A mass microsphere filling device and method for dense porous bottom plate

Abstract

The application discloses a mass microsphere filling device and method for dense porous bottom plates, which comprises an equipment test frame, a collection mechanism fixed on the equipment test frame, a three-axis carrying manipulator, a visual identification system support, a three-axis moving manipulator, a material preparation cabin and a material distribution device; the front end of the three-axis carrying manipulator is provided with a pneumatic clamping gripper; the visual identification system support is provided with a visual identification system on one side and a visual mechanism moving runner on the top end, the visual mechanism moving runner is in transmission connection with the visual identification system; and the front end of the three-axis moving manipulator is provided with a vacuum chuck. The problems that microspheres are difficult to be individually grabbed due to small size and smooth surface and the interval between material pores is small in the field of microsphere filling are solved, stable filling quantity is realized through the use of a mechanical scraper device and the matching of appropriate scraper materials under the assistance of a visual identification system and a weight monitoring system.

Description

Technical Field

[0001] This invention relates to a microsphere material filling device, and more particularly to a mass microsphere filling device and method for a dense porous substrate. Background Technology

[0002] Currently, existing spherical filling devices are typically designed for encapsulating larger spheres with relatively large spacing. However, these devices generally struggle to identify and accurately fill microspheres smaller than 300µm.

[0003] In the prior art:

[0004] The reagent tray pre-filling microsphere device from Ezhou Kangxin Medical Technology Co., Ltd. (an auxiliary device for pre-filling microspheres in a microfluidic reagent tray) primarily functions to quickly position the biological reagent tray. The biological reagent tray can accurately align with the dispensing hole of the dispensing tray, facilitating the replacement of consumables for pre-filling microspheres. BOE Technology Group Co., Ltd.'s OLED packaging patent (OLED packaging equipment and OLED packaging method) mainly focuses on using an ultrasonic vibration device to vibrate a cover plate with added filler material, thereby accelerating the diffusion speed of the filler material on the cover plate and solving the problem of air bubbles easily getting trapped inside the filler material during diffusion.

[0005] The reactor refueling device (a reactor refueling system, online loading, unloading and refueling method) of the Institute of Nuclear Physics and Chemistry, China Academy of Engineering Physics, mainly focuses on realizing the online loading and unloading of breeder microspheres or neutron multiplier microspheres in the breeder blanket of fusion reactors.

[0006] Tsinghua University's (spherical component sorting device) mainly performs spherical screening, allowing large balls, qualified balls, and microspheres to exit through three separate outlet channels. In summary, existing ball sorting devices can only screen spheres of varying sizes and sizes, and cannot accurately fill microspheres, or perform point-to-point arrays of micro-sheets similar to OLED packaging, but are not suitable for spherical objects.

[0007] Problems with the aforementioned existing technology:

[0008] In recent years, with the development of microtechnology, microsphere material filling technology, such as OLED electronic packaging and reagent filling in the medical industry, has also received widespread attention. However, there is no convenient and quick filling method for microsphere identification and filling below 300um. Traditional manual filling is not only time-consuming and labor-intensive, but also has limitations in filling rate, making it difficult to achieve a filling rate of more than 97%, which poses a great problem in practical applications.

[0009] In view of this, the present invention is hereby proposed. Summary of the Invention

[0010] The purpose of this invention is to provide a device and method for mass microsphere filling of dense porous substrates, so as to solve the above-mentioned technical problems existing in the prior art.

[0011] The objective of this invention is achieved through the following technical solution:

[0012] The present invention provides a mass microsphere filling device for dense porous substrates, comprising a test frame 1, wherein a collection mechanism 2, a visual recognition system bracket 7, a material preparation chamber 10, and a fabrication device 11 are fixed on the test frame 1.

[0013] The two ends of the equipment test frame 1 are respectively equipped with three-axis moving robotic arms 8, and the upper end of the three-axis moving robotic arms 8 is equipped with a three-axis handling robot 3. One of the three-axis handling robot 3 is equipped with a pneumatic gripper 4 at the front end, and the other three-axis handling robot 3 is equipped with a vacuum suction cup 9 at the front end.

[0014] The visual recognition system bracket 7 is equipped with a visual recognition system 5 on one side and a visual mechanism moving wheel 6 on the top. The visual mechanism moving wheel 6 is connected to the visual recognition system 5 in a transmission manner.

[0015] Compared with the prior art, the device and method for mass microsphere filling for dense porous substrates provided by the present invention solves the problems in the field of microsphere filling, such as the small size of microspheres, the smooth surface making them difficult to grasp individually, and the small spacing between material pores. By using a mechanical scraper device and matching it with a suitable scraper material, and with the assistance of a visual recognition system and a weight monitoring system, a stable filling quantity is achieved. Attached Figure Description

[0016] Figure 1 This is a schematic flowchart of a method for mass microsphere filling for a dense porous substrate provided in an embodiment of the present invention.

[0017] Figure 2 This is a schematic diagram of the structure of a mass microsphere filling device for a dense porous substrate provided in an embodiment of the present invention.

[0018] Figure 3 This is a schematic diagram of the collection mechanism of a mass microsphere filling device for a dense porous substrate provided in an embodiment of the present invention.

[0019] Figure 4 This is a schematic diagram of the overall structure of the fabric feeding device for a mass microsphere filling device for a dense porous base plate provided in an embodiment of the present invention.

[0020] Figure 5 This is a schematic diagram of the microsphere filling mechanism of the fabric distribution device for a mass microsphere filling device for a dense porous substrate provided in an embodiment of the present invention.

[0021] Figure 6This is a schematic diagram of the microsphere spreading and leveling mechanism of the mass microsphere filling device for a dense porous substrate provided in an embodiment of the present invention.

[0022] In the picture:

[0023] 1. Equipment test frame; 2. Collection mechanism; 2-1. Spring telescopic linkage; 2-2. Telescopic spring; 2-3. Stepper motor one; 2-4. Positioning and clamping mechanism; 3. Three-axis handling robot; 4. Pneumatic gripper; 5. Vision recognition system; 6. Vision mechanism moving wheel; 7. Vision recognition system bracket; 8. Three-axis moving robot arm; 9. Vacuum suction cup; 10. Material preparation chamber; 11. Material feeding device; 11-1. Moving cylinder; 11-2. Material clamping mechanism; 11-3. Orifice plate slot; 11-4. Material weighing system; 11-5. Material feeding chamber; 11-6. Observation chamber door; 11-7. Microsphere feeding mechanism; 11-8. Stepper motor two; 11-9. Moving slide rail; 11-10. Flattening material feeding mechanism; 11-11. Microsphere collection chamber; 11-12. Orifice plate adjustment mechanism; 11-13. Material orifice plate. Detailed Implementation

[0024] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them, and do not constitute a limitation on the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the protection scope of the present invention.

[0025] First, the following explanations are provided for the terms that may be used in this article:

[0026] The term "and / or" means that either or both can be achieved simultaneously. For example, X and / or Y means that it includes both "X" or "Y" as well as the three cases of "X and Y".

[0027] The terms “including,” “comprising,” “containing,” “having,” or other similar semantic descriptions should be interpreted as non-exclusive inclusion. For example, “including a technical feature element (such as raw material, component, ingredient, carrier, dosage form, material, size, part, component, mechanism, device, step, process, method, reaction conditions, processing conditions, parameter, algorithm, signal, data, product or article of manufacture, etc.)” should be interpreted as including not only the expressly listed technical feature element, but also other technical feature elements that are not expressly listed and are well-known in the art.

[0028] The term "composed of" excludes any technical features not expressly listed. When used in a claim, it closes the claim to exclude all technical features other than those expressly listed, except for associated conventional impurities. If the term appears only in a clause of a claim, it limits the claim to the elements expressly listed in that clause; elements recited in other clauses are not excluded from the overall claim.

[0029] Unless otherwise explicitly specified or limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this document according to the specific circumstances.

[0030] The terms “center,” “longitudinal,” “lateral,” “length,” “width,” “thickness,” “upper,” “lower,” “front,” “back,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” “outer,” “clockwise,” and “counterclockwise” indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience and simplification of description and do not imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this document.

[0031] The contents not described in detail in the embodiments of this invention are prior art known to those skilled in the art. Where specific conditions are not specified in the embodiments of this invention, they shall be performed according to conventional conditions in the art or conditions recommended by the manufacturer. Where the manufacturers of the reagents or instruments used in the embodiments of this invention are not specified, they are all conventional products that can be purchased commercially.

[0032] The present invention provides a mass microsphere filling device for dense porous substrates, comprising a test frame 1, wherein a collection mechanism 2, a visual recognition system bracket 7, a material preparation chamber 10, and a fabrication device 11 are fixed on the test frame 1.

[0033] The two ends of the equipment test frame 1 are respectively equipped with three-axis moving robotic arms 8, and the upper end of the three-axis moving robotic arms 8 is equipped with a three-axis handling robot 3. One of the three-axis handling robot 3 is equipped with a pneumatic gripper 4 at the front end, and the other three-axis handling robot 3 is equipped with a vacuum suction cup 9 at the front end.

[0034] The visual recognition system bracket 7 is equipped with a visual recognition system 5 on one side and a visual mechanism moving wheel 6 on the top. The visual mechanism moving wheel 6 is connected to the visual recognition system 5 in a transmission manner.

[0035] The collection mechanism 2 includes a spring telescopic link 2-1 and a telescopic spring 2-2. The telescopic spring 2-2 is installed inside the spring telescopic link 2-1. One end of the spring telescopic link 2-1 is fixed to the inner wall of the collection box, and the other end is connected to the perforated plate collection mechanism to realize the elastic displacement of the perforated plate collection mechanism.

[0036] The orifice plate collecting mechanism includes two positioning and clamping mechanisms 2-4 and a stepper motor 2-3. The output shaft of the stepper motor 2-3 is directly connected to the two positioning and clamping mechanisms 2-4. The rotation of the stepper motor 2-3 causes the two positioning and clamping mechanisms 2-4 to clamp or loosen through mechanical linkage, so as to control the clamping force.

[0037] The fabric feeding device 11 includes a fabric feeding chamber 11-5. The fabric feeding chamber 11-5 is provided with a moving cylinder 11-1, a material clamping mechanism 11-2 and a perforated plate slot 11-3 for supporting the perforated plate on both sides. The moving cylinder 11-1 clamps and pushes the perforated plate slot 11-3 to move through the material clamping mechanism 11-2.

[0038] The perforated plate slot (11-3) is placed on a smooth platform and moved. The material weighing system (11-4) is close to the bottom of the smooth platform and cooperates with the perforated plate slot (11-3) to weigh the perforated plates before and after the material is laid.

[0039] The fabric pack (11-5) is fixed in the middle of the smooth platform. After the perforated plate before fabric is weighed, the moving cylinder (11-1) on one side pushes the perforated plate slot (11-3) into the fabric pack (11-5).

[0040] After the fabric is laid, the perforated plate is pushed out of the fabric chamber (11-5) by the moving cylinder (11-1) on the other side, and then weighed.

[0041] The fabric compartment 11-5 is provided with a micro-ball feeding mechanism 11-7 on one side, and an observation door 11-6 is provided on the side wall of that side;

[0042] The inner wall of the fabric compartment 11-5 is provided with a movable slide rail 11-9, and a flattening fabric mechanism 11-10 is mounted on the movable slide rail 11-9. A stepper motor 11-8 located outside the fabric compartment 11-5 drives the flattening fabric mechanism 11-10 to move on the movable slide rail 11-9.

[0043] The bottom wall of the fabric compartment 11-5 is provided with a microsphere collection compartment 11-11, and the material perforated plate 11-13 is located above the microsphere collection compartment 11-11 and supported on the bottom wall by the perforated plate adjustment mechanism 11-12. The moving trajectory of the flat fabric distribution mechanism 11-10 is located above the material perforated plate 11-13.

[0044] The fabric smoothing mechanism 11-10 is a sweeping device with fine fluff.

[0045] The principles of the two main mechanisms in this invention are as follows:

[0046] The collection mechanism 2:

[0047] The spring-telescopic linkage bracket 2-1 acts as a connector. One end is fixed inside the collecting box by bolts, while the other end connects to the front-end mobile phone mechanism, which consists of stepper motor 2-3 and positioning clamping mechanism 2-4. The extension and retraction are achieved via a telescopic spring in the middle, and all actions are controlled by a host computer. Stepper motor 2-3 and positioning clamping mechanism 2-4 constitute the perforated plate collecting mechanism. The spring-telescopic linkage 2-1 contains a telescopic spring, allowing for extension or retraction when necessary during the transmission of mechanical force. Stepper motor 2-3 is directly connected to positioning clamping mechanism 2-4 to achieve precise position adjustment and control of clamping force. The rotation of stepper motor 2-3, through mechanical linkage, causes positioning clamping mechanism 2-4 to clamp or release, inducing movement of clamping mechanism 2-4. This movement is converted into linear or rotational motion, used to adjust or activate the clamping mechanism.

[0048] The fabric-making device 11:

[0049] The movable cylinder 11-1 and the material clamping mechanism 11-2 precisely adjust and fix the fabric. The movable slide rail 11-9 and the stepper motor 11-8 work together to ensure accurate positioning. The fabric leveling mechanism 11-10 and the microsphere feeding mechanism 11-7 further process and decorate the fabric. The perforated plate slot 11-3, the material weighing system 11-4, and the material perforated plate 11-13 provide stable support and real-time monitoring, while the microsphere collection chamber 11-11 and the observation door 11-6 increase the maintainability and ease of operation of the equipment. The entire system can flexibly adapt to different working requirements through the perforated plate adjustment mechanism 11-12.

[0050] During operation, the moving cylinder 11-1 pushes the guide carrier—the orifice plate slot 11-3—along it. The material clamping mechanism 11-2, located on both sides of the cylinder's forward path, cooperates with the guide carrier—the orifice plate slot 11-3—to correct the position of the orifice plate. The material weighing system 11-4, located below the smooth platform where the orifice plate moves, cooperates with the orifice plate slot 11-3 to weigh the device before material distribution. After completion, the orifice plate slot 11-3 is pushed into the material distribution chamber 11-5.

[0051] The material feeding chamber 11-5 is an integral material feeding chamber, fixed on a smooth platform suitable for the movement of the perforated plate. The internal material feeding situation can be observed through the observation window 11-6. The microsphere feeding mechanism 11-7 is fixed inside the material feeding chamber 11-5, located above the guide carrier (perforated plate slot 11-3) carrying the perforated plate, with a bottom distance of 15mm. The moving slide rail 11-9, the second stepper motor 11-8, and the material feeding mechanism 11-10 constitute a microsphere leveling, filling, and filling device. The second stepper motor 11-8 is fixed on the outer wall of the material feeding chamber and is internally connected to the moving slide rail 11-9. The slide rail has a sweeping device with fine bristles, which can move back and forth on the perforated plate to allow the microspheres to quickly enter the material perforated plate 11-13. Below the perforated plate is the perforated plate adjustment mechanism 11-12, which can tilt the microspheres at a certain angle to ensure that excess microspheres are completely swept off. The bottom is the excess microsphere collection chamber 11-11.

[0052] In summary, the mass microsphere filling device and method for dense porous substrates of the present invention mainly solves the problems in the field of microsphere filling, such as the small size of microspheres, their smooth surface making them difficult to grasp individually, and the small spacing between material pores. By using a mechanical scraper device and matching it with a suitable scraper material, and with the assistance of a visual recognition system and a weight monitoring system, a stable filling quantity can be achieved.

[0053] It is mainly used in the following three processes: first, to realize the filling function, realize the automatic completion of the steps of grabbing, transferring and filling the orifice plate, and ensure that the material does not spill during the movement, and the filling rate should be as close to 100% as possible; second, to detect the working system; and third, to recover spilled materials.

[0054] To more clearly demonstrate the technical solution and its effects provided by the present invention, the embodiments of the present invention will be described in detail below with reference to specific examples.

[0055] Example 1

[0056] like Figures 1 to 6 As shown:

[0057] This invention mainly comprises two parts:

[0058] The first component is the fabric placement device 11 and its parts, including a three-axis handling robot 3, a pneumatic gripper 4, a vacuum suction cup 9, a moving cylinder 11-1, a fabric placement chamber 11-5, a microsphere feeding mechanism 11-7, a moving slide rail 11-9, a flattening fabric placement mechanism 11-10, a microsphere collection chamber 11-11, and a perforated plate adjustment mechanism 11-12. The robot arm 8 uses the vacuum suction cup 9 to pick up the bottom plate from the material preparation chamber 10 and place it into the perforated plate slot 11-3 of the fabric placement device 11. Under the action of the material clamping mechanisms 11-2 on both sides, the robot arm 8 corrects and clamps the position of the perforated plate. Under the action of the moving cylinder 11-1, the robot arm pushes the perforated plate into the fabric placement chamber 11-5. There is an opening at the observation door 11-6 that is slightly higher than the thickness of the bottom plate, allowing the perforated plate to enter the fabric placement chamber 11-5 in a suitable position. After the perforated plate reaches its designated position, a strip of material is fed from one end. A mechanical device with a scraper then moves at a suitable height from the feeding side, filling the perforated plate with microspheres and scraping away any excess. The scraper is made of flexible nitrile rubber. After repeated feeding, the microspheres are pushed out through the observation door 11-6 on the other side. Since the observation door 11-6 is slightly higher than the perforated plate, any excess microspheres are scraped off as they exit the door. After filling, the perforated plate is gripped by pneumatic grippers 4, and the microsphere collection chamber 11-11 ejects from the material box. The material box clamps the perforated plate and is then retracted, completing the feeding process.

[0059] The second component is the inspection system, including a vision recognition system 5 and a material weighing system 11-4. When the robotic arm 8 uses the vacuum suction cup 9 to pick up the material plate to the loading station, the material weighing system 11-4 is placed below the station to first weigh the perforated plate before loading, and then transport it to the loading unit. During the material distribution process, the mechanical device repeatedly hangs and removes the material to perform visual recognition and photo inspection to check whether the filling rate is qualified. If it is qualified, the pneumatic gripper 4 on the robotic arm 3 will hold and move it to the secondary weighing unit for a secondary qualification test to check whether the weight of the filled material and the perforated plate is qualified. If qualified, the gripper 4 will transport it to the workpiece storage system for a secondary visual inspection. The second inspection is performed when the material is loaded into the closed device to check whether it is scattered during the movement. If it is not qualified, the material distribution is repeated.

[0060] During the operation of this mechanism, the weight change is relatively small. Therefore, the weighing system 11-4 of the microsphere mass transfer device adopts a high-precision weighing module. This module can achieve high-speed and high-precision weighing within a compact installation space, maximizing production efficiency. Measurements are taken as the perforated plate passes through each module sequentially via the conveyor belt, and the weight change of the perforated plate during its passage through different modules is recorded. After material unloading, the weight change of the material distribution bin 11-5 is detected, and the loading capacity of the perforated plate and the discharge capacity of the material distribution bin 11-5 are calculated. This module combines strain gauge weighing with automatic calibration functions, incorporates overload protection, reduces maintenance requirements, and ensures service life and weighing stability. Furthermore, this module requires no complex automation components, enabling cost-effective system networking applications. Meanwhile, the vision recognition system 5 employs a surface line scan coaxial detection structure, using high-brightness coaxial light as the light source. It uses a trigger acquisition method with two movement steps to detect the filling degree, improving detection accuracy.

[0061] The workflow of microspheres and orifice plates in mass transfer tooling is as follows: Figure 1 As shown:

[0062] Feeding device: Air is supplied by an air compressor at a pressure of 0.8 MPa into the feeding cylinder. The cylinder stroke is 20 mm, and it rises by 2 mm each time to accommodate the thickness of the perforated bottom plate, ensuring that only one perforated plate is fed out at a time.

[0063] Orifice plate gripping: The robotic arm end is equipped with a pneumatic gripper 4, which is supplied with air by an air compressor and input with a pressure of 0.4 MPa. It is controlled by G-code and draws the corresponding path in the xy coordinate system. It moves to the top of the feeding device in a plane parallel to the operating surface at a speed of 5 mm / s. After reaching the top of the orifice plate, it stops at a suitable position along the z-axis vertically downward and reads the gripping command. The air source is turned on to grip the orifice plate, and the orifice plate is moved to the designated position in the working area using the reverse code path.

[0064] Orifice plate installation: After arriving at the designated work area according to the G-code instruction, the robotic arm places the orifice plate horizontally on the work plane. The positioning cylinder is supplied with air by an air compressor and inputs air pressure of 0.4 MPa. It is clamped on three sides to put it in the ready position. After it is ready, the cylinder pushes the orifice plate into the fabric area and waits for the next action.

[0065] Discharge: When the perforated plate is pushed into place, the feeding mechanism 11-7 opens and the microspheres begin to be discharged. The discharge port is a 100*20mm square area, releasing 2300 microspheres per second. The discharge is closed after ten seconds, so that the microspheres are evenly distributed in long strips at one end of the perforated plate.

[0066] Microsphere loading: The robotic arm holds a teardrop-shaped nitrile rubber ball and moves back and forth along the X-axis in a Z-shape from one corner of the orifice plate with material to the side without material, until it reaches the diagonal side of the starting end, which counts as one stroke. This is repeated three times. After finishing, the robotic arm repeats the motion three times along the Y-axis from the starting point. The downward pressure of the robotic arm is adjusted so that the pressure of the rubber ball on the orifice plate is 0.1N and the robotic arm travel speed is 3mm / s. After finishing, the robotic arm rises to prepare for the next action.

[0067] Orifice plate cleaning and refilling: After the material is applied, the scraper mechanism cleans the orifice plate evenly at a speed of 3 mm / s and a pressing height of 2 mm from the orifice plate. First, it moves in a circular motion around the center of the scraper. Unfilled holes are refilled, and then the scraper moves along the x and y axes to remove excess microspheres from the orifice plate.

[0068] Visual inspection: After filling is completed, visual recognition is performed. First, the vision module moves to 50mm above the filled orifice plate to take a picture and scan. The light reflection and deflection are analyzed to determine the microsphere loading rate of the orifice plate. When the loading rate reaches 98%, it is qualified. Otherwise, the requirements are not met and the filling process needs to continue.

[0069] Orifice plate transfer: After the orifice plate passes the filling test, the moving cylinder 11-1 pushes the orifice plate to the moving preparation position, the robot arm 3 then descends again, the pneumatic gripper 4 holds the orifice plate, and the orifice plate is transferred along the set G-code trajectory.

[0070] The weight difference of the fabric bin before and after grasping is detected: A material weighing system 11-4 is placed under the perforated plate with a detection accuracy of 0.01g. The detection device compares the weight of the fabric bin before and after grasping to determine the amount of microspheres discharged and finally determine the filling loss rate.

[0071] The weight difference of the orifice plate before and after filling is measured: After filling is completed, the orifice plate is pushed to the moving preparation position by the moving cylinder 11-1. The material weighing system 11-4 with an accuracy of 0.01g is placed below this position to measure the weight of the unfilled orifice plate and the orifice plate after filling, and to determine the weight of the filled microspheres.

[0072] To detect whether materials are spilled during the movement: The vision recognition system 5 is used to perform a second inspection on the perforated plate that has been filled and moved to the hopper before sealing. The vision camera moves to 100mm above the perforated plate to take pictures. The vision recognition algorithm is used to compare each hole and finally calculate the microsphere filling rate. It is also used to detect whether microspheres are lost on the perforated plate when it moves from the filling area to the inspection area.

[0073] Spilled material collection: After the filling and testing process is completed, the spilled microspheres in each area need to be collected manually.

[0074] The protection points and corresponding advantages of this invention are:

[0075] It includes a feeding unit, a transfer unit, a material distribution unit, and a weighing unit. The device uses a robotic arm and a vacuum suction cup to perform the microsphere distribution operation.

[0076] The technical approach is based on mechanical motion and visual recognition. A robotic arm performs point-to-point positioning and repeated scraping to achieve the microsphere distribution operation. Through precise mechanical mechanisms, the microspheres are ensured to be uniformly filled into the micropores of the perforated plate, thereby achieving efficient distribution and improving the filling rate.

[0077] The visual recognition unit employs deep learning algorithms. Deep learning constructs multi-layer nonlinear activation functions as learnable operators to train and fit feature extraction functions, converting image data into highly separable "high-level, high-dimensional features." Defect categories and locations are then regressed based on these high-level features. Through this function, the visual recognition device can effectively determine the filling effect on the perforated plate surface, identify the number of filled and unfilled holes, calculate the filling rate, and determine whether the current filling meets the requirements. After the perforated plate is filled, a second filling inspection is performed to determine if refilling is necessary. This visual inspection unit uses a specific optical system to photograph the area to be inspected on the display module. Through image processing or deep learning algorithms, it can effectively detect the working condition.

[0078] The detection system employs two repeated inspections to improve detection accuracy and reduce operational errors. The first visual recognition inspection can detect the filling quality in real time and make real-time adjustments, while the second visual recognition inspection ensures that no operational accidents occur. The weight monitoring system can corroborate the visual recognition inspection, further improving detection accuracy.

[0079] A material storage bin 11-5 was designed to store microsphere raw materials, ensuring the quality of the stored materials and proper storage conditions. The material storage bin 11-5 adopts a closed storage design with a bottom opening for feeding. The opening is equipped with a switch device to control the rate and quantity of microspheres falling. The material storage bin 11-5 has a built-in weight sensor that can measure the weight difference of the internal microspheres before and after the bin is opened and closed.

[0080] The material recovery device is located below the orifice plate, and baffles are set around the orifice plate to prevent material from spilling out of the device. Excess microspheres will remain around or below the orifice plate. A microsphere collection chamber 11-11 is set below to recover excess microsphere material. A collection chamber is also set below the transfer robotic arm. When the mechanical clamping device picks up the orifice plate after it has been filled, the recovery box rotates to the bottom of the orifice plate. After being transported to the designated position, the recovery box rotates 90° so that the orifice plate can fall into the collection chamber. The whole process ensures complete closed-loop management of materials.

[0081] This microsphere mass filling tooling loading unit module consists of a material hopper and a top-loading servo. It is divided into two sets of material hoppers, each containing 10 to 15 perforated plates, and each set of material hoppers is equipped with a top-loading servo module below it. This design can ensure the stability and efficiency of the loading process, and achieve stable loading of perforated plates.

[0082] During operation, the feeding unit programs the clamping mechanism to move the material distribution bin 11-5 and its working position. Once the clamping device reaches the designated position, the feeding unit begins operation. The top-loading servo module pushes the cylinder to ensure the thickness of the sheet material rising each time, guaranteeing stable feeding of the perforated plate. After the clamping unit secures the perforated plate, the feeding mechanism enters a preparation phase, ready for the next feeding operation. This automated feeding module design enables continuous microsphere mass filling and ensures the stability of the overall filling process.

[0083] This microsphere mass filling device uses a three-axis robotic arm to grip nitrile rubber as a scraper to scrape the experimental substrate back and forth. After obtaining the position information of key nodes and endpoints, the robotic arm is programmed in the control console to control its movement. When the robotic arm starts moving, the lowest point of the nitrile rubber is positioned inside the experimental well plate so that excess microspheres can be squeezed to the side of the well plate during scraping. At the same time, the scraper mechanism can move horizontally in the X and Y directions and make circular motions to improve the filling rate.

[0084] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims. The information disclosed in the background section is intended only to enhance the understanding of the overall background technology of the present invention and should not be construed as an admission or implication in any way that such information constitutes prior art known to those skilled in the art.

Claims

1. A mass microsphere filling device for dense porous substrates, characterized in that, Includes an equipment test rack (1), on which a collection mechanism (2), a visual recognition system bracket (7), a material preparation chamber (10), and a fabrication device (11) are fixed. The two ends of the equipment test frame (1) are respectively equipped with three-axis moving robotic arms (8), and the upper end of the three-axis moving robotic arms (8) is equipped with a three-axis handling robot (3). One of the three-axis handling robot (3) has a pneumatic gripper (4) at the front end, and the other three-axis handling robot (3) has a vacuum suction cup (9) at the front end. The visual recognition system bracket (7) is equipped with a visual recognition system (5) on one side and a visual mechanism moving wheel (6) on the top. The visual mechanism moving wheel (6) is connected to the visual recognition system (5) in a transmission manner. The collection mechanism (2) includes a spring telescopic link (2-1) and a telescopic spring (2-2). The telescopic spring (2-2) is installed inside the spring telescopic link (2-1). One end of the spring telescopic link (2-1) is fixed to the inner wall of the collection box, and the other end is connected to the perforated plate collection mechanism to realize the elastic displacement of the perforated plate collection mechanism. The orifice plate collecting mechanism includes two positioning and clamping mechanisms (2-4) and a stepper motor (2-3). The output shaft of the stepper motor (2-3) is directly connected to the two positioning and clamping mechanisms (2-4). The rotation of the stepper motor (2-3) causes the two positioning and clamping mechanisms (2-4) to clamp or loosen through mechanical linkage, so as to control the clamping force. The fabric feeding device (11) includes a fabric feeding chamber (11-5), and a moving cylinder (11-1), a material clamping mechanism (11-2), and a perforated plate slot (11-3) for carrying the perforated plate are respectively provided on both sides of the fabric feeding chamber (11-5). The moving cylinder (11-1) clamps and pushes the perforated plate slot (11-3) to move through the material clamping mechanism (11-2). The perforated plate slot (11-3) is placed on a smooth platform and moved. The material weighing system (11-4) is closely attached to the bottom of the smooth platform and cooperates with the perforated plate slot (11-3) to weigh the perforated plates before and after the material is laid. The fabric pack (11-5) is fixed in the middle of the smooth platform. After the perforated plate before fabric is weighed, the moving cylinder (11-1) on one side pushes the perforated plate slot (11-3) into the fabric pack (11-5). After the fabric is laid, the perforated plate is pushed out of the fabric chamber (11-5) by the moving cylinder (11-1) on the other side, and then weighed. The fabric compartment (11-5) is equipped with a microball feeding mechanism (11-7) on one side, and an observation door (11-6) is provided on the side wall of that side. The inner wall of the fabric compartment (11-5) is provided with a movable slide rail (11-9), and a flattening fabric mechanism (11-10) is mounted on the movable slide rail (11-9). A stepper motor (11-8) located outside the fabric compartment (11-5) drives the flattening fabric mechanism (11-10) to move on the movable slide rail (11-9). The bottom wall of the fabric compartment (11-5) is provided with a microsphere collection compartment (11-11), and the material perforated plate (11-13) is located above the microsphere collection compartment (11-11) and supported on the bottom wall by the perforated plate adjustment mechanism (11-12). The moving trajectory of the flat fabric distribution mechanism (11-10) is located above the material perforated plate (11-13).

2. The mass microsphere filling device for dense porous substrates according to claim 1, characterized in that, The fabric smoothing mechanism (11-10) is a sweeping device with fine fluff.

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