Automatic positioning and cutting device for heat-shrinkable copper sleeve

Abstract

The application relates to the field of electrical engineering and discloses a copper bar heat-shrink sleeve automatic positioning and cutting device.The device structure comprises a rack, which is provided with a feeding part, a material taking and positioning mechanical arm, a positioning part, a cutting part and a discharging structure.The feeding part is used for placing copper bars to be processed; the material taking and positioning mechanical arm is provided with a self-adaptive clamping device to ensure stable clamping and accurate rotation of the copper bar.The key positioning part is combined with a camera, a laser emitter and an image recognition module to accurately analyze the characteristics of the copper bar and provide accurate reference for subsequent cutting.The cutting part realizes high-precision cutting by using a laser cutter head and is provided with a cutter head adjusting and controlling mechanism to guarantee cutting quality and efficiency.The copper bar after processing is finally received by the discharging structure.The automatic device greatly improves the processing efficiency of the copper bar heat-shrink sleeve and reduces the error rate and labor intensity.

Description

Technical Field

[0001] This invention relates to the field of electrical engineering technology, and specifically to an automatic positioning and cutting device for copper busbar heat shrink sleeves. Background Technology

[0002] Heat shrink tubing provides insulation protection for wires, cables, and wire terminals, and is particularly suitable for copper busbars. Its main characteristics include high-temperature shrinkage, flexibility, flame retardancy, and insulation and corrosion protection, making it widely used for insulation protection of wire harnesses, solder joints, and inductors, as well as for rust and corrosion prevention of metal tubes and rods.

[0003] Currently, most copper busbar heat shrink tubing processing relies entirely on manual operation. Operators need to manually cut the heat shrink tubing to the specified length, then insert the copper busbar into the tubing and heat it in an oven. Since holes need to be drilled on the surface of the copper busbar for bolt installation, manual cutting and drilling not only increases labor input but also significantly increases the labor intensity of workers.

[0004] More specifically, after manually inserting heat-shrink tubing and heating in an oven, copper busbars can take on various structural shapes, such as straight, L-shaped, U-shaped, and S-shaped, and can be bent as needed. There are also various methods for drilling holes on the surface of the copper busbar, such as evenly or unevenly arranged round holes and oblong holes, depending on the specific application requirements. After heat shrinking, the copper busbar needs to be manually cut according to the drilled positions using a knife. This process is not only time-consuming, but the cutting position may also be inaccurate. Summary of the Invention

[0005] The present invention aims to provide an automatic positioning and cutting device for copper busbar heat shrink sleeves, which solves the problem of low processing efficiency of copper busbar heat shrink sleeves under traditional manual operation.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: an automatic positioning and cutting device for copper busbar heat shrink sleeves, comprising a frame, on which are arranged: a loading section, a material picking and positioning robot, a positioning section, a cutting section, and a unloading structure; the loading section is disposed on the frame and is used to hold the copper busbar to be processed; the material picking and positioning robot is provided with an adaptive clamping device, and the material picking and positioning robot is used to clamp and rotate the copper busbar; the positioning section includes a camera, a laser emitter, and an image recognition module, the camera is used to capture image data near the material picking and positioning robot, the laser emitter is used to irradiate laser light onto the copper busbar, and the image recognition module is used to analyze the structural morphology of the copper busbar based on the captured image data, and simultaneously analyze the position, size, and type of holes existing on the copper busbar based on the image of the copper busbar after laser irradiation; the cutting section includes a laser cutter head, a cutter head adjustment mechanism, and a cutter head control mechanism, and the cutting section is used for laser cutting; the unloading structure is used to hold the processed copper busbar.

[0007] The principle and advantages of this solution are as follows: The automatic positioning and cutting device for copper busbar heat shrink sleeves provided by this invention mainly consists of a loading section, a material handling and positioning robot, a positioning section, a cutting section, and a blanking structure. These components are all mounted on a single frame, realizing a fully automated processing flow for the copper busbars. The loading section is responsible for holding the copper busbars to be processed. Then, the material handling and positioning robot grips and rotates the copper busbars using an adaptive clamping device. The positioning section includes a camera, a laser emitter, and an image recognition module. The camera captures image data near the material handling and positioning robot, the laser emitter irradiates laser light onto the copper busbars, and the image recognition module analyzes the structural morphology of the copper busbars based on this data. Simultaneously, it analyzes the location, size, and type of holes present on the copper busbars based on the image of the copper busbars after laser irradiation. The cutting section includes a laser cutter head, a cutter head adjustment mechanism, and a cutter head control mechanism, responsible for laser cutting. Finally, the blanking structure is used to hold the processed copper busbars.

[0008] The main advantage of this equipment is that it achieves fully automated processing of copper busbars, improving production efficiency. The adaptive clamping device can adapt to copper busbars of different shapes, positions, and states, enhancing the equipment's versatility and flexibility. The combination of an image recognition module and a laser cutter head enables the equipment to accurately identify and process holes on the copper busbars, improving processing precision. Furthermore, the fully automated workflow reduces manual operation, lowers labor intensity and production costs, and increases work efficiency.

[0009] Preferably, as an improvement, the material handling and positioning robot is a multi-axis robot.

[0010] The beneficial effects of this solution are: the multi-axis robot possesses high flexibility and operability, enabling the robotic arm to perform precise gripping, movement, and rotation operations in multiple directions and angles. This design not only allows the robot to easily handle copper busbars of various shapes and structures but also ensures rapid and accurate positioning in complex processing environments. Furthermore, the multi-axis design means the robot can perform more complex motion combinations when executing tasks, thereby achieving superior gripping and rotation effects and avoiding potential collisions or misoperations.

[0011] Preferably, as an improvement, the laser cutter head of the cutting part and the laser emitter of the positioning part are the same device.

[0012] The beneficial effects of this solution are as follows: The design simplifies the equipment structure and configuration, saves additional hardware costs and space, reduces system complexity, and makes equipment installation, maintenance, and fault diagnosis more convenient. Simultaneously, this multi-purpose design increases the utilization rate of the laser equipment and optimizes resource allocation. Furthermore, since the same laser equipment is used for both cutting and positioning, the accuracy of cutting is further guaranteed, as the laser light source used for both is consistent, avoiding errors that may be caused by differences in equipment.

[0013] Preferably, as an improvement, after the cutter head control mechanism obtains the position, size, and type of the copper busbar holes based on the image recognition module results, it uses an intelligent optimization algorithm to generate a control strategy and issues instructions according to the control strategy; the cutter head adjustment mechanism adjusts the position and angle of the cutter head according to the instructions issued by the cutter head control mechanism and controls the material handling and positioning robot to perform actions.

[0014] The beneficial effects of this solution are as follows: This solution enables precise cutting and efficient automated processing of copper busbar heat shrink sleeves. The cutter head control mechanism acquires the position, size, and type information of the copper busbar holes through an image recognition module, and generates a control strategy accordingly. Based on this strategy, the cutter head control mechanism issues commands, and the cutter head adjustment mechanism responds by adjusting the position and angle of the cutter head, while simultaneously controlling the material handling and positioning robot to perform its actions. This process improves cutting accuracy and efficiency, reduces manual intervention, and also reduces potential errors and waste. Furthermore, through intelligently optimized control strategies, the equipment can adapt to various copper busbar shapes and hole types, exhibiting high versatility and flexibility. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the control framework of the automatic positioning and cutting device for the copper busbar heat shrink sleeve according to an embodiment of the present invention. Detailed Implementation

[0016] The following detailed description illustrates the specific implementation method: This invention relates to an automatic positioning and cutting device for copper busbar heat shrink sleeves, such as... Figure 1 As shown. The device comprises the following parts: First, the device has a frame. The structure and materials chosen for this frame ensure that it can stably support the other components of the entire device. The frame is made of high-strength alloy or other structural steel, which has good corrosion resistance, wear resistance, and can withstand various stresses and vibrations generated during the operation of the device.

[0017] A loading section is located above the rack, specifically designed for placing unprocessed copper busbars. The loading section is designed like a shallow tray with a certain depth and inclination, ensuring the copper busbars slide naturally into the robot's working range. The tray can also be equipped with anti-slip material or grooves to stabilize the copper busbars and prevent them from sliding or rolling during movement or vibration.

[0018] In addition, the feeding section is equipped with sensors or cameras, so that when the number of copper busbars decreases or runs out, the device can automatically stop working or issue a warning to remind the operator to replenish the material in time.

[0019] The material handling and positioning robot, as one of the components of this device, is based on advanced eight-axis robotics technology in this embodiment. Each axis is precisely designed to provide high flexibility and stability, enabling accurate positioning and movement of the copper busbar. The eight-axis structure gives the robot extremely high degrees of freedom of motion, allowing it to perform complex motion trajectories in three-dimensional space. This design aims to ensure that the robot avoids any unnecessary collisions or friction when gripping, rotating, and transferring the copper busbar, thereby ensuring the integrity of the copper busbar.

[0020] The robot's end effector, the gripper, is equipped with an adaptive gripping device. This device is designed for various possible shapes of copper busbars, and its internal structure can automatically adjust to adapt to different busbar shapes. When the robot comes into contact with the copper busbar, the gripping device's sensors immediately detect the busbar's size and shape, and automatically adjust the gripping area through its internal mechanical structure to perfectly match the busbar's shape.

[0021] This adaptive clamping method not only ensures the stability of the copper busbar during movement and cutting, but also ensures that no damage or deformation is caused to the copper busbar during clamping. Furthermore, the surface of the clamping device uses special materials and coatings to further reduce friction with the copper busbar, ensuring a smooth and efficient processing procedure.

[0022] Meanwhile, to ensure the accuracy of copper busbar cutting, the device in this embodiment also includes a positioning part, which is mainly composed of three major components.

[0023] First, the color camera can capture minute details on the copper busbar. Its optical lens is specially designed to ensure high-definition, high-contrast images under varying working distances and ambient lighting conditions. This camera may also be equipped with autofocus and exposure adjustment functions to ensure clear images are obtained even when the copper busbar's color or surface gloss changes.

[0024] Next is the laser emitter. In this embodiment, an infrared laser emitter is used, emitting a laser wavelength of 650nm. This red laser can produce clearly visible markers on the copper busbar, providing a reference for the image recognition module. Due to its fast response, the laser emitter can mark multiple reference points on the copper busbar in a short time, further improving the accuracy of positioning.

[0025] Finally, the image recognition module is equipped with a high-speed processor capable of rapidly processing the large amounts of image data captured by the camera. To ensure accurate analysis of copper busbar holes, the module is pre-installed with specialized image recognition algorithms. These algorithms can accurately distinguish the structural features of the copper busbar, identify holes, and then calculate the precise location, size, and type of the holes. To adapt to various complex working scenarios, the module may also support real-time learning and updates to continuously optimize its recognition performance.

[0026] The cutting section is the core of the overall workflow. To ensure industrial-grade precision in cutting, it is equipped with a laser cutter head made of semiconductor laser diodes. This type of laser cutter head features unique beam quality and stable power output to meet the requirements for precise cutting of copper busbars. Simultaneously, the multi-layered coated optical lens on the laser cutter head is designed for high transmittance, low reflection, and high thermal stability, ensuring the focusing effect and accuracy of the laser during the cutting process.

[0027] To further enhance the flexibility and precision of the cutting section, the blade adjustment mechanism in the device employs an advanced servo motor and slide rail system. These servo motors not only have a fast response speed but also high torque output, enabling micron-level precision movement of the laser blade in the X, Y, and Z directions. To meet the needs of multi-angle cutting, a high-precision rotation module is also incorporated into the mechanism, equipped with precision gears and a drive system, allowing the laser blade to rotate continuously or in segments within a predetermined angle range.

[0028] To achieve overall coordination and precise control in the cutting process, a cutter head control mechanism is also included in this embodiment. This mechanism is not merely a hardware system; it integrates a high-performance microprocessor and a control algorithm specifically designed for copper busbar cutting. Upon receiving data such as the shape, hole location, size, and type of the copper busbar from the image recognition module, this mechanism immediately performs calculations using its built-in cutting path optimization algorithm to generate the optimal cutting strategy. These strategies include both the real-time cutting path of the laser cutter head and the motion control trajectory that coordinates with the material handling and positioning robot.

[0029] Finally, the other end of the frame has a feeding structure, which is similar in design to the feeding section, used to place the processed copper busbars, preparing them for the next process or packaging.

[0030] In the workflow, the unprocessed copper busbars are first placed in the loading section. Then, an eight-axis robot picks up the copper busbars from the loading section and cuts them according to the instructions from the positioning section. After cutting, the copper busbars are placed into the unloading structure.

[0031] Example 2 The difference between this embodiment and Embodiment 1 is that this embodiment discloses an optimized algorithm for generating the pruning strategy, as follows: During the initialization phase, the solution is defined as an array of length equal to the number of holes, and each element of the array is a subarray containing cutter head operations and robot arm operations.

[0032] First, the location, size, and type of each hole need to be known; this is part of the input data. Then, a cutting head operation and a robotic arm operation can be randomly generated for each hole. These operations can be based on the characteristics of the hole or generated completely randomly.

[0033] For example, for cutting head operation, a position (within the hole area), an angle (between 0 and 360 degrees), and a speed (within a reasonable range) can be randomly generated. For robotic arm operation, a movement path (e.g., moving in a straight line from the current position to the hole position) and a speed (within a reasonable range) can be randomly generated.

[0034] This process can then be repeated to generate an operation for each hole, and these operations can be combined into a solution. This yields an initial solution. This process can be repeated to generate multiple initial solutions, forming an initial population. The size of the population can be determined based on the complexity of the problem and computational resources, typically ranging from tens to hundreds.

[0035] The actual control strategy is derived from these encoding conversions. For example, if the solution is [[cutter operation 1, robot operation 1], [cutter operation 2, robot operation 2], [cutter operation 3, robot operation 3]], then cutter operation 1 needs to be resolved into the actual position, angle, and speed of the cutter, and robot operation 1 needs to be resolved into the actual movement path and speed of the robot, and so on.

[0036] The computer-controlled strategy simulates the operation of the cutting head and the robotic arm, and records the corresponding accuracy, time, energy consumption and wear.

[0037] A fitness function is used to score the control strategy. The fitness function converts the accuracy, time, energy consumption, and wear measured during the operation into a score. :

[0038] in It's about precision. It is time. It's energy consumption. It's the degree of wear and tear. arrive This refers to the weights of each item. This function aims to optimize accuracy while minimizing time, energy consumption, and wear and tear.

[0039] Maximizing precision: This is the primary goal of optimization; the machine's operation should be as precise as possible. The weight w1 for precision is usually set higher than other weights to emphasize its importance.

[0040] Minimize time: The machine completes the operation as quickly as possible. Use This is used to penalize long-running operations. Taking the square root of time weakens the effect of time (since time is usually a large number), thus preventing excessive penalties for long-running operations.

[0041] Minimize energy consumption: The machine should be as energy efficient as possible. Use... To penalize high-energy-consuming operations. Taking the logarithm of energy consumption can weaken the impact of energy consumption (because energy consumption is usually a large number), thus avoiding over-penalizing high-energy-consuming operations.

[0042] Minimize wear: Extend the machine's lifespan as much as possible. This is used to penalize operations with high wear levels. Squared wear levels can amplify the effect of wear (since wear levels are typically decimals), thus effectively penalizing operations with high wear levels.

[0043] Based on the given fitness function, each individual in the roulette wheel selection method... Probability of being selected Represented as:

[0044] Individual The probability of being selected. Individual fitness value, It is the sum of the fitness of all individuals in the population.

[0045] For the selected solution s, a new solution s' is generated using the simulated annealing method.

[0046] Generating a neighboring solution s' can be achieved by making small perturbations to s, for example, by randomly changing the operation of one of the cutting tools or the robot arm. For example, randomly select a cutting tool from the current solution and make small changes to its position, angle, or velocity.

[0047] Calculate the fitness of the new solution s' .

[0048] if > If the new solution is better, then accept the new solution.

[0049] if ≤ The Metropolis criterion accepts the new solution s' with a certain probability. The acceptance probability is:

[0050] Where k is a constant; the temperature T decreases over time to ensure the algorithm eventually converges. There are various temperature reduction strategies; in this embodiment, exponential cooling is used. After each iteration, the temperature is updated step-by-step using the following formula: , .

[0051] The exponential cooling strategy is used because it allows for more "bad" moves (i.e., moves that reduce fitness) in the early stages of the algorithm, thus exploring the search space more extensively. As time progresses, the temperature decreases rapidly, and the algorithm focuses more on the neighborhood of the current solution, thus emphasizing solution utilization.

[0052] If the preset maximum number of iterations is reached, or if the improvement of the solution is less than the preset threshold in multiple consecutive iterations, the iteration stops.

[0053] The goal of the optimization algorithm in this embodiment is to find an optimal cutting strategy that maximizes the accuracy of hole cutting while minimizing time, energy consumption, and wear. This strategy consists of a series of blade operations and robotic arm operations, which are performed on each hole individually.

[0054] In summary, this optimization algorithm improves production efficiency, reduces cutting time, saves energy, and lowers production costs by optimizing the operation of the cutting head and robotic arm. It also extends equipment lifespan by reducing machine wear, thus reducing maintenance and replacement costs. By optimizing precision, it significantly improves product quality, meeting higher quality requirements. This optimization algorithm is of significant value in improving production efficiency, saving costs, and enhancing product quality.

[0055] The above descriptions are merely embodiments of the present invention, and common knowledge such as specific technical solutions and / or characteristics are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. An automatic positioning and cutting device for copper busbar heat shrink sleeves, characterized in that: It includes a frame, on which are installed: a loading section, a material picking and positioning robot, a positioning section, a cutting section, and a material unloading structure; The loading section is mounted on the frame and is used to hold the copper busbars to be processed; the picking and positioning robot is equipped with an adaptive clamping device, which is used to clamp and rotate the copper busbars. The positioning unit includes a camera, a laser emitter, and an image recognition module; the camera is used to capture image data near the material handling and positioning robot. The laser emitter is an infrared laser emitter with an emission wavelength of 650nm, used to irradiate laser light onto the copper busbar to produce clearly visible markings on the surface of the copper busbar. The image recognition module is used to analyze the structural morphology of the copper busbar based on the captured image data. At the same time, based on the image of the copper busbar with marked points after being illuminated by the laser light, it analyzes the location, size, and type of the holes covered by heat shrink tubing on the copper busbar. The cutting section includes a laser cutter head, a cutter head adjustment mechanism, and a cutter head control mechanism; the cutter head control mechanism is configured to execute a cutting path optimization algorithm based on the hole position, size, and type data obtained by the image recognition module, and generate a control strategy for controlling the coordinated action of the cutter head adjustment mechanism and the material picking and positioning robot arm. The execution process of the pruning path optimization algorithm includes: Initialization phase: Define the solution as an array of length equal to the number of holes identified. Each element of the array contains a cutting head operation and a robotic arm operation. Randomly generate a cutting head operation and a robotic arm operation for each hole to form a solution. Repeat the generation of multiple solutions to form the initial population. Evaluation Phase: Computer simulations are used to run the control strategies corresponding to each solution, recording the machining accuracy, machining time, energy consumption, and wear rate after the control strategy drives the tool head and robot arm. The fitness function is then used to evaluate the results. : Where p(s) is accuracy, t(s) is time, e(s) is energy consumption, and w(s) is wear degree; each solution is scored using a fitness function, where w1 is the accuracy weight, w2 is the time weight, w3 is the energy consumption weight, and w4 is the wear degree weight. Selection Phase: A roulette wheel selection method is used, with each individual... Probability of being selected Represented as: in Individual The probability of being selected. Individual fitness value, It is the sum of the fitness of all individuals in the population, and individuals are selected to enter the next generation according to probability; Iterative optimization phase: Apply a small perturbation to the selected solution s to generate a new solution s'. The small perturbation includes randomly changing the position, angle, or speed parameters of a certain tool operation in the solution; calculate the fitness f(s') of the new solution s'. Acceptance Criterion: If f(s') > f(s), then accept the new solution; if f(s') ≤ f(s), the Metropolis criterion accepts the new solution s' with a certain probability; the acceptance probability is: Where k is a constant and T is the current temperature; Cooling strategy: The temperature is reduced using an exponential cooling method. After each iteration, the temperature is updated step-by-step using the following formula: = α × , 0 < α < 1; Termination condition: When the preset maximum number of iterations is reached, or when the improvement of the solution in multiple consecutive iterations is less than a preset threshold, the iteration stops and the optimal solution is output as the final control strategy. The cutter head control mechanism interprets the final control strategy into position, angle, and speed commands for the cutter head adjustment mechanism, as well as movement path and speed commands for the material handling and positioning robot, to drive the various physical execution components to collaboratively complete the cutting of the copper busbar heat shrink sleeve.

2. The automatic positioning and cutting device for copper busbar heat shrink sleeves according to claim 1, characterized in that: The material handling and positioning robot is implemented using a multi-axis robot.

3. The automatic positioning and cutting device for copper busbar heat shrink sleeves according to claim 1, characterized in that: The laser cutter head of the cutting section and the laser emitter of the positioning section use the same device.

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