Full-automatic production line for household gas alarm

Abstract

The application discloses a kind of full-automatic production line of domestic gas alarm.The application is by designing mainboard automatic test procedure, assembling first-stage procedure, power-on ventilation test procedure, assembling second-stage procedure and packaging procedure, so that domestic gas alarm is from mainboard test and installation, to shell installation, window label setting, and sound button and early, late report and other function detection, again to paste fire-fighting A, B label and install qualified certificate, hang board, finally packing and packaging such as full-process procedure realizes automation production, only needs after each rotary type material bin and packaging procedure, by manual feeding and unloading, high degree of automation, save 14-15 manpower, effectively reduce production cost.

Description

Technical Field

[0001] This invention belongs to the field of automated production, and in particular relates to a fully automated production line for household gas alarms. Background Technology

[0002] For many years, household gas alarm production lines have primarily relied on manual assembly. Traditional belt conveyor lines, approximately 20 meters long, have workbenches on both sides, allowing workers to sit face-to-face and assemble semi-finished products transported from the previous process. While traditional belt conveyor lines are characterized by their simple structure, low cost, flexible personnel allocation, adjustable production pace, and wide product applicability, they suffer from poor automation, remaining almost entirely manual. This is similar to the production conditions in most current electronics assembly plants, resulting in low automation, high production costs, and weak market competitiveness. Especially with rising labor costs, production costs are also increasing, making traditional manual operations unsuitable for market demands. Seeking advanced production technologies is the most effective way to overcome the current predicament.

[0003] Many manufacturers of household gas alarms have already used automated equipment in certain processes, such as automatic screw driving and automatic finished product inspection, which has reduced the number of personnel on the production line to some extent. However, this is still far from meeting the current development needs. In addition, the automation of some processes affects the changeover of the entire line. If the automated equipment is not suitable for certain products, those products cannot be produced on it, affecting the flexibility and adaptability of the line. If the automated equipment is made mobile, the changeover time will be longer, which will also affect production efficiency. If more automated equipment is added, human intervention is still required, which results in a longer development cycle, poorer changeover capability, and weaker adaptability, which is not ideal. Summary of the Invention

[0004] The purpose of this invention is to propose a fully automated production line for household gas alarms that uses automated equipment from assembly to testing to packaging, requiring no personnel other than those handling the loading.

[0005] The objective of this invention is achieved through the following technical solution:

[0006] This invention provides a fully automated production line for household gas alarms, including a host computer and a mainboard automatically testing process coordinated and controlled by the host computer, an assembly stage one process, a power-on and gas-through testing process, a power-on and gas-through testing process, an assembly stage two process, and a packaging process;

[0007] (1) Automatic testing process for motherboards:

[0008] Place the motherboard to be tested into a blister tray, then place the blister tray onto the incoming material conveyor belt, which will transport it to the designated position, and then the elevator will lift it to the loading station.

[0009] The motherboard to be tested in the blister tray at the loading station is picked up by the loading robot and placed at the automatic motherboard testing station, where it is automatically tested by the automatic testing equipment.

[0010] After the test is completed, the unloading robot places the qualified motherboards onto the motherboard output line, from which they flow to the next process. The unqualified motherboards are placed into the NG blister tray.

[0011] After the motherboard under test is picked up by the loading robot, the empty blister tray is placed onto the empty blister tray output line by the loading robot.

[0012] (2) Assembly of a certain process:

[0013] Used to install the motherboard into the lower housing, fasten the upper housing onto the lower housing, affix window labels to the indicator light positions on the upper housing, and engrave QR codes on the surface of the upper housing on a conveyor belt assembly line.

[0014] Assemble a section of belt conveyor line including an upper synchronous belt conveyor mechanism, a lower synchronous belt conveyor mechanism, a front-end lifting mechanism, a rear-end lifting mechanism, and a first carrier for vertical circulation;

[0015] The front lifting mechanism is located at the beginning of assembling a section of belt conveyor line and is used to lift the first carrier circulating from below to the upper synchronous belt conveyor mechanism.

[0016] The first carrier, which is lifted to the upper synchronous belt conveyor, is transported from the starting end of the assembly of a section of belt conveyor line through the main board assembly station, the main board inspection station, the upper and lower shell assembly station, the window label affixing station, the laser engraving station, and the appearance inspection station to the ending end.

[0017] The rear lifting mechanism is located at the end of the assembly of a belt conveyor line and is used to lower the first carrier, which is transported from the beginning of the assembly of a belt conveyor line, to the lower synchronous belt conveyor mechanism.

[0018] The first carrier, which is lowered to the lower synchronous belt conveyor, is returned from the end of the assembled section of the belt conveyor line to the starting end by the lower synchronous belt conveyor.

[0019] Lower the shell:

[0020] The first rotary hopper rotates the lower shell to the robotic arm's automatic material handling station. The lower shell loading robotic arm picks up the lower shell and places it onto the lower shell positioning platform. The lower shell positioning mechanism performs the positioning action, and the positioned lower shell is then placed onto the first carrier by the moving module.

[0021] Install the motherboard:

[0022] The first carrier with the lower housing is transported to the motherboard assembly station. The motherboard from the motherboard input line is automatically positioned by the motherboard unloading positioning mechanism and then picked up by the motherboard assembly six-axis robot and placed into the motherboard assembly station. The motherboard is then installed into the lower housing at the station.

[0023] Motherboard assembly complete inspection:

[0024] The first carrier, carrying the assembled motherboard, is transported to the motherboard inspection station, where a distance sensor detects whether the motherboard is assembled. If it is not assembled, it is picked out when it is transported to the motherboard NG unloading station, while the assembled motherboard continues to be transported to the upper and lower housing assembly station.

[0025] Upper and lower shells fasten together:

[0026] The second rotary hopper rotates the upper shell to the robotic arm automatic material handling station. The upper shell loading robotic arm picks up the upper shell and places it onto the upper shell positioning platform. The upper shell positioning mechanism performs the positioning action. The positioned upper shell is then picked up by the upper shell module and placed onto the lower shell assembly station, completing the upper and lower shell fastening.

[0027] Apply window stickers:

[0028] The paper labels placed in the label hopper are picked up by the suction module and placed on the label peeling moving platform. The label peeling moving platform moves to the label peeling station. After the label is peeled at the label peeling station, all the labels are peeled off the backing paper and float individually in the peeling hopper, and are evenly distributed.

[0029] After the first carrier containing the snap-on product is transported to the window label application station, the six-axis window label application robot picks up the peeled window label, and after visual correction by the window label loading positioning camera, it is applied to the position on the surface of the upper shell; the shell with the window label applied is transported by the first carrier to the laser engraving station;

[0030] QR code engraved on the surface of the upper casing:

[0031] The laser engraving machine engraves a QR code on the upper housing at a designated position on its surface, which is then transported to the laser engraving station by the first carrier to the appearance inspection station.

[0032] Upper casing appearance inspection:

[0033] The upper housing surface inspection camera inspects the surface of the upper housing that is transported to the appearance inspection station. The inspection includes whether the window label is affixed to the designated position, whether the QR code is clearly engraved and in the correct position, and whether there are scratches on the surface of the upper housing. After the appearance inspection, the product is transported to the rear lifting mechanism by the first carrier.

[0034] Sorting output:

[0035] The two-axis unloading robot sorts the products conveyed to the rear lifting mechanism based on the appearance inspection results of the upper shell. Products that pass the appearance inspection are conveyed to the next process, while those that fail are placed in the NG material bin for appearance inspection.

[0036] (3) Power-on and ventilation test procedure

[0037] Used to perform sound button detection, morning alarm detection, and evening alarm detection on a power-on and air-proof test belt conveyor;

[0038] The power-on and ventilation-testing belt conveyor line includes an upper conveyor belt line, a lower conveyor return belt line, a front lifting conveyor, a rear lifting conveyor, and a second carrier for upper and lower circulation.

[0039] The front lifting conveyor is set at the beginning of the power-on and air-proof test belt conveyor line and is used to lift the second carrier circulating from below to the upper conveyor belt line.

[0040] The second carrier, which is lifted to the upper conveyor belt, is transported from the starting end of the power-on and ventilation-testing conveyor belt through the loading station, carrier identification station, first buffer station, sound button detection station, second buffer station, morning report detection station, and evening report detection station to the terminal end.

[0041] The rear lifting conveyor is located at the end of the power-on and air-on test belt conveyor line and is used to lower the second carrier that is conveyed from the beginning of the power-on and air-on test belt conveyor line to the lower conveyor return belt line.

[0042] The second carrier, which is lowered to the lower conveyor return belt, returns from the end of the energized and ventilated test belt conveyor to the beginning of the lower conveyor return belt;

[0043] The product is installed on the second vehicle:

[0044] The assembled products, transported from one assembly stage, are pressed and fastened by the product loading robot at the loading station onto the second carrier at the beginning of the power-on and ventilation-testing belt conveyor line. Each second carrier has nine product loading positions, each with a QR code number and two probes for connecting to the positive and negative terminals of the gold fingers on the product's motherboard. The two probes are connected to copper strips on both sides of the second carrier to power on the product.

[0045] Identify the serial number on the second vehicle:

[0046] After the second carrier is filled with products, it is transported to the carrier identification station. The copper strips on both sides of the second carrier contact the carbon slider on the guide rail of the carrier identification station. The carbon slider is powered by positive and negative power. At this time, the products on the second carrier are powered on and enter a three-minute delay mode. After three minutes, the products enter the normal use mode. At the same time, the vision system of the second carrier identifies the QR code number on the second carrier and the QR code numbers in 9 positions, records them and transmits them to the host computer.

[0047] First buffer:

[0048] After the product enters the normal use mode (T1 time), it is transported by the second carrier to the first buffer station. After waiting for T2 time at the first buffer station, it is transported by the second carrier to the sound button detection station.

[0049] Sound button detection:

[0050] The sound button detection station is equipped with a three-axis robotic arm for sound detection. The Z-axis of the three-axis robotic arm is equipped with a pressure sensor and a sound decibel meter.

[0051] The Z-axis of the three-axis robotic arm for sound detection presses on the button of the product delivered to the sound button detection station. When the button is pressed to a certain extent, the product enters the start mode and the product's buzzer starts to sound. The sound enters the sound decibel meter through the microphone. If the detected decibel value is greater than the set value, the product's sound button is qualified. Otherwise, when the pressure sensor reaches a certain value or the Z-axis position reaches the set value, the Z-axis is lifted upward, and the sound button is judged to be abnormal. Then, the next product is detected. The same method is used to detect the products at 9 positions on the second carrier. The results are recorded and uploaded to the host computer.

[0052] Second buffer:

[0053] After the product completes the sound button test T1 time, it is transported by the second carrier to the second buffer station, where it waits for T2 time before being transported by the second carrier to the morning test station.

[0054] Early Morning News Detection:

[0055] A morning report air box is installed at the morning report testing station;

[0056] After the second vehicle transports the product into the morning report gas chamber at the morning report detection station, the front and rear doors of the morning report gas chamber are closed for sealing; the first mass flow controller is started to start filling methane gas into the morning report gas chamber. At the same time, the first infrared analyzer detects the methane concentration in the morning report gas chamber in real time. When the concentration reaches the morning report point value of the product, the gas filling is stopped. At this time, the morning report vision system on the morning report gas chamber takes pictures to detect whether the product in the morning report gas chamber alarms. The products that alarm are judged as unqualified products, and the products that do not alarm are qualified products. Record and upload them to the host computer; after the detection is completed, the second vehicle transports the product to the evening report detection station;

[0057] Evening report detection:

[0058] An evening report gas chamber is provided at the evening report detection station;

[0059] After the second vehicle transports the product into the evening report gas chamber at the evening report detection station, the front and rear doors of the evening report gas chamber are closed for sealing;

[0060] The second mass flow controller is started to start filling methane gas into the evening report gas chamber. At the same time, the second infrared analyzer detects the methane concentration in the evening report gas chamber in real time. When the concentration reaches the evening report point value of the product, the gas filling is stopped. At this time, the evening report vision system on the evening report gas chamber takes pictures to detect whether the product in the evening report gas chamber alarms. The products that alarm are judged as qualified products, and the products that do not alarm are unqualified products. Record and upload them to the host computer; after the detection is completed, the second vehicle transports the product to the rear lifting conveyor;

[0061] Product offline sorting:

[0062] The second vehicle transports the product to the rear lifting conveyor at the blanking station for sorting. The host computer controls the blanking manipulator according to the detection results of the second vehicle, and sorts the products that are qualified in the sound key detection, morning report detection, and evening report detection onto the output conveyor belt to enter the second-stage assembly process. The unqualified products are sorted into the sound NG box, key NG box, morning report NG box, and evening report NG box in the NG sorting bin according to the unqualified types;

[0063] (4)Second-stage assembly process

[0064] Used to complete screwing at the bottom of the product, engraving the factory information at the bottom of the product, pasting the fire protection A label on the upper shell surface, pasting the fire protection B label on the certificate, and stacking the product, certificate, and hanging plate together on the second-stage assembly belt conveyor;

[0065] The second-stage assembly belt conveyor includes an upper belt line, a lower belt line, a front elevator, a rear elevator, and a third vehicle that circulates up and down;

[0066] The front elevator is arranged at the starting end of the second-stage assembly belt conveyor and is used to lift the third vehicle that circulates from below to the upper belt line;

[0067] The third carrier, which is lifted to the upper belt conveyor, starts from the beginning of the assembly of the second-section belt conveyor line, passes through the screw fastening station, the lettering station, the screw fastening and lettering inspection station, the A-label affixing station, the B-label affixing station, the AB-label inspection station, and the product certificate unloading station, and ends at the end.

[0068] The rear elevator is located at the end of the assembly section two belt conveyor line and is used to lower the third carrier that is conveyed from the beginning of the assembly section two belt conveyor line to the lower belt line.

[0069] The third carrier, which is lowered to the lower belt conveyor, flows back from the end of the assembly of the two-section belt conveyor line to the beginning of the lower belt conveyor line.

[0070] Each third vehicle is equipped with two positioning slots: a first positioning slot and a second positioning slot.

[0071] Product flip:

[0072] The product delivered from the power-on and ventilation testing process is flipped by the first flipping robot to the translation loading mechanism, so that the lower shell surface faces upward. Then, the translation loading mechanism places it into the first positioning slot of the third carrier at the starting end of the assembly two-section belt conveyor line.

[0073] Tighten screws:

[0074] After being flipped and translated, the product is transported by a third carrier to the screw fastening station, where the screw fastening machine fastens the screws onto the product.

[0075] Laser engraving:

[0076] After the wire is locked, the product is transported to the engraving station by a third carrier, where product information is engraved by a laser engraving machine.

[0077] Visual inspection of thread engraving:

[0078] After engraving, the product is transported by a third carrier to the thread engraving inspection station. The thread engraving visual inspection camera checks whether the screws on the product are tightened or misaligned, and whether the product information is off-positioned or unclear.

[0079] Products that fail the visual inspection of the threaded engraving are picked out and placed in the NG box for threaded engraving; products that pass the visual inspection of the threaded engraving are flipped by the second flipping robot into the second positioning slot of the third carrier, so that the upper shell surface faces upward.

[0080] Apply fire safety label A:

[0081] The flipped product is transported to the A-labeling station by the third carrier, where the A-labeling robot picks up the fire protection A-label peeled off by the A-label dispensing machine and affixes it to the surface of the upper housing.

[0082] Apply fire safety label B:

[0083] After the third carrier arrives at the B labeling station, the certificate picking and placing robot grabs the certificate from the certificate hopper; the B labeling robot picks up the fire protection B label peeled off by the B label dispenser and affixes it to the certificate; after the product with the fire protection A label is transported to the B labeling station by the third carrier, the certificate picking and placing robot places the certificate with the fire protection B label into the first positioning slot of the third carrier.

[0084] Visual inspection of A and B labels:

[0085] At the AB label inspection station, the visual camera compares the numbers on the fire protection A label and the fire protection B label of the product in the third carrier arriving at this station to see if they match one-to-one. If they match correctly, the product continues to the next stage; otherwise, the machine stops and an alarm sounds.

[0086] Rotary feeding with hanging plate:

[0087] The third rotary hopper rotates the hanging plate to the robotic arm's automatic material picking station. The robotic arm picks up the hanging plate and places it on the hanging plate conveyor line, which then transports the hanging plate to the product certificate unloading station.

[0088] Product and certificate of conformity removed from production line:

[0089] After visual inspection of the A and B labels, the products and certificates of conformity are transported to the product certificate off-line station by the third carrier. The unloading robot grabs the products and certificates of conformity at the same time, first placing the certificates of conformity on the already positioned hanging plate, then placing the products on the hanging plate and stacking them together, and then the push-out mechanism pushes them onto the output belt line.

[0090] (5) Packaging process

[0091] The stacked products, certificates of conformity, and hanging plates conveyed from the output belt are packed and packaged by the complete packaging equipment.

[0092] Based on the above, the rotary hopper is equipped with four stations arranged in a square. One station is used as an automatic loading station for robotic arms, and the remaining three stations are used as manual unloading stations. Each station is equipped with a fourth carrier for placing materials. When the rotary hopper's rotating mechanism rotates 90 degrees, each station rotates 90 degrees.

[0093] The rotary hopper automatically feeds materials for processes on the production line at the robotic arm automatic feeding station, and allows for manual unloading at the manual unloading station.

[0094] During the automatic feeding process, the elevator set up at the corresponding robotic arm automatic feeding station lifts the material according to the height of the material plane to ensure that the material can be picked up by the robotic arm on the production line.

[0095] After one automatic feeding cycle is completed, the rotating mechanism of the rotary hopper rotates the workstation.

[0096] Based on the above, the device for implementing the window labeling process in the assembly process includes a window label hopper, a suction module, a window label feeding and positioning camera, a window label peeling mechanism, and a waste paper hopper.

[0097] The label peeling mechanism includes the label peeling moving platform and the upper peeling chamber;

[0098] The window label loading and positioning camera is positioned above the window label hopper;

[0099] The label peeling mobile platform, the label hopper, and the waste bottom paper hopper are arranged in parallel.

[0100] The suction module is located on one side of the window label peeling moving platform, the window label hopper, and the waste bottom paper hopper, and two suction grippers are respectively provided for the window label peeling moving platform and the window label hopper;

[0101] The upper stripping chamber is located in front of the window label stripping mobile platform.

[0102] This invention has outstanding substantive features and significant progress compared to existing technologies. Specifically, this invention automates the entire process of a household gas alarm, from motherboard testing and installation to housing installation, window label affixing, and functional testing such as sound buttons and morning / evening alarms, to affixing fire safety A and B labels, attaching certificates of conformity, hanging plates, and finally boxing and packaging. Only manual feeding and unloading are required after each rotary hopper and packaging process. This high degree of automation saves 14-15 manpower and effectively reduces production costs. Attached Figure Description

[0103] Figure 1 This is a schematic diagram of the principle of the present invention.

[0104] Figure 2 This is a structural schematic diagram of the automatic motherboard testing process of the present invention.

[0105] Figure 3 This is a structural schematic diagram of an assembly process of the present invention.

[0106] Figure 4 This is a schematic diagram of the power-on and air-through testing process of the present invention.

[0107] Figure 5 This is a schematic diagram of the two-stage assembly process of the present invention.

[0108] Figure 6It is an implementation device for pasting window labels in one process of the assembly of the present invention.

[0109] Figure 7 It is a schematic structural diagram of the second carrier in the power-on and air-inlet testing process of the present invention. Specific embodiments

[0110] The technical solution of the present invention will be further described below with reference to the accompanying drawings.

[0111] Note:

[0112] Main board: The electronic control core of the household alarm product, that is, the circuit board;

[0113] Carrier: Just like a bus, it carries the semi-finished products to be assembled from one station to another. There are positioning slots on the carrier to position different products. The outer shapes of the carriers are the same, but the internal positioning slots corresponding to different products are different. To replace the product, the carrier needs to be replaced;

[0114] Early warning: When the household alarm detects gas, when the gas concentration reaches a certain value, it will alarm. This lowest value is the early warning point. When the alarm is lower than this value, it will alarm. This is the early warning. An alarm that gives an early warning is a substandard product;

[0115] Evening warning: The alarm point required by the national standard for household alarms is a range value. It is required to alarm within this range. It is qualified if it does not alarm below this range, and unqualified if it alarms. However, it is unqualified if it does not alarm above this range value, and also unqualified if it alarms. It is qualified if it alarms within this range, and unqualified if it does not alarm. Therefore, the highest point of this range for actually inspecting whether the product is qualified or not is the evening warning point. If it does not alarm when the concentration reaches the evening warning point, it is a substandard product, which is called the evening warning;

[0116] Window label: There are indicator light holes on the surface of the upper shell of the product, which are used for light transmission. In order to cover these holes, the designer designed a thin organic glass cover plate to cover these holes. The incoming material method of these cover plates is to be pasted on the backing paper, which is similar to the incoming material method of labels, so it is called a window label;

[0117] Fire protection A label: 18X33mmX50μm, red, with a basic number group indicating the identity on it, which consists of a domain number and a point number. Each of the domain number and the point number consists of ten thousand numbers; its functions are unique digital ID, anti-counterfeiting, anti-peeling, and waterproof. The basic information of the product can be queried through the clear code; it is required to be pasted at an obvious place on the product surface;

[0118] Fire safety B label: 18X33mmX50μm, silver, with a basic identification number consisting of a domain number and a location number, each consisting of 10,000 numbers, identical to the A label number; its functions include a unique digital ID, anti-counterfeiting, anti-tampering, and waterproof; basic product information can be found through the clear code; it must be affixed to the product certificate of conformity.

[0119] like Figure 1 As shown, this embodiment provides a fully automated production line for household gas alarms, including a host computer and a mainboard automatically testing process coordinated and controlled by the host computer, an assembly stage one process, a power-on and gas-through testing process, a power-on and gas-through testing process, an assembly stage two process, and a packaging process.

[0120] (1) Automatic testing process for motherboards (e.g.) Figure 2 (as shown)

[0121] Place the motherboard to be tested into the blister tray 1-1, then place the blister tray 1-1 onto the incoming material conveyor belt 1-2, which will transport it to the designated position, and then the elevator will lift it to the loading station.

[0122] The motherboard 1 to be tested in the blister tray 1-1 at the loading station is picked up by the gripper 1-3-1 of the loading robot and placed on the motherboard automatic testing station, where it is automatically tested by the automatic testing equipment 1-4.

[0123] After the test is completed, the gripper 1-5-1 of the unloading robot 1-5 places the qualified motherboard 1 onto the motherboard output line 1-6, and the motherboard output line 1-6 flows to the next process. The unqualified motherboard 1 is placed into the NG blister tray 1-7.

[0124] After the motherboard under test 1 is picked up by the loading robot 1-3, the empty blister tray is picked up by the loading robot 1-3 and placed onto the empty blister tray output line 1-8.

[0125] In this embodiment, the automatic testing equipment performs automatic detection, including:

[0126] a. The host computer performs tests on the writing, reading, and verification functions of product parameters;

[0127] b. Test the closing function of the product's valve body;

[0128] c. Perform a functional test on the product's power input port to ensure it functions properly;

[0129] d. Test the functionality of the product's four indicator lights;

[0130] e. Test data is automatically stored and uploaded to the host computer;

[0131] f. Automatically sort qualified and defective products, read the motherboard ID, record and store test data to the host computer.

[0132] (2) Assemble a process (such as) Figure 3 (as shown)

[0133] 1) Completed actions: Used to install the mainboard 1 into the lower housing, fasten the upper housing onto the lower housing on a conveyor belt, attach a window label to the indicator light position on the upper housing, and engrave a QR code on the surface of the upper housing.

[0134] 2) Organizational Structure:

[0135] a. Assemble a section of belt conveyor line (carrier up-and-down circulation mechanism): upper synchronous belt conveyor mechanism 2-1, lower synchronous belt conveyor mechanism, front end lifting mechanism 2-2, rear end lifting mechanism 2-3, and the first carrier 2-4 for up-and-down circulation; mainly to transport the first carrier 2-4 to perform cyclical movement;

[0136] The front lifting mechanism 2-2 is located at the starting end of the assembly section of the belt conveyor line, and is used to lift the first carrier 2-4 circulating from below to the upper synchronous belt conveyor 2-1; the first carrier 2-4 lifted to the upper synchronous belt conveyor 2-1 is then transported from the starting end of the assembly section of the belt conveyor line by the upper synchronous belt conveyor 2-1 through the main board assembly station 2-5, the main board inspection station 2-6, the upper and lower shell assembly station 2-7, the window label affixing station 2-8, the laser engraving station 2-9, and the appearance inspection station 2-10 to the ending end; the rear lifting mechanism 2-3 is located at the ending end of the assembly section of the belt conveyor line, and is used to lower the first carrier 2-4 transported from the starting end of the assembly section of the belt conveyor line to the lower synchronous belt conveyor; the first carrier 2-4 lowered to the lower synchronous belt conveyor is then returned from the ending end of the assembly section of the belt conveyor line to the starting end by the lower synchronous belt conveyor.

[0137] b. Lower shell loading station: includes lower shell loading robot 2-11, lower shell positioning platform and moving module 2-13, mainly to place the lower shell picked up by lower shell loading robot 2-11 onto the first carrier 2-4 after positioning;

[0138] c. Motherboard assembly station 2-5: includes motherboard input line 2-14 and motherboard assembly six-axis robot 2-15. It mainly uses the robot to assemble the motherboards from the motherboard output line 1-6 of the automatic motherboard testing process onto the lower housing.

[0139] d. Motherboard Inspection Station 2-6: Includes a distance sensor; the distance sensor detects the distance between the motherboard at Motherboard Inspection Station 2-6 and the distance sensor to determine whether the motherboard has been assembled. If the detected distance is not equal to the preset distance, the motherboard is judged to be not assembled; otherwise, the motherboard is judged to be assembled.

[0140] e. Upper shell loading station: includes upper shell loading robot 2-16, upper shell positioning platform and upper shell module 2-18. It mainly places the upper shell picked up by upper shell loading robot 2-16 into the lower shell on the upper and lower shell assembly station 2-7 after positioning, and the upper shell loading robot 2-16 squeezes to complete the upper and lower shell fastening.

[0141] f. Label peeling station; including suction module 2-19, label peeling moving platform 2-20 and label loading positioning camera 2-21; mainly for label peeling;

[0142] g. Label loading and positioning camera: When the entire label is loaded, the label is photographed and positioned when it is picked up by the suction module 2-19. After positioning, the entire label can be accurately placed in the corresponding position on the label peeling moving platform 2-20, which facilitates the peeling of the label.

[0143] h. Window Label Station 2-8: Includes a six-axis robot arm for applying window labels 2-22 and a window label calibration camera 2-23; mainly responsible for applying window labels.

[0144] i. Laser engraving stations 2-9: including laser engraving machines 2-24, used to complete the engraving of QR codes;

[0145] j. Appearance inspection station 2-10: includes upper housing surface inspection camera 2-25, used to inspect the surface of the upper housing;

[0146] k. Unloading mechanism: including a two-axis unloading robot 2-26 and an NG inspection hopper 2-27;

[0147] l. Rotary hoppers: including the first rotary hopper 2-28 and the second rotary hopper 2-29;

[0148] The rotary hopper has four stations arranged in a square. One station is used for automatic loading by a robotic arm, and the remaining three stations are used for manual unloading. Each station is equipped with a fourth carrier for placing materials. Every 90-degree rotation of the rotary hopper's rotating mechanism causes each station to rotate 90 degrees. The rotary hopper automatically loads materials for the production line at the robotic loading station, while manual unloading is done by hand. During automatic loading, the lifting mechanism at the corresponding robotic loading station adjusts the height of the material according to the material's surface to ensure it can be picked up by the robotic arm on the production line. After one automatic loading cycle, the rotary hopper's rotating mechanism rotates the stations.

[0149] 3) Operating steps:

[0150] Lower the shell:

[0151] The first rotary hopper 2-28 rotates the lower shell to the automatic material handling station of the robotic arm. The lower shell loading robotic arm 2-11 picks up the lower shell and places it onto the lower shell positioning platform. The lower shell positioning mechanism performs the positioning action, and the positioned lower shell is then placed onto the first carrier 2-4 by the moving module 2-13.

[0152] Install the motherboard:

[0153] The first carrier 2-4, which is equipped with the lower housing, is transported to the motherboard assembly station 2-5. The motherboard from the motherboard input line 2-14 is automatically positioned by the motherboard unloading positioning mechanism 2-30 and then picked up by the motherboard assembly six-axis robot 2-15 and placed into the motherboard assembly station 2-5. The motherboard is then installed into the lower housing at this station.

[0154] Motherboard assembly complete inspection:

[0155] The first carrier 2-4, which carries the assembled motherboard, is transported to the motherboard inspection station 2-6, where a distance sensor detects whether the motherboard has been assembled. If the motherboard is not assembled, it is picked out and placed in the motherboard NG material bin 2-32 when it is transported to the motherboard NG unloading station 2-31. The assembled motherboard continues to be transported to the upper and lower housing assembly station 2-7.

[0156] Upper and lower shells fasten together:

[0157] The second rotary hopper 2-29 rotates the upper shell to the robotic arm automatic material handling station. The upper shell loading robotic arm 2-16 picks up the upper shell and places it onto the upper shell positioning platform. The upper shell positioning mechanism performs the positioning action. The positioned upper shell is then picked up by the upper shell module 2-18 and placed onto the lower shell assembly station 2-7, completing the upper and lower shell fastening.

[0158] Apply window stickers:

[0159] like Figure 6 As shown, the device for applying window labels includes a window label hopper 2-33, a suction module 2-19, a window label feeding and positioning camera 2-34, a window label peeling mechanism 2-35, and a waste paper hopper 2-36;

[0160] The label peeling mechanism includes the label peeling moving platform 2-20 and the upper peeling chamber 2-35;

[0161] The label loading and positioning camera 2-34 is positioned above the label hopper 2-33; the label peeling moving platform 2-20, the label hopper 2-33, and the waste paper hopper 2-36 are arranged in parallel; the suction module 2-19 is positioned on one side of the label peeling moving platform 2-20, the label hopper 2-33, and the waste paper hopper 2-36, and two suction grippers are respectively provided corresponding to the label peeling moving platform 2-20 and the label hopper 2-33; the upper peeling chamber 2-35 is positioned in front of the label peeling moving platform 2-20;

[0162] The initial positions of the two suction grippers of the suction module 2-19 are above the window label peeling moving platform 2-20 and the window label hopper 2-33; one suction gripper can move between the two positions of the window label peeling moving platform 2-20 and the waste bottom paper hopper 2-36, and the other suction gripper moves between the two positions of the window label peeling moving platform 2-20 and the window label hopper 2-33, thereby completing the cycle of picking up the window label and placing the bottom paper;

[0163] The label peeling moving platform 2-20 includes a lower peeling chamber and peeling protrusions with the same shape as the label. The peeling protrusions are located at the bottom of the lower peeling chamber. During peeling, the label peeling moving platform 2-20, which holds the entire label, moves to the upper peeling chamber. After it is in place, the peeling protrusions at the bottom of the lower peeling chamber move upward, and the peeling protrusions squeeze individual labels in the entire label to achieve peeling.

[0164] Paper labels placed in the label hopper are picked up by the suction module 2-19 during loading. The label loading and positioning camera 2-34 takes a picture of the label and sends the positioning information to the suction module 2-19. The suction module 2-19 then accurately places the entire label into the corresponding position on the label peeling moving platform 2-20. The label peeling moving platform 2-20 moves forward to the label peeling mechanism 2-35 at the label peeling station. After the labels are peeled at the label peeling station, all the labels have their backing paper peeled off and are individually suspended in the upper peeling hopper, evenly distributed. After the labels are peeled off, the label peeling moving platform 2-20 moves backward back to its initial position, and the suction module 2-19 picks up the backing paper and puts it into the waste backing paper hopper 2-36.

[0165] After the first carrier 2-4 containing the snap-on product is transported to the window label application station 2-8, the six-axis window label application robot 2-22 picks up the peeled window label, and after visual correction by the window label loading positioning camera 2-23, it is applied to the position on the surface of the upper shell; the shell with the window label applied is transported by the first carrier 2-4 to the laser engraving station 2-9.

[0166] QR code engraved on the surface of the upper casing:

[0167] Laser engraving machine 2-24 engraves a QR code on the upper housing of the laser engraving station 2-9 at a designated position on its surface. Then the housing is transported by the first carrier 2-4 to the appearance inspection station 2-10.

[0168] Upper casing appearance inspection:

[0169] The upper housing surface inspection camera 2-25 inspects the surface of the upper housing that is transported to the appearance inspection station 2-10. The inspection includes whether the window label is affixed to the designated position, whether the QR code is clearly engraved and in the correct position, and whether there are scratches on the surface of the upper housing. After the appearance inspection, the product is transported by the first carrier 2-4 to the rear lifting mechanism 2-3.

[0170] Sorting output:

[0171] The two-axis unloading robot 2-26 sorts the products conveyed to the rear lifting mechanism 2-3 according to the appearance inspection results of the upper shell. Products that pass the appearance inspection are conveyed to the next process, while those that fail are placed in the appearance inspection NG hopper 2-27.

[0172] (3) Power-on and ventilation testing procedures (e.g.) Figure 4 (as shown)

[0173] 1) Completed actions: Used to complete sound button detection, morning report detection and evening report detection on the power-on and air-proof test belt conveyor line.

[0174] 2) Organizational Structure:

[0175] a. Power and ventilation test belt conveyor (carrier up-and-down circulation mechanism): includes an upper conveyor belt 3-1, a lower return conveyor belt, a front lifting conveyor, a rear lifting conveyor, and a second carrier 3-4 circulating up and down; the front lifting conveyor is located at the beginning of the power and ventilation test belt conveyor and is used to lift the second carrier 3-4 circulating from below to the upper conveyor belt 3-1; the second carrier 3-4, lifted to the upper conveyor belt 3-1, is transported from the beginning of the power and ventilation test belt conveyor via the upper conveyor belt 3-1, through the loading station 3-5, and the carrier identification... The components 3-6, 3-7, 3-8, 3-9, 3-10, and 3-11 of the sound button detection station are transported to the terminal end. The rear lifting conveyor is set at the terminal end of the power-on and ventilation-on test belt conveyor line and is used to lower the second carrier 3-4, which is transported from the starting end of the power-on and ventilation-on test belt conveyor line, to the lower conveyor return belt line. The second carrier 3-4, which is lowered to the lower conveyor return belt line, flows back from the terminal end of the power-on and ventilation-on test belt conveyor line to the starting end.

[0176] b. Loading station 3-5: includes the incoming material conveyor line 3-12 and the product loading robot 3-13. It mainly uses the product loading robot 3-13 to place the products conveyed from one assembly process onto the second carrier 3-4.

[0177] c. Carrier identification station 3-6: Identify the carrier number and the positions of 9 products on the second carrier 3-4 that is being transported in, and start timing after a 3-minute delay;

[0178] d. Sound button testing station 3-8: includes a sound decibel meter 3-14, a pressure sensor 3-15, and a three-axis sound detection robot 3-16; mainly to test whether the product buttons and sounds are normal.

[0179] e. Power-on and ventilation-operated early warning mechanism; including early warning air box 3-17, first mass flow controller, first infrared analyzer, and early warning vision system 3-18; mainly used to detect whether the alarm lower limit of the product meets the requirements;

[0180] f. Power-on and air-operated alarm mechanism; including alarm air box 3-19, second mass flow controller, second infrared analyzer, and alarm vision system 3-20; mainly to detect whether the alarm upper limit of the main detection product meets the requirements;

[0181] g. Unloading mechanism: including output conveyor belt and unloading robot 3-21; mainly outputting qualified products and sorting out unqualified products.

[0182] 3) Operating steps:

[0183] The product is installed on the second vehicle 3-4:

[0184] The assembled products, transported from one assembly stage, are pressed and fastened by the product loading robot 3-13 at the loading station 3-5 onto the second carrier 3-4 at the beginning of the power-on and ventilation-testing belt conveyor line. Each second carrier 3-4 is designed with 9 product loading positions, each with a QR code number and two probes for connecting to the positive and negative terminals of the gold fingers on the product's motherboard. The two probes are connected to copper strips on both sides of the second carrier to connect the product to power.

[0185] Identify the serial numbers on the second vehicle 3-4:

[0186] After the second carrier 3-4 is filled with products, it is transported to the carrier identification station 3-6. The copper strips on both sides of the second carrier 3-4 contact the carbon sliders on the guide rails of the carrier identification station. The carbon sliders are powered by positive and negative electricity. At this time, the products on the second carrier 3-4 are powered on and enter a three-minute delay mode. After three minutes, the products enter the normal use mode. At the same time, the second carrier vision system 3-22 identifies the QR code number 3-4-1 and the QR code number 3-4-2 in 9 positions on the second carrier 3-4 (e.g., Figure 7 (as shown), and record it and send it to the host computer.

[0187] First buffer:

[0188] After the product enters the normal use mode (T1 time), it is transported by the second carrier 3-4 to the first buffer station 3-7. After waiting for T2 time at the first buffer station 3-7, it is transported by the second carrier 3-4 to the sound button detection station 3-8.

[0189] Sound button detection:

[0190] The sound button detection station 3-8 is equipped with a three-axis robot arm 3-16 for sound detection. The Z-axis of the three-axis robot arm 3-16 is equipped with a pressure sensor 3-15 and a sound decibel meter 3-14.

[0191] The Z-axis of the three-axis robotic arm 3-16 presses on the button of the product transported to the sound button detection station 3-8. When the product button is pressed to a certain extent, the product enters the start mode, and the product's buzzer starts to sound. The sound enters the decibel meter 3-14 through the microphone. If the detected decibel value is greater than the set value, it means that the product sound button is qualified. Otherwise, when the pressure sensor 3-15 reaches a certain value, or the Z-axis position reaches the set value, the Z-axis will lift up, indicating that the sound button is abnormal. Then, the next product is detected. The same method is used to detect the products at 9 positions on the second carrier 3-4. The results are recorded and uploaded to the host computer.

[0192] Second buffer:

[0193] After the product completes the sound button test time T1, it is transported by the second carrier 3-4 to the second buffer station 3-9. After waiting for time T2 at the second buffer station 3-9, it is transported by the second carrier 3-4 to the early report test station 3-10.

[0194] Early Morning News Detection:

[0195] Early morning air chamber 3-17 is installed at early morning testing station 3-10;

[0196] After the second carrier 3-4 transports the product to the early morning gas box 3-17 at the early morning inspection station 3-10, it closes the front and rear door seals of the early morning gas box 3-17. The first mass flow controller is activated to start filling the early morning gas box 3-17 with methane gas. At the same time, the first infrared analyzer monitors the methane concentration in the early morning gas box 3-17 in real time. When the concentration reaches the early morning inspection point value of the product, the filling stops. At this time, the early morning vision system 3-18 on the early morning gas box 3-17 takes pictures to detect whether the product in the early morning gas box 3-17 alarms. Products that alarm are judged as unqualified products, and products that do not alarm are qualified products. The data is recorded and uploaded to the host computer. After the inspection is completed, the second carrier 3-4 transports the product to the evening inspection station 3-11.

[0197] Evening News Inspection:

[0198] Evening News gas box 3-19 is installed at testing station 3-11;

[0199] After the second carrier 3-4 transports the product into the evening newspaper air box 3-19 at the evening newspaper testing station 3-11, it closes the front and rear doors of the evening newspaper air box 3-19 to seal it.

[0200] The second mass flow controller is activated to begin filling the gas chamber 3-19 with methane gas. Simultaneously, the second infrared analyzer monitors the methane concentration in the gas chamber 3-19 in real time. When the concentration reaches the product's reporting point value, the filling stops. At this time, the vision system 3-20 on the gas chamber 3-19 takes pictures to detect whether the product in the gas chamber 3-19 alarms. Products that alarm are judged as qualified products, and products that do not alarm are as unqualified products. The data is recorded and uploaded to the host computer. After the detection is completed, the second carrier 3-4 transports the product to the rear lifting conveyor 3-3.

[0201] Product sorting after production line:

[0202] The second carrier 3-4 transports the products to the rear lifting conveyor at the unloading station 3-23 for sorting. Based on the detection results of the second carrier 3-4, the host computer controls the unloading robot 3-21 to sort the products that have passed the sound button detection, morning report detection, and evening report detection onto the output conveyor belt to enter the second assembly process. The unqualified products are sorted into the sound NG box, button NG box, morning report NG box, and evening report NG box in the NG sorting bin 3-24 according to the type of unqualified product.

[0203] (4) Assembly of two-stage processes (such as...) Figure 5 (as shown)

[0204] 1) Assembly Project:

[0205] a. Screw the bottom of the product: 4-13 screw fastening machine;

[0206] b. Product bottom engraved with factory information: Laser engraving machine 4-14;

[0207] c. Apply fire safety A-labels to the surface of the upper housing: A-label dispensing machine 4-15 + A-label affixing robot 4-16;

[0208] d. Fire safety B label affixed to the certificate of conformity: B label dispensing machine 4-17 + B label affixing robot 4-18 + certificate of conformity handling robot 4-19;

[0209] e. Products, certificates of conformity, and hanging plates are stacked together: unloading robot 4-20 + rotary hopper 4-12 + hanging plate loading robot 4-21 + hanging plate conveyor line 4-22.

[0210] 2) Organizational Structure:

[0211] a. Assemble a two-section belt conveyor line (carrier up-and-down circulation mechanism): including an upper belt line 4-1, a lower belt line, a front elevator 4-2, a rear elevator 4-3, and a third carrier 4-4 circulating up and down; the front elevator 4-2 is located at the starting end of the two-section belt conveyor line and is used to lift the third carrier 4-4 circulating from below to the upper belt line 4-1; the third carrier 4-4, lifted to the upper belt line 4-1, is connected to the upper belt line 4-1 from the starting end of the two-section belt conveyor line via the screw-locking station 4-5. Engraving station 4-6, thread-locking and engraving inspection station 4-7, A-label affixing station 4-8, B-label affixing station 4-9, AB-label inspection station 4-10, product certificate unloading station 4-11 to the end; the rear elevator 4-3 is set at the end of the assembly section two belt conveyor line, used to lower the third carrier 4-4 conveyed from the beginning of the assembly section two belt conveyor line to the lower belt line; the third carrier 4-4 lowered to the lower belt line flows back from the end of the assembly section two belt conveyor line to the beginning of the lower belt line;

[0212] Each third vehicle 4-4 is provided with two positioning slots: a first positioning slot and a second positioning slot.

[0213] b. Flipping robotic arms: Two, completing two product flips;

[0214] c. Vision system: Two cameras, one to detect the condition of screws and laser engraving on the lower housing, and the other to check whether the numbers on the fire protection A and B labels correspond one-to-one;

[0215] d. Third rotary hopper 4-12: The structure is the same as the first and second rotary hoppers.

[0216] 3) Operating steps:

[0217] Product flip:

[0218] The product transported from the power-on and ventilation testing process is flipped by the first flipping robot 4-23 to the translational loading mechanism 4-24, so that the lower shell surface faces upward. Then, the translational loading mechanism 4-24 places it into the first positioning slot of the third carrier 4-4 at the starting end of the assembly two-section belt conveyor line.

[0219] Tighten screws:

[0220] After being flipped and translated, the product is transported by the third carrier 4-4 to the screw fastening station 4-5, where the screw fastening machine 4-13 fastens the screws onto the product.

[0221] Laser engraving:

[0222] After the wire is locked, the product is transported by the third carrier 4-4 to the engraving station 4-6, where the product information is engraved by the laser engraving machine 4-14.

[0223] Visual inspection of thread engraving:

[0224] After engraving, the product is transported by the third carrier 4-4 to the thread-engraving inspection station 4-7. The thread-engraving visual inspection camera 4-25 checks whether the screws on the product are tightened or misaligned, and whether the product information is off-positioned or unclear.

[0225] Products that fail the visual inspection of the thread engraving are picked out by the thread engraving NG unloading robot 4-31 and placed in the thread engraving NG frame 4-26; products that pass the visual inspection of the thread engraving are flipped by the second flipping robot 4-27 into the second positioning groove of the third carrier 4-4, so that the upper shell surface faces upward.

[0226] Apply fire safety label A:

[0227] The flipped product is transported by the third carrier 4-4 to the A-labeling station 4-8, where the A-labeling robot 4-16 picks up the fire protection A-label peeled off by the A-label dispenser 4-15 and affixes it to the surface of the upper housing.

[0228] Apply fire safety label B:

[0229] After the third carrier 4-4 arrives at the B-labeling station 4-9, the certificate retrieval robot 4-19 grabs the certificate from the certificate hopper 4-30; the B-labeling robot 4-18 picks up the fire protection B label peeled off by the B-label dispenser 4-17 and affixes it to the certificate; after the product with the fire protection A label affixed is transported by the third carrier 4-4 to the B-labeling station 4-9, the certificate retrieval robot 4-19 places the certificate with the fire protection B label affixed into the first positioning slot of the third carrier 4-4.

[0230] Visual inspection of A and B labels:

[0231] At the AB label inspection station 4-10, the label vision camera 4-28 compares the numbers on the fire protection A label and the fire protection B label of the product arriving at the third carrier 4-4 with those numbers. If they match correctly, the product continues to the next stage; otherwise, the machine stops and an alarm sounds.

[0232] Rotary feeding with hanging plate:

[0233] The third rotary hopper 4-12 rotates the hanging plate to the automatic material picking station of the robotic arm. The hanging plate loading robotic arm 4-21 picks up the hanging plate and puts it onto the hanging plate conveyor line 4-22. The hanging plate conveyor line 4-22 then conveys the hanging plate to the product certificate unloading station 4-11.

[0234] Product and certificate of conformity removed from production line:

[0235] After visual inspection of the A and B labels, the products and certificates of conformity are transported by the third carrier 4-4 to the product certificate unloading station 4-11. The unloading robot 4-20 picks up the products and certificates of conformity at the same time, first placing the certificates of conformity on the already positioned hanging plate, then placing the products on the hanging plate and stacking them together, and then the push-out mechanism pushes them onto the output belt line 4-29.

[0236] (5) Packaging process

[0237] The stacked products, certificates of conformity, and hanging plates conveyed from the output belt are packed and packaged by the complete packaging equipment.

[0238] The embodiments of the present invention described above do not constitute a limitation on the scope of protection of the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A fully automated production line for household gas alarms, characterized in that, This includes the host computer and the motherboard automatic testing process coordinated and controlled by the host computer, the first assembly process, the power-on and air-through testing process, the second assembly process, and the packaging process; (1) Automatic testing process for motherboards: Place the motherboard to be tested into a blister tray, then place the blister tray onto the incoming material conveyor belt, which will transport it to the designated position, and then the elevator will lift it to the loading station. The motherboard to be tested in the blister tray at the loading station is picked up by the loading robot and placed at the automatic motherboard testing station, where it is automatically tested by the automatic testing equipment. After the test is completed, the unloading robot places the qualified motherboards onto the motherboard output line, from which they flow to the next process. The unqualified motherboards are placed into the NG blister tray. After the motherboard under test is picked up by the loading robot, the empty blister tray is placed onto the empty blister tray output line by the loading robot. (2) Assembly of a certain process: Used to install the motherboard into the lower housing, fasten the upper housing onto the lower housing, affix window labels to the indicator light positions on the upper housing, and engrave QR codes on the surface of the upper housing on a conveyor belt assembly line. Assemble a section of belt conveyor line including an upper synchronous belt conveyor mechanism, a lower synchronous belt conveyor mechanism, a front-end lifting mechanism, a rear-end lifting mechanism, and a first carrier for vertical circulation; The front lifting mechanism is located at the beginning of assembling a section of belt conveyor line and is used to lift the first carrier circulating from below to the upper synchronous belt conveyor mechanism. The first carrier, which is lifted to the upper synchronous belt conveyor, is transported from the starting end of the assembly of a section of belt conveyor line through the main board assembly station, the main board inspection station, the upper and lower shell assembly station, the window label affixing station, the laser engraving station, and the appearance inspection station to the ending end. The rear lifting mechanism is located at the end of the assembly of a belt conveyor line and is used to lower the first carrier, which is transported from the beginning of the assembly of a belt conveyor line, to the lower synchronous belt conveyor mechanism. The first carrier, which is lowered to the lower synchronous belt conveyor, is returned from the end of the assembled section of the belt conveyor line to the starting end by the lower synchronous belt conveyor. Lower the casing: The first rotary hopper rotates the lower shell to the robotic arm's automatic material handling station. The lower shell loading robotic arm picks up the lower shell and places it onto the lower shell positioning platform. The lower shell positioning mechanism performs the positioning action, and the positioned lower shell is then placed onto the first carrier by the moving module. Install the motherboard: The first carrier with the lower housing is transported to the motherboard assembly station. The motherboard from the motherboard input line is automatically positioned by the motherboard unloading positioning mechanism and then picked up by the motherboard assembly six-axis robot and placed into the motherboard assembly station. The motherboard is then installed into the lower housing at the station. Motherboard assembly complete inspection: The first carrier, carrying the assembled motherboard, is transported to the motherboard inspection station, where a distance sensor detects whether the motherboard is assembled. If it is not assembled, it is picked out when it is transported to the motherboard NG unloading station, while the assembled motherboard continues to be transported to the upper and lower housing assembly station. Upper and lower shells fasten together: The second rotary hopper rotates the upper shell to the robotic arm automatic material handling station. The upper shell loading robotic arm picks up the upper shell and places it onto the upper shell positioning platform. The upper shell positioning mechanism performs the positioning action. The positioned upper shell is then picked up by the upper shell module and placed onto the lower shell assembly station, completing the upper and lower shell fastening. Apply window stickers: The paper labels placed in the label hopper are picked up by the suction module and placed on the label peeling moving platform; The label peeling platform moves to the label peeling station. After the label is peeled off at the label peeling station, all the labels are peeled off the backing paper and float individually in the peeling chamber, and are evenly distributed. After the first carrier containing the snap-on product is transported to the window label application station, the six-axis window label application robot picks up the peeled window label, and after visual correction by the window label loading positioning camera, it is applied to the position on the surface of the upper shell; the shell with the window label applied is transported by the first carrier to the laser engraving station; QR code engraved on the surface of the upper casing: The laser engraving machine engraves a QR code on the upper housing of the laser engraving station at a designated position on its surface. The housing is then transported by the first carrier to the appearance inspection station. Upper casing appearance inspection: The upper housing surface inspection camera inspects the surface of the upper housing that is transported to the appearance inspection station. The inspection includes whether the window label is affixed to the designated position, whether the QR code is clearly engraved and in the correct position, and whether there are scratches on the surface of the upper housing. After the appearance inspection, the product is transported to the rear lifting mechanism by the first carrier. Sorting output: The two-axis unloading robot sorts the products conveyed to the rear lifting mechanism based on the appearance inspection results of the upper shell. Products that pass the appearance inspection are conveyed to the next process, while those that fail are placed in the NG material bin for appearance inspection. (3) Power-on and ventilation test procedure Used to perform sound button detection, morning alarm detection, and evening alarm detection on a power-on and air-proof test belt conveyor; The power-on and ventilation-testing belt conveyor line includes an upper conveyor belt line, a lower conveyor return belt line, a front lifting conveyor, a rear lifting conveyor, and a second carrier for upper and lower circulation. The front lifting conveyor is set at the beginning of the power-on and air-proof test belt conveyor line and is used to lift the second carrier circulating from below to the upper conveyor belt line. The second carrier, which is lifted to the upper conveyor belt, is transported from the starting end of the power-on and ventilation-testing conveyor belt through the loading station, carrier identification station, first buffer station, sound button detection station, second buffer station, morning report detection station, and evening report detection station to the terminal end. The rear lifting conveyor is located at the end of the power-on and air-on test belt conveyor line and is used to lower the second carrier that is conveyed from the beginning of the power-on and air-on test belt conveyor line to the lower conveyor return belt line. The second carrier, which is lowered to the lower conveyor return belt, returns from the end of the energized and ventilated test belt conveyor to the beginning of the lower conveyor return belt; The product is installed on the second vehicle: The assembled products, transported from one assembly stage, are pressed and fastened by the product loading robot at the loading station onto the second carrier at the beginning of the power-on and ventilation-testing belt conveyor line. Each second carrier has nine product loading positions, each with a QR code number and two probes for connecting to the positive and negative terminals of the gold fingers on the product's motherboard. The two probes are connected to copper strips on both sides of the second carrier to power on the product. Identify the serial number on the second vehicle: After the second carrier is filled with products, it is transported to the carrier identification station. The copper strips on both sides of the second carrier contact the carbon slider on the guide rail of the carrier identification station. The carbon slider is powered by positive and negative power. At this time, the products on the second carrier are powered on and enter a three-minute delay mode. After three minutes, the products enter the normal use mode. At the same time, the vision system of the second carrier identifies the QR code number on the second carrier and the QR code numbers in 9 positions, records them and transmits them to the host computer. First buffer: After the product enters the normal use mode (T1 time), it is transported by the second carrier to the first buffer station. After waiting for T2 time at the first buffer station, it is transported by the second carrier to the sound button detection station. Sound button detection: The sound button detection station is equipped with a three-axis robot for sound detection. The Z-axis of the three-axis robot for sound detection is equipped with a pressure sensor and a sound decibel meter. The Z-axis of the three-axis robotic arm for sound detection presses on the button of the product delivered to the sound button detection station. When the button is pressed to a certain extent, the product enters the start mode and the product's buzzer starts to sound. The sound enters the sound decibel meter through the microphone. If the detected decibel value is greater than the set value, the product's sound button is qualified. Otherwise, when the pressure sensor reaches a certain value or the Z-axis position reaches the set value, the Z-axis is lifted upward, and the sound button is judged to be abnormal. Then, the next product is detected. The same method is used to detect the products at 9 positions on the second carrier. The results are recorded and uploaded to the host computer. Second buffer: After the product completes the sound button test T1 time, it is transported by the second carrier to the second buffer station, where it waits for T2 time before being transported by the second carrier to the morning test station. Early Morning News Detection: A morning report air box is installed at the morning report testing station; After the second carrier transports the product to the early morning gas chamber at the early morning inspection station, it closes the front and rear doors of the early morning gas chamber. The first mass flow controller is activated to start filling the early morning gas chamber with methane gas. At the same time, the first infrared analyzer monitors the methane concentration in the early morning gas chamber in real time. When the concentration reaches the early morning inspection point value of the product, the filling stops. At this time, the early morning vision system on the early morning gas chamber takes pictures to detect whether the product in the early morning gas chamber alarms. Products that alarm are judged as unqualified products, and products that do not alarm are qualified products. The data is recorded and uploaded to the host computer. After the inspection is completed, the second carrier transports the product to the evening inspection station. Evening News Inspection: Evening News gas box is installed at the Evening News testing station; After the second carrier delivers the product into the evening newspaper gas box at the evening newspaper testing station, it closes the front and rear doors of the evening newspaper gas box to seal it. Start the second mass flow controller to start filling methane gas into the evening report gas box. At the same time, the second infrared analyzer continuously detects the methane concentration in the evening report gas box. When the concentration reaches the evening report point value of the product, stop inflating. At this time, the evening report vision system above the evening report gas box takes pictures to detect whether the product in the evening report gas box alarms. The alarmed products are judged as qualified products, and the non-alarmed products are unqualified products. Record and upload them to the host computer. After the detection is completed, the second carrier transports the product to the rear lifting conveyor; Product offline sorting: The second carrier transports the product to the rear lifting conveyor at the blanking station for sorting. The host computer controls the blanking manipulator according to the detection results of the second carrier, and sorts the products that pass the sound key detection, morning report detection, and evening report detection onto the output conveyor belt to enter the second assembly process. The unqualified products are sorted into the sound NG box, key NG box, morning report NG box, and evening report NG box in the NG sorting bin according to the unqualified types; (4)Second assembly process Used to complete screwing on the bottom of the product, engraving the factory information on the bottom of the product, pasting the fire protection A label on the upper shell surface, pasting the fire protection B label on the certificate, and stacking the product, certificate, and hanging plate together on the second assembly belt conveyor line; The second assembly belt conveyor line includes an upper belt line, a lower belt line, a front elevator, a rear elevator, and a third carrier for upper and lower circulation; The front elevator is arranged at the starting end of the second assembly belt conveyor line and is used to lift the third carrier circulating from below to the upper belt line; The third carrier lifted to the upper belt line is transported by the upper belt line from the starting end of the second assembly belt conveyor line through the screw locking station, engraving station, screw locking and engraving detection station, A label pasting station, B label pasting station, AB label detection station, product certificate offline station to the termination end; The rear elevator is arranged at the termination end of the second assembly belt conveyor line and is used to lower the third carrier transported from the starting end of the second assembly belt conveyor line to the lower belt line; The third carrier lowered to the lower belt line is transported by the lower belt line from the termination end of the second assembly belt conveyor line back to the starting end; Each third carrier is provided with two positioning grooves, namely a first positioning groove and a second positioning groove; Product flipping: The product transported from the power-on and gas-on test process is flipped by the first flipping manipulator to the translation feeding mechanism, making the lower shell face upward, and then placed by the translation feeding mechanism into the first positioning groove of the third carrier at the starting end of the second assembly belt conveyor line; Screw locking: The flipped and translated product is transported by the third carrier to the screw locking station, and the screw locking machine locks the screws for the product; Laser engraving: The screw-locked product is transported by the third carrier to the engraving station, and the product information is engraved by the laser engraving machine; Screw locking and engraving vision detection: The engraved product is transported by the third carrier to the screw locking and engraving detection station, and the screw locking and engraving vision detection camera is used to detect whether the screws of the product are locked and misaligned, and whether the product information is deviated from the position and clear or not; The products that fail the screw locking and engraving vision detection are picked out and placed into the screw locking and engraving NG box; the products that pass the screw locking and engraving vision detection are flipped by the second flipping manipulator into the second positioning groove of the third carrier, making the upper shell face upward; Paste the fire protection A label: The flipped product is transported to the A-labeling station by the third carrier, where the A-labeling robot picks up the fire protection A-label peeled off by the A-label dispensing machine and affixes it to the surface of the upper housing. Apply fire safety label B: After the third carrier arrives at the B labeling station, the certificate picking and placing robot grabs the certificate from the certificate hopper; the B labeling robot picks up the fire protection B label peeled off by the B label dispenser and affixes it to the certificate; after the product with the fire protection A label is transported to the B labeling station by the third carrier, the certificate picking and placing robot places the certificate with the fire protection B label into the first positioning slot of the third carrier. Visual inspection of A and B labels: At the AB label inspection station, the visual camera compares the numbers on the fire protection A label and the fire protection B label of the product in the third carrier arriving at this station to see if they match one-to-one. If they match correctly, the product continues to the next stage; otherwise, the machine stops and an alarm sounds. Rotary feeding with hanging plate: The third rotary hopper rotates the hanging plate to the robotic arm's automatic material picking station. The robotic arm picks up the hanging plate and places it on the hanging plate conveyor line, which then transports the hanging plate to the product certificate unloading station. Product and certificate of conformity removed from production line: After visual inspection of the A and B labels, the products and certificates of conformity are transported to the product certificate off-line station by the third carrier. The unloading robot grabs the products and certificates of conformity at the same time, first placing the certificates of conformity on the already positioned hanging plate, then placing the products on the hanging plate and stacking them together, and then the push-out mechanism pushes them onto the output belt line. (5) Packaging process The stacked products, certificates of conformity, and hanging plates conveyed from the output belt are packed and packaged by the complete packaging equipment.

2. The fully automated production line for household gas alarms according to claim 1, characterized in that: The rotary hopper has four stations arranged in a square. One station is used for automatic loading by a robotic arm, and the remaining three stations are used for manual unloading. Each station is equipped with a fourth carrier for placing materials. When the rotary hopper's rotating mechanism rotates 90 degrees, each station rotates 90 degrees. The rotary hopper automatically feeds materials for processes on the production line at the robotic arm automatic feeding station, and allows for manual unloading at the manual unloading station. During the automatic feeding process, the elevator set up at the corresponding robotic arm automatic feeding station lifts the material according to the height of the material plane to ensure that the material can be picked up by the robotic arm on the production line. After one automatic feeding cycle is completed, the rotating mechanism of the rotary hopper rotates the workstation.

3. The fully automated production line for household gas alarms according to claim 1, characterized in that: The device for implementing the window labeling process in a certain assembly process includes a window label hopper, a suction module, a window label feeding and positioning camera, a window label peeling mechanism, and a waste paper hopper; The label peeling mechanism includes the label peeling moving platform and the upper peeling chamber; The window label loading and positioning camera is positioned above the window label hopper; The label peeling mobile platform, the label hopper, and the waste bottom paper hopper are arranged in parallel. The suction module is located on one side of the window label peeling moving platform, the window label hopper and the waste bottom paper hopper, and two suction grippers are respectively provided for the window label peeling moving platform and the window label hopper; The upper stripping chamber is located in front of the window label stripping mobile platform.

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