Automatic production carrier and loading method for new energy ceramic relay

Abstract

The invention discloses a new energy ceramic relay automatic production carrier and a loading method. The loading method comprises the following steps: S1, visual identification and positioning; s2, visual positioning of the ceramic relay; s3, calculating the positions and angles of the storage grids and the ceramic relays; s4, precise positioning and dynamic angle adjustment of the mechanical arm; s5, loading and calibrating the ceramic relay; and S6, electrical and mechanical connection testing after loading. Through high-precision visual identification and an automatic mechanical arm grabbing and loading system, participation of manual operation is reduced, and efficient and continuous loading operation can be achieved, so that the overall production efficiency is improved, and the downtime and the bottleneck of a production line are reduced; coordinates and rotation angles of the ceramic relays are detected in real time through the visual system, an error correction algorithm and secondary calibration are combined, it is ensured that each relay can be accurately aligned with the position and direction of a storage grid in the loading process, deviation occurring in the loading process is effectively reduced, and the loading precision is improved.

Description

Technical Field

[0001] The present invention relates to the field of new energy relay ceramics, and in particular to an automated production carrier and a loading method for new energy ceramic relays. Background Art

[0002] At present, manual operation and the use of traditional plastic baskets dominate the loading and handling of new energy ceramic relays. However, this method has many technical bottlenecks in practical applications, which not only limits production efficiency but also increases operational risks.

[0003] First, when manually carrying multiple ceramic relays, the plastic basket usually carries a large weight, which exceeds the comfortable load range of the human body. Long-term handling can easily lead to excessive fatigue of the operator, increasing the risk of work-related injuries. In addition, due to the lack of effective protection, the relays are easily damaged by collision, affecting product quality.

[0004] Secondly, due to the randomness of manual placement, the placement and quantity of products in the basket are inconsistent, which makes subsequent automated loading and robot operation difficult. Traditional automation systems rely on the standardization of product positions, and irregular placement prevents the robot from accurately picking and placing, hindering the design and application of automated production lines. Finally, plastic baskets are prone to deformation after long-term use, and their structures are unstable under high temperatures or heavy pressure, causing product position deviations and increasing the difficulty of loading and automation equipment. Summary of the invention

[0005] The purpose of the present invention is to provide an automated production carrier and a loading method for a new energy ceramic relay to solve the problems raised in the background technology.

[0006] To solve the above technical problems, the embodiments of the present invention provide the following solutions:

[0007] A loading method for automated production of new energy ceramic relays, comprising the following steps:

[0008] S1. Visual recognition and positioning: The carrier and relay are accurately positioned through high-resolution cameras and image processing technology. There are several fixed storage compartments arranged vertically and horizontally on the carrier. The arrangement information of the storage compartments is processed in real time through the visual recognition system to ensure accurate positioning of each storage compartment on the carrier.

[0009] S2: Visual positioning of ceramic relays: The image of each ceramic relay is acquired through a camera, and the center coordinates (x, y) and rotation angle θ of the ceramic relay are calculated and output using image processing technology;

[0010] S3. Calculation of the position and angle of the storage grid and the ceramic relay: by calculating the precise coordinates of the storage grid and combining the offset of the ceramic relay in the storage grid of the carrier, the precise coordinates of each ceramic relay are determined, and the rotation angle of the ceramic relay is detected in real time using the image processing system to ensure that the relay is completely aligned with the direction of the storage grid during loading;

[0011] S4, precise positioning and dynamic angle adjustment of the robotic arm: The robotic arm is precisely positioned according to the calculated current precise coordinates and rotation angle of the ceramic relay, and the robotic arm performs precise grasping and real-time angle adjustment of the ceramic relay;

[0012] S5. Ceramic relay loading and calibration: A secondary calibration is performed before loading, using a high-precision angle sensor to accurately check the angle of the ceramic relay and make fine adjustments when necessary to ensure its posture is accurate. Subsequently, the robotic arm accurately places the ceramic relay in the designated storage compartment of the carrier, ensuring that the horizontal, vertical coordinates and rotation angles meet the standards.

[0013] S6. Electrical and mechanical connection test after loading: After loading is completed, electrical and mechanical connection tests are automatically performed, using high-precision sensors and test equipment to ensure that each relay meets quality standards after loading and to detect its electrical performance and mechanical stability.

[0014] As a further solution of the present invention, in step S3, the specific method of calculating the position and angle of the storage grid and the ceramic relay is:

[0015] S31. Calculation of storage grid coordinates: Calculate the precise coordinates of each storage grid based on the arrangement rules of the storage grid of the carrier and the reference points provided by the visual system:

[0016] Set the center coordinates of the first storage cell to (x0, y0), and calculate the horizontal and vertical coordinates of each storage cell using the following formula: n =x0+n·dx,y m =y0+n·dy;

[0017] Where dx and dy are the distances between two adjacent cells in the horizontal and vertical directions, respectively, and n and m are the horizontal and vertical indexes of the cells, respectively;

[0018] S32, relay position calculation: Combine the coordinates of the storage grid and the offset of the relay to obtain the precise position coordinates (x c ,y c ), where x c =x n +Δx,y c =y n +Δy, Δx and Δy are the offsets of the center of the component relative to the center of the storage compartment.

[0019] S33, rotation angle calculation: Use the image processing system to calculate the rotation angle of the current ceramic relay in real time, determine the direction of the component relative to the storage grid, and ensure angle alignment during loading.

[0020] As a further solution of the present invention, in step S4, the specific method of precise positioning and dynamic angle adjustment of the robot arm is as follows:

[0021] S41, Robotic arm positioning: According to the center coordinates (x c ,y c ) and the rotation angle θ c , this information is passed to the robot control system, and the robot moves to the specified position;

[0022] S42. Grasping and angle adjustment: The robot arm accurately grasps the ceramic relay and adjusts the posture of the relay according to the detected rotation angle θ. It uses the real-time feedback from the sensor to perform dynamic angle adjustment to ensure that the angle of the relay remains accurate during the grasping and loading process.

[0023] An embodiment of the present invention also provides an automated production carrier for new energy ceramic relays, which is used to implement any of the loading methods described above, including a carrier body, a plurality of storage compartments are provided on the top of the carrier body, a plurality of positioning grooves are evenly distributed in the storage compartments, the sides of the storage compartments adopt a sunken arc design, and a load-bearing buckle seat is provided on the outside of the carrier body.

[0024] As a further solution of the present invention, the storage compartments are arranged vertically and horizontally on the carrier body to form a grid-like layout.

[0025] As a further solution of the present invention, the depth of the storage compartment is 1 / 2 of the height of the carrier body.

[0026] As a further solution of the present invention, the center axis offset accuracy of the storage compartment is 0-0.2mm.

[0027] Compared with the prior art, the beneficial effects of the present invention are:

[0028] 1. The loading method of the present invention reduces the involvement of manual operation through high-precision visual recognition and automated robotic arm grabbing loading system, and can achieve efficient and continuous loading operation, thereby improving overall production efficiency, reducing downtime and production line bottlenecks;

[0029] 2. The loading method of the present invention detects the coordinates and rotation angles of the ceramic relay in real time through a visual system, and combines an error correction algorithm and secondary calibration to ensure that each relay can accurately align the position and direction of the storage grid during the loading process, effectively reducing the deviation during the loading process and improving the loading accuracy;

[0030] 3. The loading method of the present invention adopts a fully automated operation process, including visual positioning of the relay, robotic arm grasping and dynamic adjustment, and automatic loading confirmation, which eliminates human operation errors and makes the loading process more stable and reliable, especially in mass production to ensure consistency.

[0031] 4. The side of the carrier storage compartment of the present invention adopts an ergonomically designed sunken arc, which is convenient for manual and robotic pick-up and placement, while enhancing the strength of the box, making it convenient to control the loading quantity and count. The design of the storage compartment realizes precise positioning of the product and supports the automated operation of the robot; the semi-leaking structure is convenient for robotic pick-up and placement and provides a positioning and fixing function, effectively preventing ceramics from colliding with each other. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 The present invention is a flow chart of the loading method for the automated production of new energy ceramic relays.

[0033] Figure 2 This is one of the structural schematic diagrams of the automatic production carrier of new energy ceramic relays of the present invention;

[0034] Figure 3 This is the second structural schematic diagram of the automatic production carrier of new energy ceramic relays of the present invention;

[0035] Figure 4 This is the third structural schematic diagram of the automatic production carrier of new energy ceramic relays of the present invention;

[0036] In the figure: 1. Carrier body; 2. Storage compartment; 3. Positioning groove; 4. Load-bearing buckle seat. DETAILED DESCRIPTION

[0037] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0038] Example 1

[0039] refer to Figure 1 , a loading method for automated production of new energy ceramic relays, comprising the following steps:

[0040] S1. Visual recognition and positioning: Through high-resolution cameras and image processing technology, the carrier and relay are accurately positioned. There are several fixed storage compartments arranged vertically and horizontally on the carrier. The visual recognition system processes the arrangement information of the storage compartments in real time to ensure accurate positioning of each storage compartment on the carrier. Through high-resolution cameras and advanced image processing technology, high-precision positioning of relays and carriers can be achieved, reducing possible positioning errors in manual operation. The automated visual recognition system can quickly identify and process the arrangement information of the storage compartments, which is much faster than manual vision, thereby significantly improving the processing speed and throughput of the production line.

[0041] S2: Visual positioning of ceramic relays: The camera acquires the image of each ceramic relay, and uses image processing technology to calculate and output the center coordinates (x, y) and rotation angle θ of the ceramic relay. By acquiring the image of each ceramic relay and calculating its center coordinates and rotation angle, it ensures that the subsequent robot arm can accurately grasp and place it, reducing production defects caused by incorrect position or angle.

[0042] S3. Calculation of the position and angle of the storage grid and the ceramic relay: By calculating the precise coordinates of the storage grid and combining the offset of the ceramic relay in the storage grid of the carrier, the current precise coordinates of each ceramic relay are determined, and the rotation angle of the ceramic relay is detected in real time using the image processing system to ensure that the relay is completely aligned with the direction of the storage grid during loading. The specific method is as follows:

[0043] S31. Calculation of storage grid coordinates: Calculate the precise coordinates of each storage grid based on the arrangement rules of the storage grid of the carrier and the reference points provided by the visual system:

[0044] Set the center coordinates of the first storage cell to (x0, y0), and calculate the horizontal and vertical coordinates of each storage cell using the following formula: n =x0+n·dx,y m =y0+n·dy;

[0045] Where dx and dy are the distances between two adjacent cells in the horizontal and vertical directions, respectively, and n and m are the horizontal and vertical indexes of the cells, respectively;

[0046] S32, relay position calculation: Combine the coordinates of the storage grid and the offset of the relay to obtain the precise position coordinates (x c ,y c ), where x c =x n +Δx,y c =y n +Δy, Δx and Δy are the offsets of the center of the component relative to the center of the storage compartment.

[0047] S33, rotation angle calculation: Use the image processing system to calculate the current rotation angle θ of the ceramic relay in real time c , determine the orientation of the component relative to the storage compartment to ensure angle alignment during loading.

[0048] By accurately calculating the position and angle of the relay and the storage grid, each relay can be correctly aligned and loaded, reducing physical interference and potential damage; automatic calculation and correction reduce the steps requiring manual intervention, reducing production costs and time.

[0049] S4. Precise positioning and dynamic angle adjustment of the robotic arm: The robotic arm is precisely positioned according to the calculated current precise coordinates and rotation angle of the ceramic relay. The robotic arm performs precise grasping and real-time angle adjustment of the ceramic relay. The specific method is as follows:

[0050] S41, Robotic arm positioning: According to the center coordinates (x c ,y c ) and the rotation angle θ c , this information is passed to the robot control system, and the robot moves to the specified position;

[0051] S42. Grasping and angle adjustment: The robot arm accurately grasps the ceramic relay and adjusts the posture of the relay according to the detected rotation angle θ. It uses the real-time feedback from the sensor to perform dynamic angle adjustment to ensure that the angle of the relay remains accurate during the grasping and loading process.

[0052] The robotic arm accurately grasps and adjusts the angle of the relay based on real-time data, and uses sensor feedback for dynamic adjustment to ensure high precision and low error rate in the grasping process; the robotic arm can be flexibly adjusted to the optimal position and angle to reduce production problems caused by position deviation.

[0053] S5. Ceramic relay loading and calibration: A secondary calibration is performed before loading, using a high-precision angle sensor to accurately check the angle of the ceramic relay, and fine-tuning is performed when necessary to ensure that its posture is accurate. Subsequently, the robotic arm accurately places the ceramic relay in the designated storage compartment of the carrier, ensuring that the horizontal, vertical coordinates and rotation angles meet the standards. High-precision angle sensor verification improves the quality and consistency of the final product; accurate loading reduces the defect rate of the finished product, saves costs and improves customer satisfaction.

[0054] S6. Electrical and mechanical connection test after loading: After loading is completed, electrical and mechanical connection test is automatically performed, using high-precision sensors and test equipment to ensure that each relay meets quality standards after loading, and to detect its electrical performance and mechanical stability. By using high-precision sensors and test equipment, it is ensured that the electrical performance and mechanical stability of each relay after loading meet strict quality standards; possible defects and problems are detected early to reduce the possibility of faulty products on the market.

[0055] Example 2

[0056] refer to Figure 2-4 A new energy ceramic relay automated production carrier, used to implement the loading method described in the above embodiment 1, includes a carrier body 1, a plurality of storage compartments 2 are provided on the top of the carrier body 1, a plurality of positioning slots 3 are evenly distributed in the storage compartments 2, the side surfaces of the storage compartments 2 adopt a sunken arc design, and a load-bearing buckle 5 is provided on the outer side of the carrier body 1.

[0057] Specifically, the storage compartments 2 are arranged vertically and horizontally on the carrier body 1 to form a grid-like layout. The grid-like layout formed by the vertical and horizontal arrangement can maximize the space utilization of the carrier body. This layout enables a single carrier to place more relays at the same time, simplifies the material handling process, reduces production time and cost, and thus improves production efficiency.

[0058] Specifically, the depth of the storage compartment is 1 / 2 of the height of the carrier body. Each storage compartment is equipped with multiple positioning slots, which can accurately fix each relay in the correct position and posture. This is particularly important for the automated assembly and welding of relays, which can reduce assembly errors, improve product consistency and quality, and reduce the defective rate caused by position deviation.

[0059] Specifically, the center axis offset accuracy of the storage compartment is 0-0.2mm. It can effectively protect the relay from external impact and facilitate the operation of the upper automation equipment. The center axis offset accuracy is controlled within 0-0.2mm, ensuring extremely high component positioning accuracy. This high-precision configuration ensures the correct assembly of the relay in the automated production process, reduces production defects caused by misalignment, and improves the reliability and repeatability of the production process.

[0060] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A loading method for automated production of new energy ceramic relays, characterized in that: The following steps are involved: S1. Visual recognition and positioning: The carrier and relay are accurately positioned through high-resolution cameras and image processing technology. There are several fixed storage compartments arranged vertically and horizontally on the carrier. The arrangement information of the storage compartments is processed in real time through the visual recognition system to ensure accurate positioning of each storage compartment on the carrier. S2: Visual positioning of ceramic relays: The image of each ceramic relay is acquired through a camera, and the center coordinates (x, y) and rotation angle θ of the ceramic relay are calculated and output using image processing technology; S3. Calculation of the position and angle of the storage grid and the ceramic relay: by calculating the precise coordinates of the storage grid and combining the offset of the ceramic relay in the storage grid of the carrier, the precise coordinates of each ceramic relay are determined, and the rotation angle of the ceramic relay is detected in real time using the image processing system to ensure that the relay is completely aligned with the direction of the storage grid during loading; S4, precise positioning and dynamic angle adjustment of the robotic arm: The robotic arm is precisely positioned according to the calculated current precise coordinates and rotation angle of the ceramic relay, and the robotic arm performs precise grasping and real-time angle adjustment of the ceramic relay; S5. Ceramic relay loading and calibration: A secondary calibration is performed before loading, using a high-precision angle sensor to accurately check the angle of the ceramic relay and make fine adjustments when necessary to ensure its posture is accurate. Subsequently, the robotic arm accurately places the ceramic relay in the designated storage compartment of the carrier, ensuring that the horizontal, vertical coordinates and rotation angles meet the standards.

2. A loading method for automated production of new energy ceramic relays according to claim 1, characterized in that: Also includes S6, electrical and mechanical connection test after loading: After loading is completed, electrical and mechanical connection tests are automatically performed, using high-precision sensors and test equipment to ensure that each relay meets quality standards after loading and detect its electrical performance and mechanical stability.

3. A loading method for automated production of new energy ceramic relays according to claim 1, characterized in that: In step S3, the specific method of calculating the position and angle of the storage compartment and the ceramic relay is: S31. Calculation of storage grid coordinates: Calculate the precise coordinates of each storage grid based on the arrangement rules of the storage grid of the carrier and the reference points provided by the visual system: Set the center coordinates of the first storage cell to (x0, y0), and calculate the horizontal and vertical coordinates of each storage cell using the following formula: n =x0+n·dx,y m =y0+n·dy; Where dx and dy are the distances between two adjacent cells in the horizontal and vertical directions, respectively, and n and m are the horizontal and vertical indexes of the cells, respectively; S32, relay position calculation: Combine the coordinates of the storage grid and the offset of the relay to obtain the precise position coordinates (x c ,y c ), where x c =x n +Δx,y c =y n +Δy, Δx and Δy are the offsets of the center of the component relative to the center of the storage compartment. S33, rotation angle calculation: Use the image processing system to calculate the current rotation angle θ of the ceramic relay in real time c , determine the orientation of the component relative to the storage compartment to ensure angle alignment during loading.

4. A loading method for automated production of new energy ceramic relays according to claim 1, characterized in that: In step S4, the specific method of precise positioning and dynamic angle adjustment of the robot arm is as follows: S41, Robotic arm positioning: According to the center coordinates (x c ,y c ) and the rotation angle θ c , this information is passed to the robot control system, and the robot moves to the specified position; S42. Grasping and angle adjustment: The robot arm accurately grasps the ceramic relay and adjusts the posture of the relay according to the detected rotation angle θ. It uses the real-time feedback from the sensor to perform dynamic angle adjustment to ensure that the angle of the relay remains accurate during the grasping and loading process.

5. An automated production carrier for new energy ceramic relays, used to implement the loading method described in any one of claims 1 to 4 above, characterized in that: The invention comprises a carrier body (1), a plurality of storage compartments (2) are provided on the top of the carrier body (1), a plurality of positioning partitions (3) are evenly distributed in the storage compartments (2), the sides of the storage compartments (2) adopt a sunken arc design, and a load-bearing buckle seat (4) is provided on the outside of the carrier body (1).

6. The automatic production vehicle for new energy ceramic relays according to claim 5 is characterized in that: The storage compartments (2) are arranged vertically and horizontally on the carrier body (1) to form a grid-like layout.

7. The automatic production vehicle for new energy ceramic relays according to claim 5 is characterized in that: The depth of the storage compartment (2) is 1 / 2 of the height of the carrier body (1).

8. The automatic production carrier and loading method of a new energy ceramic relay according to claim 5, characterized in that: The center axis deviation accuracy of the storage compartment (2) is 0-0.2 mm.

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