A flexible intelligent assembly production line for electromagnets

Abstract

This invention discloses a flexible intelligent assembly production line for electromagnets, comprising a first assembly line for assembling a housing, coil, and yoke together to form a housing assembly, and a second assembly line for assembling the housing assembly, core, gasket, retaining ring, and spring together. The first assembly line includes a double-layer circulating conveyor line, a first tray circulating on the double-layer conveyor line, a carrier storage unit located at one end of the double-layer conveyor line and temporarily storing several carriers, a carrier loading / unloading station, a coil housing assembly station, a yoke assembly and inspection station, and a yoke unloading station arranged sequentially along the double-layer conveyor line. The second assembly line includes a single-line conveyor line, a second tray feeding bin located at the input end of the single-line conveyor line, a spring retaining ring assembly station, a multi-functional inspection station, and a tray unloading and storage station arranged sequentially along the single-line conveyor line. This invention enables the automatic assembly of electromagnet retaining rings, yokes, coils, cores, and housings, achieving high assembly efficiency.

Description

Technical Field

[0001] This invention belongs to the technical field of electromagnet assembly equipment, and in particular relates to a flexible intelligent assembly production line for electromagnets. Background Technology

[0002] An electromagnet is a device that generates electromagnetic fields when an electric current flows through it. A conductive winding, matching the power of the current, is wound around an iron core. This current-carrying coil exhibits magnetism like a magnet, hence the name electromagnet. It is typically made in a bar or horseshoe shape to make the iron core easier to magnetize. Currently, one type of electromagnet includes a housing, coil, yoke, iron core, spring, retaining ring, and washers. In traditional manufacturing processes, electromagnets are mostly assembled manually, resulting in low efficiency. Existing patent publication CN114434146B discloses an automated electromagnet assembly system and method. However, this system only vaguely describes the electromagnet assembly station and does not provide a clear and complete description of the assembly structure of specific components. When assembling an electromagnet, a front yoke and a back yoke need to be installed, but this is not disclosed in the assembly system. In addition, for the installation of the retaining ring, the opening and closing stroke of the electromagnet needs to be tested after the retaining ring is installed. If the opening and closing stroke test is not qualified, the thickness of the retaining ring needs to be adjusted according to the test results, but this function is not implemented in the assembly system.

[0003] Therefore, it is necessary to provide a new flexible intelligent assembly production line for electromagnets to solve the above-mentioned technical problems. Summary of the Invention

[0004] The main objective of this invention is to provide a flexible intelligent assembly production line for electromagnets, which can realize the automatic assembly of electromagnet retaining rings, yokes, coils, iron cores and shells with high assembly efficiency.

[0005] This invention achieves the above objective through the following technical solution: a flexible intelligent assembly production line for electromagnets, comprising...

[0006] The first assembly line assembles the housing, coil, and yoke together to obtain a housing assembly. It includes a double-layer circulating conveyor line, a first tray circulating on the double-layer circulating conveyor line, a carrier storage unit located at one end of the double-layer circulating conveyor line and temporarily storing several carriers, a carrier loading / unloading station, a coil housing assembly station, a yoke assembly and testing station, and a yoke unloading station arranged sequentially along the double-layer circulating conveyor line. The yoke assembly and testing station includes a second robotic arm, a yoke feeding and assembly mechanism within the working range of the second robotic arm, a dispensing mechanism, a drying oven, a second coil resistance testing mechanism, and an insulation resistance testing mechanism. Several carrier bearing positions are provided on the first tray.

[0007] The second assembly line assembles the housing components, iron core, gaskets, retaining rings, and springs together to obtain an electromagnet. It includes a single-line conveyor line, a second tray feeding bin located at the input end of the single-line conveyor line, a spring retaining ring assembly station, a multi-functional testing station, and a tray unloading and storage station arranged sequentially along the single-line conveyor line. The spring retaining ring assembly station includes a third robot arm, a spring feeding unit, a retaining ring feeding mechanism, a gasket feeding mechanism, a second measuring instrument for measuring the outer diameter of the iron core, a testing mechanism, a clamping fixture support, and several clamping modules and a test conduction head module that assists the testing mechanism in performing performance tests, all located within the range of motion of the third robot arm. Several second trays are stacked in the second tray, and several housing components and iron cores are placed in the second trays.

[0008] Furthermore, the vehicle storage unit includes an automated warehouse, a plurality of vehicles stored in the automated warehouse, and a vehicle retrieval and placement mechanism for enabling the vehicles to enter and exit the automated warehouse; the vehicles are provided with a housing limiting support, a plurality of first wire clamps for clamping coil wires, and a wire end limiting seat for fixing the position of the end of the coil wires.

[0009] Furthermore, the vehicle loading and unloading mechanism includes a third motor, a second support plate driven by the third motor to move left and right, a fourth motor fixed on the second support plate, a third support plate driven by the fourth motor to move up and down, a fifth motor fixed on the third support plate, and a telescopic tray driven by the fifth motor to move back and forth.

[0010] Furthermore, the coil housing assembly station includes a tray-type housing feeding area and a tray-type coil feeding area located beside the double-layer circulating conveyor line, a lifting and positioning mechanism for positioning the first tray on the double-layer circulating conveyor line, a first coil resistance testing mechanism for testing the resistance of the coil, and a scanning and input mechanism for recording and uploading the engraving information on the housing to the host computer; the tray-type housing feeding area has several housing transfer trays, and several housings are placed on the housing transfer trays. The outer circumference of the housing is engraved with engraving information and the inner diameter is tested and found to be qualified; the tray-type coil feeding area has several coil transfer trays, and the coil transfer trays are filled with coils.

[0011] Furthermore, the yoke feeding assembly mechanism includes a yoke feeding module and a yoke pressing module arranged side by side, a yoke material handling module and a yoke forward and reverse detection module located on the output side of the yoke feeding module.

[0012] Furthermore, the second tray is provided with a first supporting through hole for supporting the housing assembly, a second supporting through hole for supporting the iron core, and a second wire clamp for fixing the position of the coil wire end on the housing assembly; the first supporting through hole, the second supporting through hole, and the second wire clamp are all provided separately at a predetermined interval.

[0013] Furthermore, the clamping module and the test continuity head module are installed at the movable end of the third robotic arm in a quick-change manner during use; the clamping module includes a retaining ring clamping module for clamping the retaining ring, a housing clamping module for clamping the housing assembly, and a combined clamping module for clamping the spring and the iron core; the test continuity head module includes a first continuity head module that conducts electrical connection with the product under test during auxiliary electrical performance testing.

[0014] Furthermore, the retaining ring feeding mechanism is provided in several groups, each used for feeding retaining rings of different specifications; the gasket feeding mechanism includes a gasket clip for storing stacked gaskets, a second receiving platform located in front of the gasket clip, a third pusher plate located behind the gasket clip and pushing the bottom gasket of the gasket clip forward onto the second receiving platform, and a twenty-fourth cylinder for driving the third pusher plate to move back and forth; the end of the second receiving platform is provided with a clearance hole to facilitate the iron core passing through the gasket.

[0015] Furthermore, the testing mechanism is located above the single-line conveyor line and includes a third XY-axis transfer module, a seventeenth support plate disposed at the movable end of the third XY-axis transfer module, a first test module fixed on the seventeenth support plate for detecting the working force of the electromagnet, a second test module fixed on the seventeenth support plate for detecting the opening and closing stroke of the electromagnet, a third test module for detecting the inner diameter of the housing, and a vision module for recording the marking information on the housing. When the first test module and the second test module are performing performance testing, they are electrically connected to the electromagnet using the test conduction head module.

[0016] Furthermore, the pallet unloading and storage station includes a pallet storage unit for storing a second pallet, an unloading and outbound transfer module located on the inlet / outlet side of the pallet storage unit, and a pallet handling module for transporting the second pallet from the single-line conveyor to the pallet storage unit or for transporting the second pallet output from the pallet storage unit to the unloading and outbound transfer module.

[0017] Compared with the prior art, the beneficial effects of the electromagnet flexible intelligent assembly production line of the present invention are: it can realize the automatic assembly of electromagnet retaining ring, yoke, coil, iron core and shell, with high assembly efficiency. Attached Figure Description

[0018] Figure 1This is a schematic diagram of the exploded structure of the electromagnet in an embodiment of the present invention;

[0019] Figure 2 This is a three-dimensional structural diagram of an embodiment of the present invention;

[0020] Figure 3 This is a three-dimensional structural diagram of the shell marking detection unit in an embodiment of the present invention;

[0021] Figures 4-5 These are schematic diagrams of the tray feeding and receiving mechanism at two different angles in an embodiment of the present invention;

[0022] Figure 6 This is a partial structural schematic diagram of the shell marking detection unit in an embodiment of the present invention;

[0023] Figure 7 This is a three-dimensional structural diagram of the first assembly line in an embodiment of the present invention;

[0024] Figure 8 This is a three-dimensional structural diagram of the vehicle storage unit in an embodiment of the present invention;

[0025] Figures 9-10 This is a schematic diagram of the vehicle loading and unloading mechanism in an embodiment of the present invention;

[0026] Figure 11 This is a schematic diagram of the structure of the vehicle loading and unloading station in an embodiment of the present invention;

[0027] Figure 12 This is a schematic diagram of the coil housing assembly station in an embodiment of the present invention;

[0028] Figure 13 This is a schematic diagram of the structure of the first coil resistance testing mechanism in an embodiment of the present invention;

[0029] Figure 14 This is a schematic diagram of the structure of the yoke assembly and testing station in an embodiment of the present invention;

[0030] Figure 15 This is a schematic diagram of the structure of the second carrier gripper in an embodiment of the present invention;

[0031] Figures 16-17 This is a three-dimensional and exploded structural schematic diagram of the yoke feeding assembly mechanism in an embodiment of the present invention;

[0032] Figure 18 This is a schematic diagram of the yoke feeding module in an embodiment of the present invention;

[0033] Figure 19 This is a schematic diagram of the dispensing mechanism in an embodiment of the present invention;

[0034] Figure 20This is a partial structural diagram of the drying oven in an embodiment of the present invention;

[0035] Figure 21 This is a schematic diagram of the yoke unloading station in an embodiment of the present invention;

[0036] Figure 22 This is a schematic diagram of the structure of the second assembly line in an embodiment of the present invention;

[0037] Figure 23 This is a schematic diagram of the structure of the second tray in an embodiment of the present invention;

[0038] Figure 24 This is a schematic diagram of the spring retaining ring assembly station in an embodiment of the present invention;

[0039] Figures 25-28 This is a schematic diagram of the structure of the retaining ring clamping module, the housing clamping module, the combined clamping module, and the first conductive head module in an embodiment of the present invention;

[0040] Figure 29 This is a schematic diagram of the end structure of the spring feeding unit in an embodiment of the present invention;

[0041] Figures 30-31 This is a schematic diagram of the testing mechanism in an embodiment of the present invention;

[0042] Figure 32 This is a schematic diagram of the structure of the retaining ring feeding mechanism and the gasket feeding mechanism in an embodiment of the present invention;

[0043] Figure 33 This is a schematic diagram of the structure of the fourth robotic arm's movable end effector in an embodiment of the present invention;

[0044] Figure 34 This is a schematic diagram of the pallet unloading and storage station in an embodiment of the present invention;

[0045] Figure 35 This is a schematic diagram of the pallet handling module in an embodiment of the present invention;

[0046] Figure 36 This is a schematic diagram of the pallet gripper structure in an embodiment of the present invention;

[0047] The numbers in the image represent:

[0048] 100-Electromagnetic flexible intelligent assembly production line;

[0049] 70-Electromagnet, 701-Housing, 702-Coil, 703-Yoke, 704-Housing assembly, 705-Core, 706-Washer, 707-Retaining ring, 708-Spring;

[0050] 10-House casing marking detection unit,

[0051] 11-Tray feeding and receiving mechanism; 111-Tray channel; 112-First tray feeding bin; 113-Working position; 1131-Elastic limiting pressure plate; 114-Tray receiving bin; 115-Material feeding and transferring mechanism; 1151-First motor; 1152-First support plate; 1153-Elastic lever; 116-First lifting mechanism; 117-Second lifting mechanism; 118-Distribution assembly; 1181-First cylinder; 1182-Drive plate; 11821-Guide chute; 1183-Support base; 1184-Distribution tray; 119-Single-pass support assembly.

[0052] 12-First robotic arm, 121-First housing gripper, 13-First vision camera, 14-First measuring instrument, 15-Laser marking mechanism, 151-First pneumatic gripper, 152-Second motor, 16-Tilting mechanism, 161-Second cylinder, 162-Second housing gripper, 17-Defective product temporary storage mechanism;

[0053] 20 - First Assembly Line

[0054] 21-Double-layer circulating conveyor line, 211-Upper layer conveyor line, 212-Lower layer conveyor line, 213-Elevator,

[0055] 22-Vehicle storage unit, 221-Automatic warehouse, 2211-Vehicle storage sub-unit, 22111-Storage cavity, 22112-Supporting pallet, 22113-Clearing clearance, 222-Vehicle, 2221-Shell limiting support, 2222-First wire clamp, 2223-Wire end limiting seat, 2224-Positioning socket, 223-Vehicle loading and unloading mechanism, 2231-Third motor, 2232-Second support plate, 2233-Fourth motor, 2234-Third support plate, 2235-Fifth motor, 2236-Telescopic pallet, 2237-Slide rail, 2238-First rack, 2239-Guide rod, 22310-Fourth support plate, 22311-Synchronous belt, 22312-First supporting upright plate, 22313-Second rack, 22314-Second drive gear

[0056] 23-Carrier loading / unloading station, 231-Carrier loading / unloading mechanism, 2311-First XY axis transfer module, 2312-Fifth support plate, 2313-Third cylinder, 2314-First carrier gripper.

[0057] 24-Coil housing assembly station; 241-First coil resistance testing mechanism; 2411-Base; 2412-Wire end clamping block; 2413-Fourth cylinder; 2414-Wire end limiting groove; 2415-Limiting clamping strip; 2416-Third continuity probe; 242-Scanning and input mechanism; 2421-Sixth motor; 2422-Second pneumatic gripper; 2423-Second vision camera.

[0058] 25-Yoke assembly and inspection station, 251-Second robotic arm, 2511-Second carrier gripper, 25111-Sixth support plate, 25112-Clamping assembly, 251121-Fifth cylinder, 251122-Sixth cylinder, 251123-Clamping plate, 251124-Positioning rod, 251125-Clamping block, 25113-Code scanner, 252-Yoke feeding and assembly mechanism, 2521-Yoke feeding module 25211 - Discharge platform, 25212 - First pusher plate, 25213 - Seventh cylinder, 25214 - Seventh support plate, 25215 - First yoke clip, 25216 - Second yoke clip, 25217 - Eighth cylinder, 25218 - Yoke limiting groove, 25219 - First sensor, 2522 - Yoke pressing module, 25221 - Second support plate, 25222 - Thirteenth cylinder, 2522 3-Clamping block, 25224-Fourteenth cylinder, 25225-Pressing head, 2523-Yoke material handling module, 25231-Tenth cylinder, 25232-Ninth support plate, 25233-Eleventh cylinder, 25234-Tenth support plate, 25235-Twelfth cylinder, 25236-Yoke suction plate, 2524-Yoke forward / reverse detection module, 25241-Ninth cylinder, 25242-Eighth support plate 25243 - Detection rod; 25244 - Second sensor; 253 - Dispensing mechanism; 2531 - Dispensing support; 2532 - Dispensing head; 2533 - Fifteenth cylinder; 2534 - Seventh motor; 2535 - Oscillator; 254 - Drying oven; 2541 - Box body; 2542 - Drawer-type support plate; 2543 - Sealed front baffle; 255 - Second coil resistance testing mechanism; 256 - Insulation resistance testing mechanism.

[0059] 26-Yoke unloading station, 261-Carrier unloading and handling mechanism, 2611-Second XY axis transfer module, 2612-Eleventh support plate, 2613-Sixteenth cylinder, 2614-Third housing gripper, 2615-Pulling needle, 2616-Qualified product receiving box, 2617-NG product receiving box;

[0060] 30 - Second Assembly Line

[0061] 31-Single-line conveyor line, 32-Second tray feeding hopper,

[0062] 33-Spring retainer ring assembly station, 331-Third robotic arm, 332-Spring feeding unit, 3321-Vibrating plate, 3322-Conveying channel, 3323-Material baffle, 3324-Avoidance notch, 3325-Third sensor, 333-Retainer ring feeding mechanism, 3331-Retainer ring clip, 3332-First receiving platform, 3333-Second pusher plate, 3334-Twenty-third cylinder, 3335-First limit baffle, 334-Gasket feeding mechanism, 3341-Gasket clip, 3342-Second receiving platform, 3343-Third pusher plate, 3 344 - Twenty-fourth cylinder, 3 - Second limit baffle, 3346 - Clearance hole, 335 - Second measuring instrument, 3351 - Measuring support, 336 - Testing mechanism, 3361 - Third XY axis transfer module, 3362 - Seventeenth support plate, 3363 - First testing module, 33631 - Eighth motor, 33632 - Eighteenth support plate, 33633 - Pressure sensor, 33634 - Twenty-fifth cylinder, 33635 - Core chuck, 33636 - Housing pressure plate, 3364 - Second testing module, 33641 - Ninth motor, 3364 2-Nineteenth Support Plate, 33643-Fixed Pressure Pin, 33644-Detection Pin, 33645-Distance Sensor, 3365-Third Test Module, 33651-Twenty-Sixth Cylinder, 33652-Twentieth Support Plate, 33653-Inner Diameter Detection Probe, 3366-Vision Module, 33661-Twenty-Seventh Cylinder, 33662-Third Vision Camera, 337-Clamping Fixture Support, 338-Clamping Module, 3381-Retaining Ring Clamping Module, 33811-Seventeenth Cylinder, 33812-Material Pickup Pin, 3382-Housing Clamping Module 33821 - Eighteenth Cylinder, 33822 - Housing Gripper, 3383 - Combined Gripper Module, 33831 - Twelfth Support Plate, 33832 - Nineteenth Cylinder, 33833 - Twentieth Cylinder, 33834 - Iron Core Gripper, 33835 - Multifunctional Gripper, 339 - Test Conductor Head Module, 3391 - First Conductor Head Module, 33911 - Fifteenth Support Plate, 33912 - First Wire End Support Plate, 33913 - Twenty-second Cylinder, 33914 - Sixteenth Support Plate, 33915 - First Conductor Probe, 3310 - Retaining Ring Recycling Box

[0063] 34-Multifunctional testing station, 341-Fourth robotic arm, 342-Thirteenth support plate, 343-Second conductive head module, 3431-Second wire end support plate, 3432-Twenty-first cylinder, 3433-Fourteenth support plate, 3434-Second conductive probe, 344-Third conductive head module;

[0064] 35-Pallet unloading and storage station, 351-Pallet storage unit, 352-Unloading and outbound transfer module, 353-Pallet handling module, 3531-Y-axis transfer assembly, 3532-Bracket, 3533-Tenth motor, 3534-Pallet gripper, 35341-Twenty-eighth cylinder, 35342-Pallet hook plate, 3535-Material picking assembly, 35351-Eleventh motor, 35352-Twenty-ninth cylinder, 35353-Fourth housing gripper, 3536-Twenty-first support plate, 354-Electronic scale, 355-NG box;

[0065] 40 - tray; 50 - first tray; 60 - second tray; 601 - first support through hole; 602 - second support through hole; 603 - second wire clamp. Detailed Implementation

[0066] Example 1:

[0067] Please refer to Figures 1-36 This embodiment is a flexible intelligent assembly production line 100 for electromagnets, which includes a housing marking and detection unit 10, a first assembly line 20 for assembling a housing 701, a coil 702 and a yoke 703 together to obtain a housing assembly 704, and a second assembly line 30 for assembling a housing assembly 704, an iron core 705, a gasket 706, a retaining ring 707 and a spring 708 together to obtain an electromagnet 70.

[0068] The shell marking detection unit 10, the first assembly line 20, and the second assembly line 30 can be arranged in a straight line or in a U-shape.

[0069] The shell marking and detection unit 10 includes a tray feeding and receiving mechanism 11, a first robotic arm 12 that picks up and transfers a single shell 701 from the tray feeding and receiving mechanism 11, a first vision camera 13 located within the working range of the first robotic arm 12, a first measuring instrument 14 that measures the inner diameter of the shell 701, and a laser marking mechanism 15. In this embodiment, since the placement angle of the shell 701 when it arrives is exactly opposite to the placement angle when the inner diameter is measured, a flipping mechanism 16 is also provided in this embodiment. The first robotic arm 12 cooperates with the flipping mechanism 16 to achieve a 180° vertical flip of the shell 701.

[0070] The tray feeding and receiving mechanism 11 includes a tray flow channel 111 extending in the left-right direction, a first tray feeding bin 112 arranged sequentially along the tray flow channel 111, a working position 113 and a tray receiving bin 114, a material transfer mechanism 115 for driving the tray 40 to move on the tray flow channel 111, a first lifting mechanism 116 disposed below the first tray feeding bin 112, and a second lifting mechanism 117 disposed below the tray receiving bin 114.

[0071] The bottom periphery of the first tray feeding bin 112 is provided with a material distribution component 118 that works with the first lifting mechanism 116 to separate stacked trays. The bottom periphery of the tray receiving bin 114 is provided with a single-pass support component 119 that only allows trays to pass upwards and supports the bottom of the trays after they have passed. The material distribution component 118 has two modules, located on opposite sides of the first tray feeding bin 112. It includes a first cylinder 1181, a drive plate 1182 driven by the first cylinder 1181 to move horizontally, and a material distribution tray 1184 that slides back and forth on a support base 1183. The drive plate 1182 is provided with a guide groove 11821 that guides the material distribution tray 1184 to slide back and forth when it moves left and right. One end of the material distribution tray 1184 extends into or retracts into the first tray feeding bin 112 through telescopic movement, and the other end is provided with a transmission roller (not shown in the figure) that extends into the guide groove 11821. There are four single-channel support components 119, which are divided into two pairs and respectively set on the opposite sides of the tray receiving bin 114.

[0072] The material transfer mechanism 115 includes a first motor 1151, a first support plate 1152 driven by the first motor 1151 to move along the tray flow channel 111, and an elastic lever 1153 disposed on the first support plate 1152. The elastic lever 1153 only has a pushing force on the tray 40 in the direction from the first tray feed bin 112 to the tray receive bin 114, and has no pushing force in the opposite direction.

[0073] An elastic limiting pressure plate 1131 is provided at the working position 113 on the tray flow channel 111 to limit the two sides of the tray 40.

[0074] The first robotic arm 12 has a first housing gripper 121 at its movable end. The first measuring instrument 14 is a pneumatic measuring instrument and has a measuring support (not shown in the figure). The housing 701 needs to be upside down on the measuring support during measurement. The working area of ​​the laser marking machine 15 includes a support (not shown in the figure) for supporting the housing 701, a first pneumatic gripper 151 for fixing the housing 701 on the support, and a second motor 152 for driving the first pneumatic gripper 151 to rotate about a vertical axis. The flipping mechanism 16 includes a second cylinder 161 and a second housing gripper 162 driven by the second cylinder 161 to rotate about a horizontal axis.

[0075] The housing marking detection unit 10 also includes a defective product storage mechanism 17. If the first measuring instrument 14 detects that the inner diameter of the housing 701 does not meet the requirements, it is placed on the defective product storage mechanism 17. When the defective product storage mechanism 17 is filled with a set number of defective products, it will be pushed out to notify the operator to come and pick them up.

[0076] The workflow of the shell marking detection unit 10 is as follows: The operator places several trays 40, each fully loaded with shells 701, in a stacked manner within the first tray feeding hopper 112. Then, the unit is activated. The material distribution component 118 separates the bottom tray. The first lifting mechanism 116 supports the bottom tray and moves it downwards onto the tray flow channel 111. The material transfer mechanism 15 pushes the bottom tray along the tray flow channel 111 to the working position 113, where it is fixed by the elastic limiting plate 1131. The first robotic arm 12 removes a shell 701 from the tray 40 and places it below the first vision camera 13 to identify and record the product marking information. Then, it is transferred to the flipping mechanism 16. The housing 701 is rotated 180 degrees, and the first robotic arm 12 removes the housing 701 from the flipping mechanism 16 and transfers it to the measuring support. The inner diameter of the housing is then detected by the first measuring instrument 14. The housing that passes the test is then transferred back to the carrier and laser-engraved by the laser marking machine 15. If there are any defects, they are placed on the defective product storage mechanism 17. The engraved and marked housing is then placed back on the tray 40 at the working position 13. After all the housings on the tray 40 have completed the above operations, they are pushed by the material transfer mechanism 15 to the area below the tray receiving bin 114. The second lifting mechanism 117 pushes the tray 40 upward into the tray receiving bin 114 and places it on the single-pass support assembly 119, completing one cycle of operation.

[0077] The first assembly line 20 includes a double-layer circulating conveyor line 21 that conveys in the left-right direction, a first pallet 50 that circulates on the double-layer circulating conveyor line 21, a carrier storage unit 22 located at one end of the double-layer circulating conveyor line 21 and temporarily storing several carriers, a carrier loading and unloading station 23, a coil housing assembly station 24, a yoke assembly and inspection station 25, and a yoke unloading station 26 arranged sequentially along the double-layer circulating conveyor line 21.

[0078] The double-layer circulating conveyor line 21 includes an upper conveyor line 211, a lower conveyor line 212, and elevators 213 installed at both ends of the conveyor lines. The vehicle storage unit 22 includes an automated warehouse 221, several vehicles 222 stored in the automated warehouse 221, and a vehicle retrieval and placement mechanism 223 for moving vehicles 222 in and out of the automated warehouse 221.

[0079] The automated warehouse 221 includes two vehicle storage sub-units 2211 arranged opposite each other, with a vehicle retrieval and placement mechanism 223 located between the two vehicle storage sub-units 2211. Each vehicle storage sub-unit 2211 has several layers, and each layer has several storage cavities 22111, each of which can accommodate one vehicle 222. Each storage cavity 22111 has support plates 22112 on both sides to support the vehicle 222, with a clearance gap 22113 between the two support plates 22112.

[0080] The first tray 50 is provided with several carrier bearing positions (not shown in the figure), and each carrier bearing position is provided with a positioning element (not shown in the figure) for positioning the carrier 222. The positioning element can be a positioning post or a limiting block. The carrier 222 is provided with a housing limiting support 2221, several first wire clamps 2222 for clamping the coil wire, and a wire end limiting seat 2223 for fixing the position of the end of the coil wire. Positioning insertion holes 2224 are provided on two opposite sides of the carrier 222 to facilitate the carrier's gripping.

[0081] The vehicle loading and unloading mechanism 223 includes a third motor 2231, a second support plate 2232 driven by the third motor 2231 to move left and right, a fourth motor 2233 fixed on the second support plate 2232, a third support plate 2234 driven by the fourth motor 2233 to move up and down, a fifth motor 2235 fixed on the third support plate 2234, and a telescopic tray 2236 driven by the fifth motor 2235 to move back and forth.

[0082] The second support plate 2232 is slidably mounted on a pair of slide rails 2237. A first rack 2238 is provided between the two slide rails 2237. The third motor 2231 is fixed on the second support plate 2232, and its rotating end is provided with a first drive gear (not shown in the figure) that meshes with the first rack 2238. Several vertically arranged guide rods 2239 are provided on the second support plate 2232. A fourth support plate 22310 is provided on the top of the guide rods 2239. The second support plate 2232, the guide rods 2239, and the fourth support plate 22310 together form a bracket structure. The third support plate 2234 is slidably mounted on the guide rods 2239. The rotating end of the fourth motor 2233 is provided with a drive wheel, and the fourth support plate 22310 is provided with a driven wheel. A synchronous belt 22311 is wound between the drive wheel and the driven wheel. The third support plate 2234 is fixedly connected to one side of the synchronous belt 22311.

[0083] A pair of first support plates 22312 are provided on the third support plate 2234, and a slide rail is formed between the first support plates 22312. The telescopic support plate 2236 is slidably disposed on the slide rail and located between the first support plates 22312. A second rack 22313 is provided on the lower surface of the telescopic support plate 2236. A fifth motor 2235 is fixed on the first support plates 22312, and a second drive gear 22314 that meshes with the second rack 22313 is provided on its rotating end. By rotating the fifth motor 2235 forward and backward, the telescopic support plate 2236 can move forward or backward. Driven by the fifth motor 2235, the telescopic tray 2236 extends into the lower part of the storage cavity 22111, and then moves upward under the drive of the fourth motor 2233. The telescopic tray 2236 lifts the carrier 222 in the storage cavity 22111 upward. Then, the fifth motor 2235 drives the telescopic tray 2236 to retract, removing the carrier 222. Conversely, the carrier 222 can be placed into the storage cavity 22111. In this embodiment, the telescopic tray 2236 is provided with two carrier-bearing acupoints, allowing for the simultaneous input or output of two carriers 222.

[0084] In this embodiment, the automated warehouse 221 is equipped with multiple sets of carriers 222 according to different product models. When the product model is changed, the carrier inventory unit 22 automatically outputs the corresponding model of carrier 222.

[0085] A carrier loading and unloading mechanism 231 is installed at the carrier loading and unloading station 23. The carrier loading and unloading mechanism 231 includes a first XY axis transfer module 2311, a fifth support plate 2312 located at the movable end of the first XY axis transfer module 2311, a third cylinder 2313 fixed on the fifth support plate 2312, and a first carrier gripper 2314 driven by the third cylinder 2313 to move up and down. The carrier picking and placing mechanism 223 in the carrier storage unit 22 takes out a carrier 222 of a set model from the automated warehouse 221 and moves it to below the first carrier gripper 2314. The hook rod on the first carrier gripper 2314 extends into the positioning insertion hole 2224 to clamp the carrier 222. Then, it is placed on the first pallet 50 according to the set position until the set number of carriers 222 are placed on the first pallet 50, thus completing the loading of the carriers 222. Conversely, when a product is changed, the first pallet 50 carries several carriers 222 and moves them to the carrier loading and unloading station 23. The carrier loading and unloading mechanism 231 then moves them one by one to the carrier picking and placing mechanism 223, and then the carrier picking and placing mechanism 223 puts them back into the automated warehouse 221.

[0086] The coil housing assembly station 24 includes a tray-type housing feeding area and a tray-type coil feeding area located next to the double-layer circulating conveyor line 21, a lifting and positioning mechanism (not shown in the figure) for positioning the first tray 50 on the double-layer circulating conveyor line 21, a first coil resistance value testing mechanism 241 for testing the resistance of the coil, and a scanning and input mechanism 242 for inputting and uploading the marking information on the housing 701 to the host computer.

[0087] The material tray type housing feeding area is equipped with several housing transfer trays, on which are placed several housings 701 that have passed the laser marking and inner diameter detection by the housing marking detection unit 10.

[0088] The material tray type coil feeding area is equipped with several coil transfer trays, which are filled with finished coils.

[0089] The first coil resistance testing mechanism 241 includes a base 2411, a wire end clamping block 2412 located above the base 2411, and a fourth cylinder 2413 for driving the wire end clamping block 2412 to move up and down. The base 2411 is provided with a wire end limiting groove 2414 for guiding and limiting the position of the coil wire end. The wire end clamping block 2412 is provided with a limiting pressure strip 2415 aligned with the wire end limiting groove 2414. The third conduction probe 2416 of the electrical continuity resistance testing instrument is provided in the wire end limiting groove 2414. When a resistance test is required on the coil, the operator places the coil end into the end-limiting groove 2414, then starts the equipment. The fourth cylinder 2413 drives the end-pressing block 2412 to descend, and the limiting strip 2415 extends into the end-limiting groove 2414, pressing the coil end onto the third conduction probe 2416, making the coil end electrically connected to the resistance testing instrument, and the resistance test begins. After the test is completed, the end-pressing block 2412 rises, and the operator pulls out the coil end, completing the test.

[0090] The scanning and input mechanism 242 includes a sixth motor 2421, a second pneumatic gripper 2422 driven by the sixth motor 2421 to rotate around a horizontal axis, and a second vision camera 2423 located above the second pneumatic gripper 2422. When it is necessary to identify and input the engraving information, the housing 701 is placed in a horizontal position on the second pneumatic gripper 2422, and then the second pneumatic gripper 2422 clamps the housing 701. The sixth motor 2421 drives the housing 701 to rotate, and the second vision camera 2423 captures the engraving information on the housing 701 and then uploads it to the host computer to complete the input of the engraving information of the housing 701.

[0091] At the coil housing assembly station 24, the operator takes a coil from the tray in the tray-type coil feeding area and places it into the first coil resistance testing mechanism 241 for resistance testing; at the same time, the operator takes a housing from the tray in the tray-type housing feeding area and places it into the scanning and input mechanism 242 for automatic input of the coding information. If the coil test is OK, it is assembled into the housing 701 and then placed into the carrier 222 on the first tray 50. The housing limiting support 2221 on the carrier 222 supports and limits the housing 701. At the same time, the wire end limiting seat 2223 and the first wire clamp 2222 limit the position of the coil wire to prevent the wires from being messy or tangled together.

[0092] The yoke assembly and testing station 25 is equipped with a second robotic arm 251, a yoke feeding and assembly mechanism 252 located within the working range of the second robotic arm 251, a glue dispensing mechanism 253, a drying oven 254, a second coil resistance testing mechanism 255, and an insulation resistance testing mechanism 256.

[0093] The second robotic arm 251 is used to transport the carrier 222 along with the housing 701 on the first tray 50 to the yoke feeding and assembly mechanism 252 to complete the yoke assembly. Then, it is transported to the dispensing mechanism 253 to dispense glue to the designated area. After that, it is transported to the drying oven 254 to dry the glue. After drying, it is taken out from the drying oven 254 and placed on the second coil resistance testing mechanism 255 and the insulation resistance testing mechanism 256 in sequence to complete the resistance test and the product insulation resistance test, respectively. Finally, it is put back into the first tray 50.

[0094] The second robotic arm 251 has a second carrier gripper 2511 at its end. The second carrier gripper 2511 includes a sixth support plate 25111 at the movable end of the second robotic arm 251, two gripping assemblies 25112 at opposite ends of the sixth support plate 2511, and a barcode scanner 25113 fixed on the sixth support plate 25111. The gripping assembly 25112 includes a fifth cylinder 251121 and a sixth cylinder 251122 fixed on the sixth support plate 25111, a clamping plate 251123 driven by the fifth cylinder 251121 to perform opening or clamping actions, a positioning rod 251124 set on the clamping plate 251123 and extending into the positioning insertion hole 2224 on the side of the carrier 222, and a clamping block 251125 driven by the sixth cylinder 251122 to move up and down and press against the housing 701 on the carrier 222. The clamping assembly 25112 can clamp the carrier 222 on the one hand, and automatically pull out the front panel of the upper drawer of the drying oven 254 on the other hand. It uses four positioning rods 251124 to hold the front panel of the upper drawer of the drying oven 254 in a vertically opposite manner, and then pulls it out along the slide rail.

[0095] The yoke feeding assembly mechanism 252 includes a yoke feeding module 2521 and a yoke pressing module 2522 arranged side by side, a yoke picking and handling module 2523 located on the output side of the yoke feeding module 2521, and a yoke forward and reverse detection module 2524.

[0096] The yoke feeding module 2521 includes a discharge platform 25211, a first pusher plate 25212 that aligns with the discharge platform 25211 and pushes the yoke 703 to the right onto the discharge platform 25211, a seventh cylinder 25213 that drives the first pusher plate 25212 to move left and right, a seventh support plate 25214 located between the discharge platform 25211 and the first pusher plate 25212, a first yoke clip 25215 and a second yoke clip 25216 arranged side by side on the seventh support plate 25214 in the front-back direction, and an eighth cylinder 25217 that drives the seventh support plate 25214 to move back and forth so that the first yoke clip 25215 and the second yoke clip 25216 alternately align with the discharge platform 25211. The discharge platform 25211 is equipped with a yoke limiting groove 25218 that can only accommodate one yoke, and a first sensor 25219 is provided at the bottom to detect whether there is a yoke in the yoke limiting groove 25218.

[0097] In this embodiment, the first yoke clip 25215 contains yokes with their front sides facing up, while the second yoke clip 25216 contains yokes with their back sides facing up. Driven by the eighth cylinder 25217, the two clips are alternately aligned with the discharge platform 25211. When the first yoke clip 25215 aligns with the discharge platform 25211, the first pusher plate 25212 pushes the bottom yoke of the first yoke clip 25215 outwards and stops it on the discharge platform 25211, thus feeding the front yoke. Similarly, when the second yoke clip 25216 aligns with the discharge platform 25211, the first pusher plate 25212 pushes the bottom yoke of the second yoke clip 25216 outwards and stops it on the discharge platform 25211, thus feeding the back yoke.

[0098] The yoke orientation detection module 2524 includes a ninth cylinder 25241 and an eighth support plate 25242 driven by the ninth cylinder 25241 to move up and down. The end of the eighth support plate 25242 extends above the discharge platform 25211. A detection rod 25243 and a second sensor 25244 are floatingly mounted on the end of the eighth support plate 25242 to detect whether the detection rod 25243 is pushed upwards. When a yoke 703 appears on the discharge platform 25211, the detection rod 25243 descends to detect whether it can extend into the center hole of the yoke 703. If it can, it means that the yoke is facing upwards. If it cannot extend, the detection rod 25243 will be pushed up and then sensed by the second sensor 25244, thus determining that it is a yoke facing downwards, thereby realizing the yoke orientation detection function.

[0099] The yoke material handling module 2523 is located between the yoke forward and reverse detection module 2524 and the discharge platform 25211. It includes a tenth cylinder 25231, a ninth support plate 25232 driven by the tenth cylinder 25231 to move back and forth, an eleventh cylinder 25233 fixed on the ninth support plate 25232, a tenth support plate 25234 driven by the eleventh cylinder 25233 to move up and down, a twelfth cylinder 25235 fixed on the tenth support plate 25234, and a yoke suction plate 25236 driven by the twelfth cylinder 25235 to move left and right. Driven by the tenth cylinder 25231, the yoke suction plate 25236 moves between the discharge platform 25211 and the yoke pressing module 2522. Under the combined action of the eleventh cylinder 25233 and the twelfth cylinder 25235, the yoke is picked up and placed. The yoke suction plate 25236 has a flat structure to avoid interference with the detection rod 25243 above.

[0100] The yoke pressing module 2522 includes a second support plate 25221 vertically arranged for supporting the back of the upright vehicle, a thirteenth cylinder 25222 fixed to the side and rear of the second support plate 25221, a pressing block 25223 driven by the thirteenth cylinder 25222 to fasten the housing 701 towards the second support plate 25221 and thus press the vehicle 222 onto the second support plate 25221, a fourteenth cylinder 25224 fixed to the upper part of the second support plate 25221, and a pressing head 25225 driven by the fourteenth cylinder 25224 to move up and down and to press the yoke 703 into the housing 701.

[0101] The carrier 222 is positioned vertically against the second support plate 25221 by the second robotic arm 251 and secured by the clamping block 25223. At this time, the housing 701 on the carrier 222 is vertical with the yoke mounting opening facing upwards and the pressing head 25225 directly facing the housing 701. The yoke suction plate 25236 attracts the yoke and moves above the housing 701, then places the yoke inside. After the yoke suction plate 25236 retracts, the pressing head 25225, driven by the fourteenth cylinder 25224, presses the yoke 703 into the housing 701 and secures it in place. Designing the yoke suction plate 25236 as a flat structure also avoids interference with the pressing head 25225.

[0102] The dispensing mechanism 253 includes a dispensing support 2531, a dispensing head 2532 located above the dispensing support 2531, a fifteenth cylinder 2533 driving the dispensing head 2532 to move up and down, and a seventh motor 2534 driving the fifteenth cylinder 2533 to move back and forth. To ensure the uniformity of dispensing, a vibrator 2535 is also provided below the dispensing support 2531. After the carrier 200 is pressed onto the yoke, it is transported onto the dispensing support 2531. Then, the dispensing head 2532 dispenses glue to a designated area on the outer periphery of the housing. After dispensing is completed, the vibrator 2535 generates vibration to make the glue area on the outer periphery of the housing smooth and uniform.

[0103] The drying oven 254 includes a body 2541 and several drawer-type support plates 2542 slidably disposed within the body 2541. A sealing front baffle 2543 is provided at the front end of each drawer-type support plate 2542. Several carriers 222 can be placed on the drawer-type support plates 2542 to improve overall drying efficiency. A second robotic arm 251 can use a gripping assembly 25112 to hook onto the sealing front baffle 2543 to pull out the drawer-type support plate 2542, and then remove or place the carriers 222.

[0104] The yoke unloading station 26 is equipped with a carrier unloading and conveying mechanism 261. The carrier unloading and conveying mechanism 261 includes a second XY axis transfer module 2611, an eleventh support plate 2612 located at the movable end of the second XY axis transfer module 2611, a sixteenth cylinder 2613 fixed on the eleventh support plate 2612, a third housing gripper 2614 driven by the sixteenth cylinder 2613 to move up and down, a puller 2615 driven by the sixteenth cylinder 2613 to open the first wire clamp 2222 on the carrier 222 to facilitate the pulling out of the coil wire, a qualified product receiving box 2616 located below the transfer range of the second XY axis transfer module 2611, and an NG product receiving box 2617.

[0105] The workflow of the first assembly line 20 is as follows: Based on the product model, the carrier inventory unit 22 automatically outputs the corresponding carrier 222; at the carrier loading / unloading station 23, the first pallet 50 moves into position, and the carrier loading / unloading mechanism 231 transports the carriers 222 output from the carrier inventory unit 22 one by one onto the first pallet 50 and arranges them neatly in the set positions; after the first pallet 50 is filled with a set number of empty carriers 222, the first pallet 50 moves to the coil housing assembly station 24 under the conveying action of the upper conveyor line 211; the operator takes out the housing 701 that has passed the marking and inner diameter inspection from the housing transfer tray and places it in the scanning and input area. The mechanism 242 records the coded information, then takes a coil from the coil transfer tray and places it on the first coil resistance testing mechanism 241 for resistance testing. After passing the test, it is assembled into the housing 701 and then placed in the carrier 222 of the first tray 50. When all carriers 222 on the first tray 50 contain the housing and coil assembly, the first tray 50 is transported to the yoke assembly and testing station 25. At the yoke assembly and testing station 25, the second robot arm 251 moves all carriers 222 on the first tray 50 one by one into the yoke pressing module 2522 and fixes them in place. At the same time, the yoke feeding module 2521 alternately feeds... The front and back yokes are produced. The yoke material handling module 2523 transports the two yokes sequentially to the yoke pressing module 2522 according to the installation order of the front and back yokes. Each time a yoke is placed into the housing 701, the yoke pressing module 2522 presses it once. After both yokes are pressed, the second robot arm 251 transports the carrier 222 to the dispensing mechanism 253 for dispensing. After dispensing, it is placed in the drying oven 254 for drying. After drying, it is placed in the second coil resistance testing mechanism 255 for a second coil resistance test, and then in the insulation resistance testing mechanism 256 for product insulation resistance testing. After all the housings on the carriers 222 are in place... After the yoke is assembled and its performance is tested, the first pallet 50 moves to the yoke unloading station 26. The housing assembly 704, which is formed by assembling the housing 701, coil, and yoke 703, is taken out from the carrier 222 by the carrier unloading and handling mechanism 261. Then, according to the test results of the previous station, it is placed in the qualified product receiving box 2616 or the NG product receiving box 2617 to complete the assembly, testing, and unloading of the housing assembly 704. The first pallet 50 then carries the empty carrier and is transferred to the lower conveyor line 212 by the elevator 213. The lower conveyor line 212 then transports the carrier outbound loading station 23 for the next cycle operation.

[0106] The second assembly line 30 includes a single-line conveyor line 31 that conveys materials in the left-right direction, a second tray feeding bin 32 located at the input end of the single-line conveyor line 31, a spring retainer assembly station 33, a multi-functional testing station 34, and a tray unloading and storage station 35 arranged sequentially along the single-line conveyor line 31.

[0107] The second tray feeding bin 32 contains several second trays 60, each containing several housing assemblies 704 and iron cores 705. A third lifting mechanism (not shown in the figure) is located at the bottom of the second tray feeding bin 32, and a second distributing assembly (not shown in the figure) is located around the bottom periphery of the second tray, cooperating with the third lifting mechanism to separate the bottommost second tray 60 of the second tray feeding bin 32. The second tray 60 has a first supporting through hole 601 for supporting the housing assembly 704, a second supporting through hole 602 for supporting the iron core 705, and a second wire clamp 603 for fixing the coil wire ends on the housing assembly 704. The first supporting through hole 601, the second supporting through hole 602, and the second wire clamp 603 are spaced apart to facilitate the clamping of the iron core 705, provide sufficient space above the housing assembly 704 for various performance tests, or provide sufficient space around the second wire clamp 603 for the conductive connector to reach when energizing the electromagnet for electrical performance tests.

[0108] The spring retainer assembly station 33 includes a third robot arm 331, a spring feeding unit 332 located within the range of motion of the third robot arm 331, a retainer feeding mechanism 333, a gasket feeding mechanism 334, a second measuring instrument 335 for measuring the outer diameter of the iron core, a testing mechanism 336, a jig support 337, and several clamping modules 338 and a test guide head module 339 for auxiliary testing, all located on the jig support 337.

[0109] Both the clamping module 338 and the test continuity head module 339 are equipped with robot tool quick-change devices. When needed, the third robot arm 331 moves to the fixture support 337 to install and remove the clamping module 338 and the test continuity head module 339 as required, achieving quick replacement. During use, the clamping module 338 and the test continuity head module 339 are mounted on the movable end of the third robot arm 331. The clamping module 338 includes a retaining ring clamping module 3381 for clamping the retaining ring 707, a housing clamping module 3382 for clamping the housing assembly 704, and a combined clamping module 3383 for clamping the spring 708 and the iron core 705. The test continuity head module 339 includes a first continuity head module 3391 that provides electrical conductivity with the product under test during auxiliary electrical performance testing.

[0110] The retaining ring clamping module 3381 includes a seventeenth cylinder 33811 and two picking pins 33812 driven by the seventeenth cylinder 33811 to open or close. The picking pins 33812 pick up the retaining ring by inserting into two small holes on the retaining ring 707. The seventeenth cylinder 33811 drives the two picking pins 33812 to open, which can expand the narrowing of the retaining ring 707 and facilitate the installation of the retaining ring 707.

[0111] The housing clamping module 3382 includes an eighteenth cylinder 33821 and a housing gripper 33822 driven by the eighteenth cylinder 33821 to perform opening or clamping actions.

[0112] The combined clamping module 3383 includes a twelfth support plate 33831, a nineteenth cylinder 33832 and a twentieth cylinder 33833 fixed on the twelfth support plate 33831 and vertically distributed, a core gripper 33834 driven by the nineteenth cylinder 33832 to perform opening or clamping actions, and a multi-functional gripper 33835 driven by the twentieth cylinder 33833 to perform opening or clamping actions. The multi-functional gripper 33835 can clamp the assembly of the core 705 and the washer 706; during clamping, directly clamping the washer 706 fitted on the core 705 will pick up the core and washer together. Furthermore, the multi-functional gripper 33835 can also clamp springs.

[0113] The first conductive head module 3391 includes a fifteenth support plate 33911, a first wire end support plate 33912 fixed on the fifteenth support plate 33911 and supporting the ends of the two wires of the coil, a twenty-second cylinder 33913 fixed on the fifteenth support plate 33911, a sixteenth support plate 33914 driven by the twenty-second cylinder 33913 to move up and down, and a pair of first conductive probes 33915 fixed on the sixteenth support plate 33914 and aligned downwards with the first wire end support plate 33912.

[0114] The spring feeding unit 332 includes a vibratory feeder 3321, a conveying channel 3322 connecting to the output end of the vibratory feeder 3321, and a material baffle 3323 located at the end of the conveying channel 3322. A pair of material baffles 3323 are provided, spaced apart and opposite to each other, forming clearance notches 3324 for the spring grippers 33835 to extend into. A third sensor 3325 is also provided at the end of the conveying channel 3322 to detect whether a spring is in position.

[0115] The retaining ring feeding mechanism 333 is provided with several sets, each used for feeding retaining rings 707 of different specifications. The retaining ring feeding mechanism 333 includes a retaining ring clip 3331 for storing stacked retaining rings, a first receiving platform 3332 located in front of the retaining ring clip 3331, a second pusher plate 3333 located behind the retaining ring clip 3331 and pushing the bottom retaining ring 707 of the retaining ring clip 3331 forward onto the first receiving platform 3332, and a twenty-third cylinder 3334 for driving the second pusher plate 3333 to move back and forth. A first limiting baffle 3335 is provided in front of the first receiving platform 3332, and a fourth sensor (not shown in the figure) is provided on the first limiting baffle 3335 to detect whether there are retaining rings on the first receiving platform 3332.

[0116] The gasket feeding mechanism 334 is also provided with several sets to feed gaskets 706 of different specifications to suit various product models. The gasket feeding mechanism 334 includes a gasket clip 3341 for storing stacked gaskets 706, a second receiving platform 3342 located in front of the gasket clip 3341, a third pusher plate 3343 located behind the gasket clip 3341 and pushing the bottom gasket 706 of the gasket clip 3341 forward onto the second receiving platform 3342, and a twenty-fourth cylinder 3344 for driving the third pusher plate 3343 to move back and forth. A second limit baffle 3 is provided in front of the second receiving platform 3342, and a fifth sensor (not shown in the figure) is provided on the second limit baffle 3 to detect whether there are gaskets on the second receiving platform 3342. To facilitate the fitting of the shim 706 onto the iron core 705, the end of the second receiving platform 3342 is provided with a clearance hole 3346. The diameter of the clearance hole 3346 is smaller than the inner diameter of the shim 706 and larger than the outer diameter of the iron core 705, so that when the shim 706 is pushed to the end of the second receiving platform 3342, the third robot arm 331 can grip the iron core 705 and insert it directly downward into the shim 706, and then pick up the shim and the iron core together.

[0117] The second measuring instrument 335 is a pneumatic measuring instrument used to detect the outer diameter of the iron core, and it is equipped with a measuring support 3351.

[0118] The testing mechanism 336 is located above the single-line conveyor line 31. It includes a third XY-axis transfer module 3361, a seventeenth support plate 3362 located at the movable end of the third XY-axis transfer module 3361, a first test module 3363 fixed on the seventeenth support plate 3362 for detecting the working force of the electromagnet, a second test module 3364 fixed on the seventeenth support plate 3362 for detecting the opening and closing stroke of the electromagnet, a third test module 3365 for detecting the inner diameter of the housing, and a vision module 3366 for recording the marking information on the housing.

[0119] The first test module 3363 includes an eighth motor 33631, an eighteenth support plate 33632 driven by the eighth motor 33631 to move up and down, a pressure sensor 33633 fixed on the eighteenth support plate 33632, a twenty-fifth cylinder 33634 fixed on the sensing end of the pressure sensor 33633, a core chuck 33635 driven by the twenty-fifth cylinder 33634 to clamp the top of the core 705, and a housing pressure plate 33636 fixed on the seventeenth support plate 3362 and located below the core chuck 33635 to press the housing 701. The housing pressure plate 33636 is provided with an avoidance opening (not shown in the figure) for the core chuck 33635 to extend through. When testing the working force of an electromagnet, the third robotic arm 331 is equipped with a first conductive head module 3391 at its end, then moves to the area of ​​the second tray 60, and then to the position of the second wire clamp 603 corresponding to the electromagnet to be tested. The first wire end support plate 33912 supports the two wire ends on the second wire clamp 603, while the first conductive probe 33915 remains disconnected. Then, the first test module 3363 moves above the electromagnet to be tested, and the iron core clamp 33635 extends into the electromagnet through the clearance opening and clamps the top of the iron core 705. The first conductive probe 33915 contacts the wire ends downward to conduct electricity, the electromagnet is energized, and the iron core 705 is driven to move downward. At this time, the iron core clamp 33635 is pulled downward. The pulling force is detected by the pressure sensor 33633, which is the working force of the electromagnet. This working force is uploaded to the host computer system, which determines whether it meets the requirements and completes the test.

[0120] The second test module 3364 includes a ninth motor 33641, a nineteenth support plate 33642 driven by the ninth motor 33641 to move up and down, a fixing pin 33643 fixed on the nineteenth support plate 33642 for pressing the electromagnet housing, a detection pin 33644 floating on the nineteenth support plate 33642 for pressing the top of the iron core 705, and a distance sensor 33645 fixed on the nineteenth support plate 33642 for detecting the downward movement distance of the detection pin 33644. During the electromagnet opening and closing stroke detection, the third robotic arm 331 is also equipped with a first conductive head module 3391 at its end. After the working force detection of the same electromagnet is completed, it remains stationary and only performs a power-off operation. The second test module 3364 moves above the electromagnet and uses the fixed pressure pin 33643 to press the housing 701. At the same time, the detection pin 33644 presses the iron core 705. Then, the first conductive head module 3391 connects the lead wire of the electromagnet, the electromagnet is energized, and the iron core 705 moves downward. The detection pin 33644 moves downward the same distance as the iron core 705 under the action of the spring. The distance of movement of the detection pin 33644 is detected by the distance sensor 33645, which is the opening and closing stroke of the electromagnet. This information is then uploaded to the host computer system, where it is determined whether the opening and closing stroke of the electromagnet meets the requirements, thus completing the detection.

[0121] Both the third test module 3365 and the vision module 3366 are fixedly mounted on the nineteenth support plate 33642. The third test module 3365 includes a twenty-sixth cylinder 33651 fixed on the nineteenth support plate 33642, a twentieth support plate 33652 driven by the twenty-sixth cylinder 33651 to move up and down, an inner diameter detection probe 33653 floating up and down on the twentieth support plate 33652, and a sixth sensor (not shown in the figure) fixed on the twentieth support plate 33652 to monitor the height position of the inner diameter detection probe 33653. The vision module 3366 includes a twenty-seventh cylinder 33661 fixed on the nineteenth support plate 33642 and a third vision camera 33662 driven by the twenty-seventh cylinder 33661 to move up and down.

[0122] The workflow of spring retainer assembly station 33 is as follows:

[0123] S1. The second tray 60, carrying several housing components 704 and iron core 705, moves into place;

[0124] S2. The third robotic arm 331 is equipped with a housing clamping module 3382 at its end, which clamps the housing assembly 704. It removes the housing assembly 704 from the second tray 60 and moves it to the position of the vision module 3366 in the testing mechanism 336. The vision module 3366 identifies the engraving information on the housing assembly 704 and uploads it to the host computer system. Repeating this step can complete the engraving information entry for all housing assemblies 704 on the second tray 60.

[0125] S3, the third test module 3365 in the test mechanism 336 detects the inner diameter of the housing assembly 704; repeating this step can complete the detection of the inner diameter of all housings on the second tray 60;

[0126] S4. The third robotic arm 331 is equipped with a combined clamping module 3383 capable of clamping springs at its end. It picks up a spring from the spring feeding unit 332 and then inserts it into the housing assembly 704 to complete the spring installation. Repeating this step can complete the spring installation in all housing assemblies 704 on the second tray 60.

[0127] S5. The third robotic arm 331 is equipped with a combined clamping module 3383 at its end, which can clamp the iron core 705. It takes an iron core 705 out of the second tray 60 and places it on the second measuring instrument 335 to detect the outer diameter of the iron core.

[0128] S6. During the execution of steps S1 to S5, the gasket feeding mechanism 334 supplies gaskets 706 of the corresponding specifications to the second receiving platform 3342. After the outer diameter of the iron core is detected, the combined clamping module 3383 inserts the iron core 705 into the gasket 706, and then picks up the iron core and the gasket together. If the initial set number of gaskets to be installed is 2, the gasket feeding mechanism 334 outputs another gasket, and the combined clamping module 3383 inserts the iron core and the first gasket into the second gasket, then picks up the iron core and the two gaskets together and puts them into the housing assembly 704 to complete the iron core installation. Repeating steps S5 to S6 can complete the outer diameter detection and installation of all iron cores on the second tray 60.

[0129] S7. During the execution of steps S1 to S6, the retaining ring feeding mechanism 333 supplies retaining rings 707 of various specifications to the first receiving platform 3332; the end of the third robot arm 331 is quickly replaced with a retaining ring clamping module 3381 to clamp the retaining rings 707, and then moves to the retaining ring feeding mechanism 333 to pick up the standard retaining ring set by the system. For example, the thickness of the standard retaining ring at this time is 1.0mm. The retaining ring clamping module 3381 picks up the retaining ring 707 with a thickness of 1.0mm, and then installs it into the housing assembly 704 to complete the retaining ring installation and obtain the electromagnet 70; repeating this step can complete the retaining ring installation in all electromagnets 70 on the second tray 60;

[0130] S8. After the electromagnet is assembled, various performance tests are conducted to determine whether the retaining ring and gasket are installed effectively. The end effector of the third robotic arm 331 is quickly replaced with the first conductive head module 3391. The testing mechanism 336 moves above the second tray 60. The first conductive head module 3391 clamps the wire end of the electromagnet to achieve electrical conduction. First, the electromagnet comprehensive tester, which is electrically connected to the first conductive head module 3391, is used to test the electromagnet's pull-in / release current and pull-in / release time, and the data is uploaded to the host computer system. Then, the first test module 3363 and the second test module 3364 are used to detect the working force and opening / closing stroke of the electromagnet, respectively.

[0131] S9. If the electromagnet's attraction / discharge current detection is OK, then the number of shims 706 installed is correct and effective; otherwise, the number of shims needs to be readjusted. If the electromagnet's opening / closing stroke detection is OK, then the thickness of the retaining ring 707 is correct and effective; otherwise, the thickness of the retaining ring needs to be replaced. If the number of shims needs to be replaced, the quick-change retaining ring clamping module 3381 at the end of the third robotic arm 331 removes the retaining ring 707, then quickly changes to the combined clamping module 3383 to remove the iron core and shims. Then, the number of shims is increased or decreased at the shim feeding mechanism 334. Finally, the shims with the correct number of shims are installed... The iron core of the sheet is placed back into the housing assembly 704, and then the retaining ring is inserted. If the retaining ring thickness needs to be changed, the quick-change retaining ring clamping module 3381 at the end of the third robot 331 removes the retaining ring 707, and then picks up the retaining ring of the corresponding thickness at the retaining ring feeding mechanism 333 according to the electromagnet opening and closing stroke detection result for installation. If a set number (e.g., 5) of products need to be replaced with the same thickness of retaining ring each time, the system automatically changes the program and uses the retaining ring of the same thickness that has been replaced multiple times as the latest standard retaining ring. When the next product is to be installed with a retaining ring, the retaining ring of that thickness is picked up directly.

[0132] If the retaining ring or shim is replaced in step S9, the electromagnet after adjusting the number of shims or changing the thickness of the retaining ring needs to be retested for electromagnet engagement / disengagement current, engagement / disengagement time, working force, and working force stroke; only after passing the test can it proceed to the next workstation. A retaining ring recycling box 3310 is provided within the range of motion of the third robot 331 to collect the disassembled retaining rings.

[0133] The multi-functional testing station 34 includes a fourth robotic arm 341, a thirteenth support plate 342 located at the movable end of the fourth robotic arm 341, and a second conductive module 343 and a third conductive head module 344 fixed on the thirteenth support plate 342. Both the second conduction module 343 and the third conduction head module 344 include a second wire end support plate 3431 fixed on the thirteenth support plate 342 and supporting the ends of the two wires of the coil, a twenty-first cylinder 3432 fixed on the thirteenth support plate 342, a fourteenth support plate 3433 driven by the twenty-first cylinder 3432 to move up and down, and a plurality of second conduction probes 3434 fixed on the fourteenth support plate 3433. Two of the second conduction probes 3434 in the second conduction module 343 are located directly above the second wire end support plate 3431. Three of the second conduction probes 3434 in the third conduction head module 343 are provided, two of which are located directly above the second wire end support plate 3431, and the other second conduction probe 3434 is aligned with the housing 701 at a set position.

[0134] The multi-functional testing station 34 is mainly used to perform online testing of the electromagnet coil resistance, insulation resistance, and insulation dielectric strength, and upload the data to the host computer system. The fourth robotic arm 341 has an NG (Not From Good) material box within its range of motion; products that fail the test are placed in the NG material box. The pallet unloading and storage station 35 includes a pallet storage unit 351 for storing the second pallet 60, an unloading and transfer module 352 located on the inlet / outlet side of the pallet storage unit 351, and a pallet handling module 353 that transports the second pallet 60 from the single-line conveyor line 31 to the pallet storage unit 351 or transports the second pallet 60 output from the pallet storage unit 351 to the unloading and transfer module 352.

[0135] The structure of the pallet storage unit 351 is basically the same as that of the carrier storage unit 22. The difference is that the inlet and outlet of the pallet storage unit 351 are distributed in the front-to-back direction, while the inlet and outlet of the carrier storage unit 22 are distributed in the left-to-right direction. In addition, the storage cavity in the pallet storage unit 351 is larger, and a second pallet 60 is temporarily stored in each storage cavity.

[0136] The second pallet 60, carrying a qualified electromagnet, moves to the pallet unloading and storage station 35. The pallet handling module 353 removes it from the single-line conveyor line 31 and sends it to the pallet storage unit 351 for storage. When a subsequent station needs electromagnet feeding, the pallet storage unit 351 outputs the second pallet 60 carrying the electromagnet, and then the pallet handling module 353 transports it to the unloading and outbound transfer module 352. The unloading and outbound transfer module 352 moves it to the outbound position, waiting for the robot arm of the next station to pick it up. The transfer direction of the unloading and outbound transfer module 352 is parallel to the conveying direction of the single-line conveyor line 31 and is located below the pallet handling module 353. The pallet handling module 353 includes a Y-axis transfer assembly 3531, a bracket 3532 located at the movable end of the Y-axis transfer assembly 3531, a tenth motor 3533 fixed on the bracket 3532, a twenty-first support plate 3536 driven by the tenth motor 3533 to move up and down, a pallet gripper 3534 fixed on the twenty-first support plate 3536, and a picking assembly 3535 fixed on the twenty-first support plate 3536 for picking up individual electromagnets. Below the transfer range of the pallet handling module 353, there is an electronic scale 354 and an NG box 355. When the second pallet 60 needs to be retrieved, the picking assembly 3535 on the pallet handling module 353 removes each electromagnet from the second pallet 60 and places it on the electronic scale 354 for weighing. Electromagnets that pass the weighing test are returned to the second pallet 60, while those that fail are placed in the NG box 355.

[0137] The pallet gripper 3534 includes a pair of twenty-eighth cylinders 35341 fixed to the lower surface of the twenty-first support plate 3536 and a pallet hook plate 35342 driven by the twenty-eighth cylinders 35341 to perform opening or clamping actions. The pallet hook plate 35342 is provided with a hook needle, which can clamp the second pallet 60 by inserting the hook needle into the positioning hole on the side of the second pallet 60.

[0138] The material handling assembly 3535 includes an eleventh motor 35351 fixed to the front surface of the eleventh support plate 3536, a twenty-ninth cylinder 35352 driven by the eleventh motor 35351 to move left and right, and a fourth housing gripper 35353 driven by the twenty-ninth cylinder 35352 to move up and down.

[0139] The workflow of the second assembly line 30 is as follows: The second tray 60 carries the housing assembly 704 and the iron core 705, and is placed in the second tray feeding bin 32 in a stacked manner. A single second tray 60 is output from the bottom of the second tray feeding bin 32 and moves with the single-line conveyor line 31 to the spring retainer assembly station 33. At the spring retainer assembly station 33, the marking information on the housing is entered, the inner diameter of the housing is detected, the spring is assembled, the outer diameter of the iron core is detected, the iron core gasket is assembled, and the retainer is assembled to obtain the electromagnet. Then, the electromagnet's attraction and release current, attraction and release time, working force, and working force stroke are detected. After passing the tests, the second tray 60 moves to the multi-functional testing station 34 for electromagnet coil resistance, insulation resistance, and insulation dielectric strength tests. After passing the tests, the second tray 60 moves to the tray unloading and storage station 35 and is transported to the tray storage unit 351 for storage by the tray handling module 353.

[0140] For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this invention, and these all fall within the protection scope of this invention.

Claims

1. A flexible intelligent assembly production line for electromagnets, characterized in that: It includes The first assembly line assembles the housing, coil, and yoke together to obtain a housing assembly. It includes a double-layer circulating conveyor line, a first tray circulating on the double-layer circulating conveyor line, a carrier storage unit located at one end of the double-layer circulating conveyor line and temporarily storing several carriers, a carrier loading / unloading station, a coil housing assembly station, a yoke assembly and testing station, and a yoke unloading station arranged sequentially along the double-layer circulating conveyor line. The yoke assembly and testing station includes a second robotic arm, a yoke feeding and assembly mechanism within the working range of the second robotic arm, a dispensing mechanism, a drying oven, a second coil resistance testing mechanism, and an insulation resistance testing mechanism. Several carrier bearing positions are provided on the first tray. The second assembly line assembles the housing assembly, iron core, gasket, retaining ring, and spring together to obtain an electromagnet. It includes a single-line conveyor line, a second tray feeding bin located at the input end of the single-line conveyor line, a spring retaining ring assembly station, a multi-functional testing station, and a tray unloading and storage station arranged sequentially along the single-line conveyor line. The spring retaining ring assembly station includes a third robot arm, a spring feeding unit located within the range of motion of the third robot arm, a retaining ring feeding mechanism, a gasket feeding mechanism, a second measuring instrument for measuring the outer diameter of the iron core, a testing mechanism, a clamping fixture support, and several clamping modules and a test conduction head module that assists the testing mechanism in performing performance tests. The second tray feed hopper contains several second pallets, and the second pallets contain several shell components and iron cores; The vehicle storage unit includes a three-dimensional warehouse, several vehicles stored in the three-dimensional warehouse, and a vehicle retrieval and placement mechanism for enabling vehicles to enter and exit the three-dimensional warehouse; the vehicles are provided with a housing limiting support, several first wire clamps for clamping coil wires, and a wire end limiting seat for fixing the position of the end of the coil wire; The coil housing assembly station includes a tray-type housing feeding area and a tray-type coil feeding area located beside the double-layer circulating conveyor line, a lifting and positioning mechanism for positioning the first tray on the double-layer circulating conveyor line, a first coil resistance testing mechanism for testing the resistance of the coil, and a scanning and input mechanism for recording and uploading the engraving information on the housing to the host computer. The tray-type housing feeding area has several housing transfer trays, and several housings are placed on the housing transfer trays. The outer circumference of the housing is engraved with engraving information and the inner diameter is tested and found to be qualified. The tray-type coil feeding area has several coil transfer trays, and the coil transfer trays are full of coils. The yoke feeding assembly mechanism includes a yoke feeding module and a yoke pressing module arranged side by side, a yoke picking and handling module located on the output side of the yoke feeding module, and a yoke forward and reverse detection module. The second tray is provided with a first supporting through hole for supporting the housing assembly, a second supporting through hole for supporting the iron core, and a second wire clamp for fixing the position of the coil wire end on the housing assembly; the first supporting through hole, the second supporting through hole, and the second wire clamp are all provided separately at a predetermined interval; The testing mechanism is located above the single-line conveyor and includes a third XY-axis transfer module, a seventeenth support plate disposed at the movable end of the third XY-axis transfer module, a first test module fixed on the seventeenth support plate for detecting the working force of the electromagnet, a second test module fixed on the seventeenth support plate for detecting the opening and closing stroke of the electromagnet, a third test module for detecting the inner diameter of the housing, and a vision module for recording the marking information on the housing. When the first test module and the second test module are performing performance testing, they are electrically connected to the electromagnet using the test conduction head module.

2. The electromagnet flexible intelligent assembly production line as described in claim 1, characterized in that: The vehicle loading and unloading mechanism includes a third motor, a second support plate driven by the third motor to move left and right, a fourth motor fixed on the second support plate, a third support plate driven by the fourth motor to move up and down, a fifth motor fixed on the third support plate, and a telescopic tray driven by the fifth motor to move back and forth.

3. The electromagnet flexible intelligent assembly production line as described in claim 1, characterized in that: The clamping module and the test conduction head module are installed at the movable end of the third robot arm in a quick-change manner during use; the clamping module includes a retaining ring clamping module for clamping the retaining ring, a housing clamping module for clamping the housing assembly, and a combined clamping module for clamping the spring and the iron core; The test conduction head module includes a first conduction head module that conducts electrical connection with the product under test during auxiliary electrical performance testing.

4. The electromagnet flexible intelligent assembly production line as described in claim 1, characterized in that: The retaining ring feeding mechanism is provided in several groups, which are used for feeding retaining rings of different specifications; the gasket feeding mechanism includes a gasket clip for storing stacked gaskets, a second receiving platform located in front of the gasket clip, a third pusher plate located behind the gasket clip and pushing the bottom gasket of the gasket clip forward onto the second receiving platform, and a twenty-fourth cylinder for driving the third pusher plate to move back and forth; the end of the second receiving platform is provided with a clearance hole to facilitate the iron core to pass through the gasket.

5. The electromagnet flexible intelligent assembly production line as described in claim 1, characterized in that: The pallet unloading and storage station includes a pallet storage unit for storing a second pallet, an unloading and outbound transfer module located on the inlet / outlet side of the pallet storage unit, and a pallet handling module for moving the second pallet from the single-line conveyor line into the pallet storage unit or moving the second pallet output from the pallet storage unit into the unloading and outbound transfer module.

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