmetrically arranged on the chains of the two sets of sprocket assemblies.

[0010] Furthermore, the transfer and lifting mechanism includes a mounting frame, a guide column, a lifting frame, a linkage shaft, and a lifting motor; there are two mounting frames, symmetrically arranged on both sides of the sprocket assembly; the guide column is upright inside the mounting frame; there are two lifting frames, each lifting frame is sleeved on the guide column of each mounting frame; the loading and transfer frame is fixed on the lifting frame; the lifting motor drives the lifting frames and loading and transfer frames on both sides to move synchronously up and down along the length of the guide column through the linkage shaft.

[0011] Furthermore, the feeding mechanism also includes a centering mechanism and a sorting mechanism. The centering mechanism includes push claws and push claw cylinders. The push claws are arranged on the front and rear sides of the output station. The push claw cylinders drive the push claws to move back and forth to make the short side of the carrier stack neatly. The sorting mechanism includes a shift block, a shift block cylinder, and a connecting rod assembly. The shift block is arranged on the front and rear sides of the output station. The shift block cylinders drive the shift block to make it move in an arc shape to make the long side of the carrier stack neatly.

[0012] Furthermore, the drying station sequentially includes a pre-drying mechanism, a pre-treatment drying mechanism, a monomer drying mechanism, and a polymerization insulation mechanism. Each of the pre-drying mechanism, pre-treatment drying mechanism, monomer drying mechanism, and polymerization insulation mechanism is equipped with a drying heating chamber. Each drying heating chamber has a lifting gate assembly at its inlet and outlet for opening or closing the inlet and outlet. The lifting gate assembly includes a gate body, an upright rack, a gate motor, and a labor-saving counterweight assembly. The labor-saving counterweight assembly includes a counterweight block and a traction rope. One end of the traction rope is fixed to the gate, and the other end is guided by a fixed pulley assembly and fixed to the counterweight block. The gate motor is fixed to the top of the gate body. The power output end of the gate motor meshes with the upright rack for transmission. The rotation of the gate motor drives the gate body to move up and down, while the counterweight block moves up and down in the opposite direction.

[0013] Furthermore, the impregnation station includes a pretreatment impregnation mechanism, a single-unit impregnation mechanism, and a vacuum impregnation mechanism. One impregnation process is performed at each impregnation station. Before each impregnation process, the stacked racks from the previous process need to be separated one by one so that each impregnation process can fully impregnate each rack individually. After each impregnation process, the racks from the previous process need to be gradually stacked into a stacked rack so that the subsequent drying and heating processes can efficiently dry and react with multiple stacked racks at high temperatures. During the above-mentioned process of separating and stacking racks one by one, the transfer and lifting mechanism is used to adjust the vertical position of the racks to meet the transfer height requirements of each process in the conveying direction.

[0014] Furthermore, the pretreatment impregnation mechanism includes a pretreatment transfer frame, a first translation mechanism for moving the pretreatment transfer frame left and right, and a first lifting mechanism for moving the pretreatment transfer frame up and down; the pretreatment transfer frame is equipped with multiple sets of robotic arms for gripping the frame; the robotic arms move the frame from the previous station to the next station under the drive of the first translation mechanism and the first lifting mechanism.

[0015] Furthermore, the single-unit impregnation mechanism includes a single-unit transfer frame, a second translation mechanism for moving the single-unit transfer frame left and right, and a second lifting mechanism for moving the single-unit transfer frame up and down; the single-unit transfer frame is equipped with multiple sets of robotic arms for gripping the frame; the robotic arms move the frame from the previous workstation to the next workstation under the drive of the second translation mechanism and the second lifting mechanism.

[0016] Furthermore, the vacuum impregnation mechanism includes a vacuum tank, a vacuum cover, a vacuum cover lifting mechanism, and a vacuum cover locking mechanism. Multiple sets of vacuum tanks are arranged side-by-side on a fixed frame along the workpiece conveying direction. The vacuum cover is located above the vacuum tank and is lifted by the vacuum cover lifting mechanism to seal or open the opening of the vacuum tank. The vacuum cover locking mechanism is located on both sides of the vacuum tank; during vacuum impregnation, the locking mechanism presses the vacuum cover onto the vacuum tank. The vacuum impregnation mechanism also includes a vacuum transfer frame, a third translation mechanism for moving the vacuum transfer frame left and right above the vacuum tank, and a third lifting mechanism for moving the vacuum transfer frame up and down above the vacuum tank. Multiple sets of robotic arms are provided on the vacuum impregnation transfer frame for gripping the frame. Driven by the third translation mechanism and the third lifting mechanism, the robotic arms move the frame from the previous station to the vacuum tank, complete the vacuum impregnation, and then move the frame to the next station.

[0017] Furthermore, the unloading mechanism includes a transfer mechanism, a transfer lifting mechanism that drives the transfer mechanism to move up and down, and a feeding station, an intermediate waiting station, and an unloading station arranged sequentially between the transfer mechanisms; the transfer mechanism moves back and forth between the feeding station and the unloading station; the transfer lifting mechanism drives the transfer mechanism to move up and down; after the polymerization reaction is completed, the stacked racks are transported to the feeding position of the unloading mechanism by a chain transmission mechanism on the frame, and the transfer mechanism moves left and right and up and down to transfer at least two sets of stacked racks from the feeding position to the material cart at the same time; wherein the unloading mechanism is provided with a positioning structure for correcting the dropping position; the positioning structure includes a alignment guide plate provided on the transfer mechanism, two sets of limiting square tubes and two sets of positioning pin assemblies provided on the unloading material cart.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0019] (1) This application improves feeding efficiency significantly through overall structural design, especially the feeding mechanism of this application, which can feed two sets of stacked racks at one time; it realizes full automation in the entire production line operation, especially the feeding and discharging ends are the important foundation for the full automation of the impregnation production line, no longer requiring manual intervention, making it a highly efficient and energy-saving fully automatic impregnation production line for feeding and transporting materials.

[0020] (2) The feeding mechanism of this application can directly transfer the stacked racks on the material cart to the production line. It can feed at least two sets of stacked racks at the same time. By widening the gap between the two sets of stacked racks through the intermediate waiting station, the feeding frequency and interval in the next process can be maintained. This mechanism can realize the automated transportation of multiple sets of stacked racks with high efficiency. At the same time, it can prevent the material cart from entering the production line, control the feeding frequency and interval, effectively avoid collisions between racks, and improve impregnation efficiency and quality.

[0021] (3) This application designs multiple drying chambers on the production line, with a lifting gate assembly at the inlet and outlet of each drying chamber. This assembly can close or open the inlet and outlet of each drying chamber, and each lifting gate assembly is independently motor-controlled. According to the process requirements, the operation of each drying chamber can be independently controlled, improving the overall operating efficiency of the production line. In addition, by adding a counterweight, the operating load of the gate motor is reduced, and only one low-power drive motor is needed to control a single gate, making the entire line more energy-efficient and environmentally friendly. At the same time, the opening and closing speed of the gate in this lifting gate assembly is faster, and the failure rate can be effectively reduced.

[0022] (4) The carrier or stacked carrier of this impregnation production line is automatically transferred from the drying station to the impregnation station or from the impregnation station to the drying station. The transfer of workpieces between stations does not require manual intervention. Moreover, the same transfer and lifting mechanism can be used to separate the stacked carriers of the previous process one by one or to stack the carriers separated in the previous process into a stacked carrier.

[0023] (5) The impregnation production line is designed with three parts working together: a transfer frame, a translation mechanism that drives the transfer frame to move left and right, and a lifting mechanism that drives the transfer frame to move up and down. This enables automated material feeding in the impregnation process and meets the transfer height requirements of the upper and lower processes in the conveying direction. Attached Figure Description

[0024] Figure 1 This is a partial structural schematic diagram of a fully automated capacitor impregnation production line according to a preferred embodiment of the present invention;

[0025] Figure 2 for Figure 1 A schematic diagram of the feeding mechanism, pre-drying mechanism, and pre-treatment impregnation mechanism in an impregnation production line;

[0026] Figure 3 for Figure 1 A schematic diagram of the pretreatment drying mechanism, monomer impregnation mechanism, and monomer drying mechanism in the impregnation production line;

[0027] Figure 4 for Figure 1 A schematic diagram of the vacuum impregnation mechanism, polymerization insulation mechanism, and feeding mechanism in the impregnation production line;

[0028] Figure 5 This is a schematic diagram of the material cart and stacked rack of the present invention;

[0029] Figure 6 for Figure 5 Enlarged view of point a in the middle;

[0030] Figure 7 This is a schematic diagram of the feeding mechanism according to a preferred embodiment of the present invention;

[0031] Figure 8 This is a schematic diagram of the transfer mechanism and the transfer lifting mechanism in the feeding mechanism of a preferred embodiment of the present invention;

[0032] Figure 9 This is a schematic diagram of the transfer mechanism and the transfer lifting mechanism in the feeding mechanism of the preferred embodiment of the present invention from another angle;

[0033] Figure 10 This is a schematic diagram of the transfer mechanism in the feeding mechanism of a preferred embodiment of the present invention;

[0034] Figure 11 This is a step diagram of the horizontal feeding mechanism of the preferred embodiment of the present invention;

[0035] Figure 12 This is a schematic diagram of the centering mechanism and the sorting structure in the feeding mechanism of a preferred embodiment of the present invention;

[0036] Figure 13 This is a schematic diagram of the pre-drying mechanism in a preferred embodiment of the present invention;

[0037] Figure 14 This is a schematic diagram of the structure of the lifting gate assembly according to a preferred embodiment of the present invention;

[0038] Figure 15 This is a schematic diagram of the gate in the open state of the lifting gate assembly according to a preferred embodiment of the present invention;

[0039] Figure 16 This is a schematic diagram of the gate closed state in a preferred embodiment of the lifting gate assembly of the present invention;

[0040] Figure 17 This is a schematic diagram of the pretreatment impregnation mechanism or monomer impregnation mechanism according to a preferred embodiment of the present invention;

[0041] Figure 18 This is a schematic diagram of the vacuum impregnation mechanism according to a preferred embodiment of the present invention;

[0042] Figure 19 This is a side view of the vacuum impregnation mechanism according to a preferred embodiment of the present invention;

[0043] Figure 20 This is a three-dimensional structural diagram of the vacuum transfer frame, the third translation mechanism, and the third lifting mechanism in the vacuum immersion mechanism of a preferred embodiment of the present invention;

[0044] Figure 21 This is a side view of the vacuum transfer frame, the third translation mechanism, and the third lifting mechanism in the vacuum immersion mechanism of a preferred embodiment of the present invention;

[0045] Figure 22 This is a schematic diagram of the vacuum cover locking mechanism in a preferred embodiment of the present invention.

[0046] Figure 23 This is a schematic diagram of the vacuum cover locking mechanism in the vacuum impregnation mechanism of a preferred embodiment of the present invention from another angle;

[0047] Figure 24 This is a schematic diagram of the vacuum cover lifting mechanism in a preferred embodiment of the present invention.

[0048] Figure 25 This is a schematic diagram of the structure of the polymer insulation mechanism according to a preferred embodiment of the present invention;

[0049] Figure 26 This is a schematic diagram of the feeding mechanism according to a preferred embodiment of the present invention;

[0050] Figure 27 This is a schematic diagram of the feeding mechanism from another angle, representing a preferred embodiment of the present invention.

[0051] In the diagram: A. Stacked rack; A1. Rack; B. Material cart; C. Capacitor; 1. Frame; 2. Loading mechanism; 21. Transfer mechanism; 211. Loading and transfer rack; 212. Rack chain support; 213. Drive gear; 214. Driven gear; 215. Chain; 216. Sprocket motor; 22. Transfer and lifting mechanism; 221. Mounting frame; 222. Guide column; 223. Lifting frame; 224. Linkage shaft; 225. Lifting motor; 23. Feeding station; 24. Intermediate waiting area. 25. Outgoing workstation; 26. Centering mechanism; 261. Push claw; 262. Push claw cylinder; 27. Sorting mechanism; 271. Pulley; 272. Pulley cylinder; 273. Linkage assembly; 3. Front drying mechanism; 31. Drying heating chamber; 32. Lifting gate assembly; 321. Gate body; 322. Vertical rack; 323. Gate motor; 324. Counterweight; 325. Traction rope; 4. Pretreatment impregnation mechanism; 41. Pretreatment transfer frame; 42. First translation mechanism; 43. First lifting mechanism; 5. Pretreatment drying mechanism; 6. Monomer impregnation mechanism; 61. Monomer transfer rack; 62. Second translation mechanism; 63. Second lifting mechanism; 7. Monomer drying mechanism; 8. Vacuum impregnation mechanism; 81. Vacuum tank; 82. Vacuum cover; 83. Vacuum cover lifting mechanism; 831. Locking motor; 832. Linkage shaft; 833. Belt; 834. Pulley; 84. Vacuum cover locking mechanism; 85. Vacuum transfer rack; 86. Third translation mechanism; 87. 9. Lifting mechanism; 10. Polymerization insulation mechanism; 11. Polymerization temperature zone 1; 12. Polymerization temperature zone 2; 13. Polymerization temperature zone 3; 14. Polymerization temperature zone 4; 15. Polymerization temperature zone 5; 16. Chain conveyor mechanism; 10. Unloading mechanism; 101. Transfer mechanism; 102. Transfer lifting mechanism; 103. Feeding station; 104. Intermediate waiting station; 105. Unloading station; 106. Positioning structure; 1061. Alignment guide plate; 1062. Limiting square tube; 1063. Positioning pin assembly. Detailed Implementation

[0052] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0053] like Figure 1-27As shown, a fully automatic capacitor impregnation production line includes a frame 1, a feeding mechanism 2, a pre-drying mechanism 3, a pre-treatment impregnation mechanism 4, a pre-treatment drying mechanism 5, a monomer impregnation mechanism 6, a monomer drying mechanism 7, a vacuum impregnation mechanism 8, a polymerization and heat preservation mechanism 9, and a discharging mechanism 10, which are sequentially arranged on the frame 1; wherein, the drying station includes the pre-drying mechanism 3, the pre-treatment drying mechanism 5, the monomer drying mechanism 7, and the polymerization and heat preservation mechanism 9, and the impregnation station includes the pre-treatment impregnation mechanism 4, the monomer impregnation mechanism 6, and the vacuum impregnation mechanism 8.

[0054] The loading mechanism 2 includes a transfer mechanism 21, a transfer lifting mechanism 22 that drives the transfer mechanism 21 to move up and down, and a feeding station 23, an intermediate waiting station 24, and a discharging station 25 arranged sequentially between the transfer mechanisms 21; the transfer mechanism 21 moves back and forth between the feeding station 23 and the discharging station 25; the transfer lifting mechanism 22 drives the transfer mechanism 21 to move up and down.

[0055] The material cart B of this invention can be equipped with at least two sets of stacked carriers A. Each set of stacked carriers A is composed of several carriers stacked from bottom to top. Preferably, in this invention, six carriers A1 are stacked to form a set of stacked carriers A. Each layer of carriers A1 is equipped with a row of capacitors C to be impregnated. Figure 5-6 As shown.

[0056] In this invention, after the material cart B, equipped with at least two sets of stacked carriers A, enters the feeding station 23, the transfer mechanism moves left and right and up and down to simultaneously transfer at least two sets of stacked carriers A from the feeding station 23 to the output station 25. Then, the materials sequentially enter the pre-drying mechanism 3, the pre-treatment impregnation mechanism 4, the pre-treatment drying mechanism 5, the monomer impregnation mechanism 6, the monomer drying mechanism 7, the vacuum impregnation mechanism 8, and the polymerization and heat preservation mechanism 9 for processing. The carriers A1 are transferred through a chain conveyor mechanism in each processing step. The chain conveyor mechanism can be designed as a multi-segment type according to actual needs. The overlapping chain at the beginning and end can realize the continuous transfer between the previous process and the next process. After all processing steps are completed, the materials are unloaded through the unloading mechanism 10.

[0057] In existing technologies, impregnation processing generally requires a combination of manual labor and semi-automatic equipment. This is because, in order to meet the multiple impregnation and drying processes in the impregnation production line, multiple drying and impregnation stations must be set up at intervals. The capacitor carriers are usually transported between the stations manually, which results in high labor costs and high labor intensity. At the same time, manual transport of the carriers can also easily lead to pollution of the working environment. However, if all processes in the entire production line can be fully automated, robotic arms need to be set up to replace manual labor in transporting the carriers A1 between the stations. However, the actual efficiency is low and the cost is high.

[0058] This application significantly improves feeding efficiency through its overall structural design, especially the feeding mechanism 2, which can feed two sets of stacked carriers A at one time. It achieves automated operation in the entire production line, especially at the feeding and discharging ends, which is an important foundation for the full automation of the impregnation production line. No manual intervention is required, making it a highly efficient and energy-saving fully automated impregnation production line for feeding and transporting materials. As a further preferred embodiment, the transfer mechanism 21 of the feeding mechanism 2 includes a feeding transfer frame 211, a sprocket assembly, and a frame chain support plate 212. The sprocket assembly is installed inside the feeding transfer frame 211, and the frame chain support plate 212 is fixed on the chain 215 of the sprocket assembly and moves back and forth with the chain 215 to support and transfer the stacked frame A. When the sprocket assembly rotates, the chain 215 on the sprocket assembly drives the frame chain support plate 212 to move back and forth. There are two sets of sprocket assemblies, and each set of sprocket assemblies includes a driving gear 213, a driven gear 214, a chain 215, and a sprocket motor 216. The chain 215 is sleeved on the driving gear 213 and the driven gear 214, and the sprocket motor 216 is connected to the driving gear 213 for transmission. The frame chain support plates 212 are correspondingly and symmetrically arranged on the chains 215 of the two sets of sprocket assemblies.

[0059] As a further preferred embodiment, the transfer lifting mechanism 22 includes a mounting frame 221, a guide column 222, a lifting frame 223, a linkage shaft 224, and a lifting motor 225. There are two mounting frames 221, symmetrically arranged on both sides of the sprocket assembly. The guide column 222 is erected inside the mounting frame 221. There are two lifting frames 223, each of which is sleeved on the guide column 222 of each mounting frame 221. The loading and transfer frame 211 is fixed on the lifting frame 223. The lifting motor 225 drives the lifting frames 223 and the loading and transfer frame 211 on both sides to move up and down synchronously along the length of the guide column 222 through the linkage shaft 224.

[0060] The feeding process of this feeding mechanism 2 is as follows:

[0061] (1) The material cart B equipped with at least two sets of stacked racks A enters the feeding station 23 of the loading mechanism 2;

[0062] (2) Driven by the transfer lifting mechanism 22, the transfer mechanism 21 descends along the guide column 222 to the lowest point. Then, the sprocket assembly rotates, moving the carrier chain support plate 212 to both sides of the stacked carrier A located on the material cart B, just supporting the two sets of stacked carrier A from the bottom. The transfer mechanism 21 rises, vertically lifting the two sets of stacked carrier A. When the two sets of stacked carrier A are in place, they are just at the rightmost end of the transfer mechanism 21. At this time, the positions of the two sets of stacked carrier A are as follows: Figure 11 As shown in (I), the vertical feeding step is completed;

[0063] (3) The sprocket assembly in the transfer mechanism 21, such as Figure 11 (II) Rotate to the left as indicated by the horizontal left arrow, simultaneously moving both sets of stacked racks A to above the middle waiting position 24, then stop moving. At this time, the positions of the two sets of stacked racks A are as follows: Figure 11 As shown in (II);

[0064] (4) The transfer mechanism 21 moves vertically downwards until the carrier chain support plate 212 is away from the bottom of the left-side stacked carrier A. The left-side stacked carrier A is supported on the middle waiting station 24, while the right-side stacked carrier A is still supported on the carrier chain support plate 212; then the sprocket assembly... Figure 11 (III) Turn right as indicated by the horizontal arrow, moving the right-side stacked rack A to the far right of the transfer mechanism 21. At this point, a certain distance is created between the two sets of stacked racks A. Then, the transfer mechanism 21 moves vertically upward until the rack chain support plates 212 have moved to both sides of the two sets of stacked racks A, just supporting the two sets of stacked racks A from the bottom. At this point, the positions of the two sets of stacked racks A are as follows: Figure 11 As shown in (III);

[0065] (5) The sprocket assembly in the transfer mechanism 21, such as Figure 11 (IV) Turn left as indicated by the horizontal arrow to the left, simultaneously moving the two sets of stacked racks A with the spacing apart to the leftmost end of the transfer mechanism 21, and stop moving. At this time, the positions of the two sets of stacked racks A are as follows: Figure 11 As shown in (IV), the stacked rack A on the left is located at the outgoing station 25 and is waiting to be picked up;

[0066] (6) The next process drying mechanism's chain conveyor will take away and send out the stacked rack A located on the left; the sprocket assembly, such as Figure 11 (V) Turn right as indicated by the horizontal right arrow, and the stacked rack A on the right returns to its initial position, that is, the stacked rack A is located at the rightmost end of the transfer mechanism 21 in step (2). At this time, continue to repeat the operation of steps (3)-(5), and finally send the stacked rack A out again to complete the loading of at least two sets of stacked racks A.

[0067] The feeding mechanism 2 of this application can directly transfer the stacked racks on the material cart B to the production line. It can feed at least two sets of stacked racks A at the same time. The intermediate waiting station 24 keeps the distance between the two sets of stacked racks A to maintain the feeding frequency and interval in the next process. This mechanism can realize the automated transportation of multiple sets of stacked racks A with high efficiency. At the same time, it avoids the material cart B from entering the production line, controls the feeding frequency and interval, effectively avoids collisions between racks, and improves impregnation efficiency and quality.

[0068] As a further preferred option, since the stacked rack A is composed of multiple racks A1 stacked together, and subsequent processes require the racks A1 to be separated or stacked, there is no fixed limiting structure between the racks A1. The stacked rack A may shift slightly during vertical and horizontal movement in the loading process. To improve the stability of moving the stacked rack A in subsequent processes, this production line further designs a centering mechanism 26 and a sorting mechanism 27. The centering mechanism 26 includes push claws 261 and push claw cylinders 262; the push claws 261 are positioned on both sides of the output station 25, and the push claw cylinders 262 drive the push claws 261 to move back and forth to ensure the racks A1 are stacked neatly along their short sides. The sorting mechanism 27 includes a lever 271, a lever cylinder 272, and a connecting rod assembly 273; the lever 271 is positioned on both sides of the output station 25, and the lever cylinder 272 drives the lever 271 to move in an arc shape to ensure the racks A1 are stacked neatly along their long sides.

[0069] The centering mechanism 26 and the sorting mechanism 27 can center the stacked racks on the left, right and rear sides in the forward direction, so that each stacked rack A can remain neat during subsequent transportation, avoid tipping over, collisions and production accidents.

[0070] As a further preferred embodiment, the pre-drying mechanism 3, the pre-treatment drying mechanism 5, the monomer drying mechanism 7, and the polymerization heat preservation mechanism 9 are each equipped with a drying heating chamber 31. Each drying heating chamber 31 has a lifting gate assembly 32 at its inlet and outlet for opening or closing the inlet and outlet. The lifting gate assembly 32 includes a gate body 321, an upright rack 322, a gate motor 323, and a labor-saving counterweight assembly. The labor-saving counterweight assembly includes a counterweight block 324 and a traction rope 325. One end of the traction rope 325 is fixed to the gate, and the other end is guided by a fixed pulley assembly and fixed to the counterweight block 324. The gate motor 323 is fixed to the top of the gate body 321. The power output end of the gate motor 323 meshes with the upright rack 322 for transmission. The rotation of the gate motor 323 drives the gate body 321 to move up and down, while the counterweight block 324 moves up and down in the opposite direction.

[0071] This application designs multiple drying chambers on the production line, with each chamber featuring a lifting gate assembly 32 at both its inlet and outlet. This assembly allows for the opening and closing of the inlet and outlet of each chamber, and each lifting gate assembly 32 is independently controlled by a motor. Based on process requirements, the operation of each drying chamber can be independently controlled, improving the overall efficiency of the production line. Furthermore, by adding a counterweight 324, the operating load of the gate motor 323 in this lifting gate assembly 32 is reduced. Only one low-power (e.g., 25W) drive motor is needed to control a single gate, making the entire production line more energy-efficient and environmentally friendly. Simultaneously, the gate of this lifting gate assembly 32 opens and closes faster and effectively reduces the failure rate.

[0072] As a further preferred embodiment, before the pretreatment impregnation, monomer impregnation, and vacuum impregnation processes, the stacked carriers A from the previous process need to be separated one by one so that each impregnation process can fully impregnate each layer of carrier A1 independently; after the pretreatment impregnation, monomer impregnation, and vacuum impregnation processes, the carriers A1 from the previous process need to be gradually stacked into stacked carriers A so that the subsequent drying and heating processes can efficiently dry and react with multiple stacked carriers A at high temperatures; during the above-mentioned process of separating and stacking the carriers one by one, the transfer lifting mechanism 22 is used to adjust the vertical position of the carriers A1 to meet the transfer height requirements of each process in the conveying direction.

[0073] As a further preferred embodiment, the pretreatment impregnation mechanism 4 includes a pretreatment transfer frame 41, a first translation mechanism 42 for moving the pretreatment transfer frame 41 left and right, and a first lifting mechanism 43 for moving the pretreatment transfer frame 41 up and down. The pretreatment transfer frame is equipped with multiple sets of robotic arms for gripping the carrier A1. The robotic arms move the carrier A1 from the previous station to the next station under the drive of the first translation mechanism 42 and the first lifting mechanism 43.

[0074] As a further preferred embodiment, the single-unit impregnation mechanism 6 includes a single-unit transfer frame 61, a second translation mechanism 62 for moving the single-unit transfer frame 61 left and right, and a second lifting mechanism 63 for moving the single-unit transfer frame 61 up and down; the single-unit transfer frame 61 is equipped with multiple sets of robotic arms for gripping the carrier frame A1; the robotic arms move the carrier frame A1 from the previous station to the next station under the drive of the second translation mechanism 62 and the second lifting mechanism 63.

[0075] As a further preferred embodiment, the vacuum impregnation mechanism 8 includes a vacuum tank 81, a vacuum cover 82, a vacuum cover lifting mechanism 83, and a vacuum cover locking mechanism 84. Multiple sets of vacuum tanks 81 are arranged side-by-side and fixed on the frame 1 along the workpiece conveying direction. The vacuum cover 82 is located above the vacuum tank 81 and is lifted or lowered by the vacuum cover lifting mechanism 83 to seal or open the opening of the vacuum tank 81. The vacuum cover locking mechanism 84 is located on both sides of the vacuum tank 81. During vacuum impregnation, the vacuum cover locking mechanism 84 presses the vacuum cover into the vacuum tank. The vacuum impregnation mechanism 8 further includes a vacuum transfer frame 85, a third translation mechanism 86 for moving the vacuum transfer frame 85 left and right above the vacuum tank 81, and a third lifting mechanism 87 for moving the vacuum transfer frame 85 up and down above the vacuum tank 81. The vacuum impregnation transfer frame is equipped with multiple sets of robotic arms for gripping the frame A1. The robotic arms move the frame A1 from the previous station to the vacuum tank 81 under the drive of the third translation mechanism 86 and the third lifting mechanism 87, and after completing the vacuum impregnation, move the frame A1 to the next station.

[0076] The vacuum cover lifting mechanism 83 includes a locking motor 831, a linkage shaft 832, a belt 833, and a pulley 834. The belt 833 is strip-shaped, with one end fixed to the pulley 834 and the other end fixed to the vacuum cover. The pulley 834 is sleeved on the linkage shaft 832, which is linked to the locking motor 831. When the locking motor 831 rotates, it drives the linkage shaft 832 to rotate, which in turn causes the pulley 834 fixed on the linkage shaft 832 to rotate synchronously, thereby tightening or loosening the length of the belt 833 and realizing the up-and-down lifting movement of the vacuum cover 82.

[0077] As a further preferred embodiment, the polymerization insulation mechanism 9 of the present invention includes polymerization zone 91, polymerization zone 92, polymerization zone 93, polymerization zone 94, and polymerization zone 95 arranged sequentially; the polymerization reaction temperature of each zone is different and independently controlled. The zones are separated by the lifting gate assembly 32 of the present invention to form a sealed reaction space, and the zones share the same chain conveyor mechanism 96.

[0078] As a further preferred embodiment, the unloading mechanism 10 has the same structure as the loading mechanism 2, both including a transfer mechanism 101, a transfer lifting mechanism 102 that drives the transfer mechanism 101 to move up and down, and a feeding station 103, an intermediate waiting station 104, and an unloading station 105 sequentially arranged between the transfer mechanisms 101; the transfer mechanism 101 moves back and forth between the feeding station 103 and the unloading station 104; the transfer lifting mechanism 102 drives the transfer mechanism 101 to move up and down. After the polymerization reaction is completed, the stacked carrier A is transported to the feeding position of the unloading mechanism 10 by the transfer mechanism on the frame 1. The transfer mechanism 101 moves left and right and up and down to simultaneously transfer at least two sets of stacked carriers A from the feeding position to the material cart B. The unloading mechanism 10 is equipped with a positioning structure 106 for correcting the dropping position. The positioning structure includes a alignment guide plate 1061 set on the transfer mechanism, two sets of limiting square tubes 1062 set on the unloading material cart, and two sets of positioning pin assemblies 1063. During the unloading process, the lower narrowing part of the alignment guide plate 1061 on the transfer mechanism is precisely engaged between the two sets of limiting square tubes 1062, so that the positioning pin assembly 1063 can be fitted into the positioning holes at the four corners of the bottom of each stacked carrier, realizing the correction of the dropping position of the two stacked carriers. The specific structure of the unloading mechanism 10 can be referred to the relevant structure of the loading structure, and its control method is exactly the opposite.

[0079] The above embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial changes and substitutions made by those skilled in the art based on the present invention shall fall within the scope of protection claimed by the present invention.

Claims

1. A fully automated capacitor impregnation production line, characterized in that, The system includes a frame, a loading mechanism, and a unloading mechanism sequentially arranged on the frame. The loading mechanism includes a transfer mechanism, a transfer lifting mechanism that drives the transfer mechanism to move up and down, and a feeding station, an intermediate waiting station, and an unloading station sequentially arranged between the transfer mechanisms. The transfer mechanism moves back and forth between the feeding station and the unloading station. The transfer lifting mechanism drives the transfer mechanism to move up and down. After a trolley equipped with at least two sets of stacked racks enters the feeding station, the transfer mechanism moves left and right and up and down to simultaneously transfer at least two sets of stacked racks from the feeding station to the unloading station. Then, the trolleys are sequentially conveyed by a chain conveyor to multiple impregnation and drying stations alternately arranged between the loading and unloading mechanisms for processing. After the impregnation process is completed, the trolleys are unloaded by the unloading mechanism. The transfer mechanism includes a loading and transfer frame, a sprocket assembly, and a carrier chain support plate. The sprocket assembly is installed inside the loading and transfer frame, and the carrier chain support plate is fixed on the chain of the sprocket assembly and moves back and forth with the chain to support and transfer the stacked carrier frame. When the sprocket assembly rotates, the chain on the sprocket assembly drives the carrier chain support plate to move back and forth left and right.

2. The fully automated capacitor impregnation production line as described in claim 1, characterized in that, The number of sprocket assemblies is two sets, and each set of sprocket assemblies includes a driving gear, a driven gear, a chain, and a sprocket motor; the chain is sleeved on the driving gear and the driven gear, and the sprocket motor is connected to the driving gear for transmission; the carrier chain support plates are correspondingly and symmetrically arranged on the chains of the two sets of sprocket assemblies.

3. The fully automated capacitor impregnation production line as described in claim 2, characterized in that, The transfer and lifting mechanism includes a mounting frame, guide columns, lifting frames, a linkage shaft, and a lifting motor. There are two mounting frames, symmetrically arranged on both sides of the sprocket assembly. The guide columns are upright inside the mounting frames. There are two lifting frames, each of which is fitted onto the guide column of each mounting frame. The loading and transfer frame is fixed on the lifting frame. The lifting motor drives the lifting frames and loading and transfer frames on both sides to move up and down synchronously along the length of the guide columns via the linkage shaft.

4. The fully automated capacitor impregnation production line as described in any one of claims 1-3, characterized in that, The feeding mechanism also includes a centering mechanism and a sorting mechanism. The centering mechanism includes push claws and push claw cylinders. The push claws are arranged on the front and rear sides of the output station. The push claw cylinders drive the push claws to move back and forth to make the short side of the carrier stack neatly. The sorting mechanism includes a shift block, a shift block cylinder, and a connecting rod assembly. The shift block is arranged on the front and rear sides of the output station. The shift block cylinders drive the shift block to make the long side of the carrier stack neatly.

5. The fully automated capacitor impregnation production line as described in any one of claims 1-3, characterized in that, The drying station sequentially includes a pre-drying mechanism, a pre-treatment drying mechanism, a monomer drying mechanism, and a polymerization insulation mechanism. Each of the pre-drying mechanism, pre-treatment drying mechanism, monomer drying mechanism, and polymerization insulation mechanism is equipped with a drying heating chamber. Each drying heating chamber has a lifting gate assembly at its inlet and outlet for opening or closing the inlet and outlet. The lifting gate assembly includes a gate body, an upright rack, a gate motor, and a labor-saving counterweight assembly. The labor-saving counterweight assembly includes a counterweight block and a traction rope. One end of the traction rope is fixed to the gate, and the other end is guided by a fixed pulley assembly and fixed to the counterweight block. The gate motor is fixed to the top of the gate body. The power output end of the gate motor meshes with the upright rack for transmission. The rotation of the gate motor drives the gate body to move up and down, while the counterweight block moves up and down in the opposite direction.

6. The fully automated capacitor impregnation production line as described in any one of claims 1-3, characterized in that, The impregnation station includes a pretreatment impregnation mechanism, a single-unit impregnation mechanism, and a vacuum impregnation mechanism. One impregnation process is performed at each impregnation station. Before each impregnation process, the stacked racks from the previous process need to be separated one by one so that each impregnation process can fully impregnate each rack individually. After each impregnation process, the racks from the previous process need to be gradually stacked into a stacked rack so that the subsequent drying and heating processes can efficiently dry and react with multiple stacked racks at high temperatures. During the process of separating the racks one by one and stacking the racks step by step, a lifting mechanism is used to adjust the vertical position of the racks to meet the transfer height requirements of each process in the conveying direction.

7. The fully automated capacitor impregnation production line as described in claim 6, characterized in that, The pretreatment impregnation mechanism includes a pretreatment transfer frame, a first translation mechanism for moving the pretreatment transfer frame left and right, and a first lifting mechanism for moving the pretreatment transfer frame up and down. The pretreatment transfer frame is equipped with multiple sets of robotic arms for gripping the frame. The robotic arms move the frame from one workstation to the next workstation under the drive of the first translation mechanism and the first lifting mechanism.

8. The fully automated capacitor impregnation production line as described in claim 6, characterized in that, The single-unit impregnation mechanism includes a single-unit transfer frame, a second translation mechanism for moving the single-unit transfer frame left and right, and a second lifting mechanism for moving the single-unit transfer frame up and down. The single-unit transfer frame is equipped with multiple sets of robotic arms for gripping the frame. The robotic arms move the frame from one workstation to the next workstation under the drive of the second translation mechanism and the second lifting mechanism.

9. The fully automated capacitor impregnation production line as described in claim 6, characterized in that, The vacuum impregnation mechanism includes a vacuum tank, a vacuum cover, a vacuum cover lifting mechanism, and a vacuum cover locking mechanism. Multiple sets of vacuum tanks are arranged side-by-side on a fixed frame along the workpiece conveying direction. The vacuum cover is located above the vacuum tank and is lifted by the vacuum cover lifting mechanism to seal or open the opening of the vacuum tank. The vacuum cover locking mechanism is located on both sides of the vacuum tank; during vacuum impregnation, the locking mechanism presses the vacuum cover onto the vacuum tank. The vacuum impregnation mechanism also includes a vacuum transfer frame, a third translation mechanism for moving the vacuum transfer frame left and right above the vacuum tank, and a third lifting mechanism for moving the vacuum transfer frame up and down above the vacuum tank. Multiple sets of robotic arms are installed on the vacuum impregnation transfer frame for gripping the frame. Driven by the third translation mechanism and the third lifting mechanism, the robotic arms move the frame from the previous station to the vacuum tank, complete the vacuum impregnation, and then move the frame to the next station.

10. The fully automated capacitor impregnation production line as described in any one of claims 1-3, characterized in that, The unloading mechanism includes a transfer mechanism, a transfer lifting mechanism that drives the transfer mechanism to move up and down, and a feeding station, an intermediate waiting station, and an unloading station arranged sequentially between the transfer mechanisms. The transfer mechanism moves back and forth between the feeding station and the unloading station. The transfer lifting mechanism drives the transfer mechanism to move up and down. After the polymerization reaction is completed, the stacked racks are transported to the feeding position of the unloading mechanism by a chain conveyor on the frame. The transfer mechanism moves left and right and up and down to transfer at least two sets of stacked racks from the feeding position to the material cart at the same time. The unloading mechanism is equipped with a positioning structure for correcting the dropping position. The positioning structure includes a alignment guide plate on the transfer mechanism, two sets of limiting square tubes and two sets of positioning pin assemblies on the unloading material cart.

Images