Automatic production line of electrochemical gas sensor

Abstract

The invention belongs to the technical field of sensor assembly, and particularly relates to an automatic production line of an electrochemical gas sensor. Comprising a lower shell feeding work station, an electrolyte injection work station, a counter electrode and reference electrode assembling work station, an isolating membrane assembling work station, a working electrode assembling work station, an upper shell assembling work station, a laser coding and discharging work station and a backflow speed chain work station. According to the automatic production line for the electrochemical gas sensor, the lower shell feeding station, the electrolyte injection station, the counter electrode and reference electrode assembling station, the isolating membrane assembling station, the working electrode assembling station, the upper shell assembling station, the laser coding and discharging station and the backflow speed-multiplying chain station are arranged; the automatic production of the electrochemical gas sensor can be realized, the production efficiency is greatly improved, and the consistency of products is greatly improved.

Description

Technical Field

[0001] The invention belongs to the technical field of sensor assembly, and in particular relates to an automatic production line for electrochemical gas sensors. Background Art

[0002] Electrochemical gas sensors have been widely used in many fields due to their high sensitivity and selectivity. With the development of science and technology, the application of electrochemical gas sensors is also developing in the direction of miniaturization, integration, modularization and intelligence. Electrochemical gas sensors include upper shell, lower shell, working electrode, counter electrode, reference electrode, isolation membrane, wire and electrolyte. The production process of electrochemical gas sensors includes internal assembly, liquid injection and packaging. There are many parts in the internal assembly process and the process is complicated. The working electrode, counter electrode, reference electrode and isolation membrane are all thin films. The nesting requirements between layers are very precise. At present, the assembly between layers is mainly manual. The liquid injection and packaging process can be assisted by equipment. For example, the packaging of the upper shell and the lower shell is mostly ultrasonic welding process or interference hard pressing process, and packaging equipment such as ultrasonic welding machine can be used. At present, the assembly of electrochemical gas sensors is mainly manual, supplemented by packaging equipment, which has problems such as low production efficiency, poor product consistency and difficulty in large-scale automated production.

[0003] Patent CN102769143B and Patent CN110061253B both disclose automated production lines for batteries, including internal assembly, liquid injection and packaging functions. The assembly process of electrochemical gas sensors is similar to that of button-type lithium manganese batteries, but not exactly the same. The essential difference is that button-type lithium manganese batteries are a closed liquid-solid closed system in which a solid encapsulates an electrolyte, which can be tightly compacted and packaged; while electrochemical gas sensors are non-closed gas-liquid-solid open systems that must allow sample gas to enter and exit. If the package is too compacted, the expansion of the electrolyte caused by gas and high temperature and humidity will cause leakage and other problems that cause the sensor to fail to work; if the package is not too compacted, the pervasive airflow will cause problems such as poor contact of the electrode circuit and electromagnetic interference. The assembly process of button-type lithium manganese batteries only realizes the process of stacking layers, and cannot realize the process of embedding the electrode PIN pin between the electrode layers. Moreover, the assembly process of electrochemical gas sensors requires more precise alignment of each component. The automated production line of button-type lithium manganese batteries is not suitable for the automated assembly of electrochemical gas sensors. Therefore, there is currently a lack of technology that can realize the automated production of electrochemical gas sensors. Summary of the invention

[0004] In view of the problems existing in the above-mentioned prior art, the present invention provides an automated production line for electrochemical gas sensors, and specifically discloses the following technical solutions:

[0005] An electrochemical gas sensor automated production line, comprising a lower shell loading station, an electrolyte injection station, a counter electrode reference electrode assembly station, an isolation membrane assembly station, a working electrode assembly station, an upper shell assembly station, a laser coding unloading station and a reflux double-speed chain station, wherein the lower shell loading station, the electrolyte injection station, the counter electrode reference electrode assembly station, the isolation membrane assembly station, the working electrode assembly station, the upper shell assembly station and the laser coding unloading station are sequentially arranged on one side of the reflux double-speed chain station, the lower shell loading station is used to realize automatic loading of the sensor lower shell and to shape the PIN pin on the sensor lower shell; the electrolyte injection station is used to add a predetermined amount of electrolyte into the sensor lower shell; the counter electrode reference electrode assembly station, the isolation membrane assembly station, the working electrode assembly station, the upper shell assembly station and the laser coding unloading station are sequentially arranged on one side of the reflux double-speed chain station, the lower shell loading station is used to realize automatic loading of the sensor lower shell and to shape the PIN pin on the sensor lower shell; the electrolyte injection station is used to add a predetermined amount of electrolyte into the sensor lower shell; the counter electrode reference electrode assembly station, the isolation membrane assembly station, the working electrode assembly station, the upper shell assembly station and the laser coding unloading station are sequentially arranged on the one side of the reflux double-speed chain station The electrode assembly station is used to realize automatic loading, cutting and installation of the sensor counter electrode and reference electrode into the lower shell of the sensor, and to realize the bending of the PIN pin of the sensor counter electrode and reference electrode; the isolation membrane assembly station is used to realize automatic loading, cutting and installation of the sensor isolation membrane into the lower shell of the sensor, and to realize the bending of the PIN pin of the sensor working electrode; the working electrode assembly station is used to realize automatic loading, cutting and installation of the sensor working electrode into the upper shell of the sensor; the upper shell assembly station is used to realize automatic loading of the sensor upper shell and press-fit sealing of the upper and lower shells of the sensor; the laser coding unloading station is used to realize sensor number printing and finished product offline; the reflux speed chain station is used for the transportation of materials to realize the series connection of all stations.

[0006] Furthermore, the lower shell loading station includes a lower shell loading mechanism, a lower shell shaping mechanism, a material picking robot I, a CCD module I and a flipping mechanism I, the lower shell loading mechanism includes a lower shell feeding area, a lower shell picking area and an empty pallet receiving area; the lower shell feeding area includes a first conveyor belt and a lower shell support placed on the first conveyor belt, the lower shell support is placed with a number of lower shell pallets filled with lower shells, L-shaped guide columns I are arranged around the lower shell pallets, a first pallet lifting mechanism is arranged at the bottom of the first conveyor belt, and it is lifted and lowered along the L-shaped guide columns I, and at the same time, a first pallet dividing mechanism is arranged at the edge of the L-shaped guide columns I, and the pallet filled with lower shells is divided; the lower shell picking area includes a second conveyor belt and a first material picking positioning mechanism, which is used to operate and position the lower shell pallet; the empty pallet receiving area includes a third conveyor belt and an empty pallet of the lower shell placed on the third conveyor belt, L-shaped guide columns II are arranged around the empty pallet of the lower shell, a second pallet lifting mechanism is arranged at the bottom of the third conveyor belt, and it is lifted and lowered along the L-shaped guide columns II; The L-shaped guide column II is arranged with an empty pallet stacking hanging plate tongue, which is used to hang the pallet after stacking; the first conveyor belt and the second conveyor belt cooperate to convey the lower shell pallet to the lower shell picking area, and the second conveyor belt and the third conveyor belt cooperate to convey the lower shell empty pallet to the empty pallet receiving area; the picking robot I includes a four-axis manipulator I and a lower shell picking clamp, which is used to take the sensor lower shell from the lower shell picking area and place it on the jig pallet handling assembly. The picking and placing process is visually corrected by the camera visual detection assembly. The CCD module I is used to perform appearance inspection and defect inspection on the sensor lower shell. When a defective product is detected, the picking robot I transfers the shell to the defective product area. The flipping clamp in the flipping mechanism I is driven by a driving cylinder and clamps the sensor lower shell, and is driven by a servo motor to flip the shell in the loading tray 180° to adjust the posture of the sensor lower shell; the lower shell shaping mechanism includes a shaping positioning fixture, which is used for positioning when trimming the lower shell, and shaping the PIN feet on the sensor lower shell by a shaping cylinder.

[0007] Furthermore, the electrolyte injection station includes an XYZ cantilever module, an injection mechanism, and a CCD module II. The injection mechanism is installed at the output end of the XYZ cantilever module, and the XYZ cantilever module is used to drive the injection mechanism to move above the fixture tray; the injection mechanism includes an intake and discharge pipe, which is used to absorb electrolyte and quantitatively inject it into the sensor lower shell of the fixture tray. The suction or discharge of the electrolyte in the intake and discharge pipe is controlled by a linear slide rail and an injection valve; the CCD module II is used to confirm the relative position of the intake and discharge pipe and the sensor lower shell during the injection process and perform visual correction.

[0008] Furthermore, the electrode reference electrode assembly station includes an electrode reference electrode loading mechanism, a picking robot II, an electrode reference electrode cutting component, a picking robot III, and a CCD module III. The electrode reference electrode loading mechanism has the same structure as the lower shell loading mechanism and is used to load the sensor electrode reference electrode plate by plate to the electrode reference electrode picking area. The picking robot II includes a four-axis manipulator II, a CCD visual guidance device I, and an electrode reference electrode suction nozzle component, which is used to transfer the electrode reference electrode from the electrode reference electrode picking area to the electrode reference electrode picking area. Move to the counter electrode reference electrode cutting station, the counter electrode reference electrode cutting assembly includes a laser cutting machine, which is used to cut the counter electrode reference electrode into the required size of the sensor, the laser cutting machine is connected to the base through a Z-axis module, and the height of the laser cutting machine is adjusted by the Z-axis module; a disc mechanism is arranged under the laser cutting machine, and the disc mechanism is connected to the base through a hollow rotating platform I. The disc mechanism is used to replace the counter electrode reference electrode after cutting, so that the material picking robot II can place the uncut counter electrode reference electrode, and the material picking robot III can move the cut counter electrode reference electrode. The counter electrode reference electrode after trimming, the processed micropores on the working surface of the disc mechanism are used to adsorb the counter electrode reference electrode before trimming and the single counter electrode reference electrode after trimming, the material picking robot III includes a four-axis manipulator III and a counter electrode reference electrode single suction nozzle assembly installed at the operating end of the four-axis manipulator III, which is used to absorb the trimmed counter electrode reference electrode and install it into the sensor lower shell of the fixture tray, and the operating end of the four-axis manipulator III is equipped with a counter electrode reference electrode PIN foot bending mechanism through a lifting cylinder, which is used to bend the sensor lower shell in the fixture tray The PIN pin of the counter electrode reference electrode corresponding to the body is bent so that the PIN pin of the counter electrode reference electrode is pressed above the counter electrode reference electrode. The operating end of the four-axis manipulator III is also equipped with a CCD visual guidance device II, which is used for visual correction and positioning during assembly of the counter electrode reference electrode and completes post-assembly inspection at the same time. When defective products are detected, the material picking robot III transfers the lower shell of the sensor on the fixture tray to the defective product area. The CCD module III is used to provide visual guidance and positioning for the material picking robot II and the counter electrode reference electrode loading mechanism when picking up materials.

[0009] Furthermore, the isolation film assembly station includes an isolation film feeding mechanism, a picking robot IV, an isolation film cutting component, a picking robot V, and a CCD module IV. The isolation film feeding mechanism includes a rotating component, and the rotating component includes a hollow rotating platform II. The hollow rotating platform II is connected to the base. An isolation film clip is installed on the hollow rotating platform II. A sensor isolation film is placed inside the isolation film clip. A lifting module is arranged below the isolation film clip. The lifting module is used to push the sensor isolation film upward to the picking height. A double-sided separation air knife is arranged on the top of the isolation film clip to layer the sensor isolation film. The picking robot IV has the same structure as the picking robot II. The picking robot IV is used to take out the sensor isolation film from the isolation film feeding mechanism and place it on the isolation film. The membrane cutting station, the isolation membrane cutting component has the same structure as the counter electrode reference electrode cutting component, and is used to cut the isolation membrane into the required size of the sensor. The material picking robot V has the same structure as the material picking robot III, and is used to install the cut isolation membrane into the sensor lower shell in the jig tray, so that the isolation membrane is placed in the sensor lower shell and pressed above the counter electrode reference electrode PIN pin; the material picking robot V is used to bend the working electrode PIN pin so that the working electrode PIN needle is pressed above the isolation membrane. The CCD module IV is used for correcting the positioning during the isolation membrane assembly and for inspection after assembly. When a defective product is detected, the material picking robot V transfers the sensor lower shell on the jig tray to the defective product area.

[0010] Furthermore, the working electrode assembly station includes a working electrode loading mechanism, a picking robot VI, a working electrode cutting component, a picking robot VII and a CCD module V. The working electrode loading mechanism has the same structure as the lower shell loading mechanism and is used to load the sensor working electrode one by one to the working electrode picking area. The picking robot VI has the same structure as the picking robot II and is used to place the working electrode in the working electrode cutting station. The working electrode cutting component has the same structure as the counter electrode and reference electrode cutting component and is used to cut the working electrode to the required size of the sensor. The picking robot VII has the same structure as the picking robot III and is used to transfer the cut working electrode to the upper shell of the sensor on the working electrode mounting fixture. The CCD module V is used to provide visual guidance and positioning for the picking robot VI when picking materials from the working electrode loading mechanism.

[0011] Furthermore, the upper shell assembly station includes an upper shell feeding mechanism, a picking robot VIII, and a flipping mechanism II. The upper shell feeding mechanism includes a flexible vibration plate and an upper shell feeding bin, which is used to evenly arrange the scattered sensor upper shells for the picking robot VIII to grab. The picking robot VIII includes a four-axis manipulator IV and an upper shell picking claw, which is used to take the sensor upper shell from the upper shell feeding mechanism and place it on the flipping mechanism II. The picking robot VII installs the sensor working electrode into the sensor upper shell. The flipping mechanism II flips the sensor upper shell 180°. The pressing mechanism arranged at the end of the picking robot VII installs the flipped sensor upper shell onto the sensor lower shell. The pressing mechanism includes a pressing cylinder, which is used to press the sensor upper shell and the sensor lower shell into a whole. The pressing mechanism is equipped with a pressure sensor and a pressing detection displacement sensor, which is used to detect whether the upper and lower shells are pressed in place while preventing excessive pressure from damaging the shells.

[0012] Furthermore, the laser coding unloading station includes a laser coding device, a picking robot IX, and a finished product unloading mechanism. The laser coding device is used to laser mark the sensor after the upper and lower shells are packaged and assign a product number. The picking robot IX has the same structure as the picking robot I, and is used to transfer the sensor after the upper and lower shells are pressed together to the finished product unloading mechanism. The finished product unloading mechanism has the same structure as the lower shell loading mechanism, and is used to transfer the assembled finished product off the line.

[0013] Furthermore, the reflow speed chain workstation includes a jig pallet transport assembly, a pallet lifting cylinder and a pallet belt line. The jig pallet transport assembly is arranged at both ends of the pallet belt line and is used for transporting and changing lines after the jig pallet flows back and forth to the terminal to form a closed loop operation. The pallet lifting cylinder is used for positioning the jig pallet at each workstation to facilitate product assembly by the robot.

[0014] Compared with the prior art, the present invention has the following beneficial effects:

[0015] An electrochemical gas sensor automated production line in the present invention can realize automated production of electrochemical gas sensors by setting a lower shell loading station, an electrolyte injection station, a counter electrode reference electrode assembly station, an isolation membrane assembly station, a working electrode assembly station, an upper shell assembly station, a laser coding unloading station and a reflux speed chain station, thereby greatly improving production efficiency and product consistency. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0017] Figure 2 for Figure 1 A partial enlarged view of the middle A;

[0018] Figure 3 for Figure 1 A partial enlarged view of point B in the middle;

[0019] Figure 4 for Figure 1 A partial enlarged view of point C in the middle;

[0020] Figure 5 for Figure 1 A partial enlarged view of point D in the middle;

[0021] Figure 6 for Figure 1 Structural diagram of the middle and lower shell loading station;

[0022] Figure 7 for Figure 6 Schematic diagram of the partial structure of the middle and lower shell loading station;

[0023] Figure 8 for Figure 1 Structural schematic diagram of the feeding mechanism of the middle and lower shells;

[0024] Fig. 9 for Figure 1 The structural diagram of the electrolyte injection station;

[0025] Fig.10 for Fig. 9 Schematic diagram of the partial structure of the electrolyte injection station;

[0026] Fig.11 for Figure 1 Schematic diagram of the structure of the counter electrode and reference electrode assembly station;

[0027] Fig.12 for Fig.11 A partial enlarged view of point E in the middle;

[0028] Fig.13 for Fig.11 A partial enlarged view of the F in the middle;

[0029] Fig.14 for Figure 1 Structural diagram of the middle and upper shell assembly station;

[0030] Fig.15 for Fig.14 A partial enlarged view of the G in the middle;

[0031] Fig.16 for Figure 1 Schematic diagram of the structure of the middle isolation membrane feeding mechanism.

[0032] in:

[0033] Lower shell loading station-100, lower shell loading mechanism-110, lower shell feeding area-111, first conveyor belt-111a, lower shell bracket-111b, lower shell tray-111c, L-shaped guide column I-111d, first tray lifting mechanism-111e, first tray separation mechanism-111f, lower shell material collection area-112, second conveyor belt-112a, first material collection positioning mechanism-112b, empty tray collection area-113, third conveyor belt-113a, lower shell empty tray -113b, L-shaped guide column II-113c, second pallet lifting mechanism-113d, empty pallet stacking hanging tongue-113e, lower shell shaping mechanism-120, shaping positioning fixture-121, shaping cylinder-122, material picking robot I-130, four-axis manipulator I-131, lower shell material picking claw-132, camera visual detection component-133, CCD module I-140, flip mechanism I-150, servo motor-151, flip claw-152, drive cylinder-153;

[0034] Electrolyte injection station-200, XYZ cantilever module-210, injection mechanism-220, suction and discharge pipeline-221, linear slide rail-222, injection valve-223, CCD module II-230;

[0035] Counter electrode reference electrode assembly station-300, counter electrode reference electrode feeding mechanism-310, material picking robot II-320, four-axis manipulator II-321, CCD visual guidance device I-322, counter electrode reference electrode nozzle assembly-323, counter electrode reference electrode cutting assembly-330, laser cutting machine-331, Z-axis module-332, disc mechanism-334, hollow rotating platform I-335, material picking robot III-340, four-axis manipulator III-341, counter electrode reference electrode single nozzle assembly-342, CCD visual guidance device II-343, counter electrode reference electrode PIN foot bending mechanism-344, lifting cylinder-345, CCD module III-350;

[0036] Isolation film assembly station-400, isolation film feeding mechanism-410, rotating assembly-411, hollow rotating platform II-411a, isolation film clip-411b, lifting module-412, double-sided separation air knife-413, material picking robot IV-420, isolation film cutting assembly-430, material picking robot V-440, CCD module IV-450;

[0037] Working electrode assembly station-500, working electrode loading mechanism-510, material picking robot VI-520, working electrode cutting assembly-530, material picking robot VII-540, CCD module V-550;

[0038] Upper shell assembly station-600, upper shell feeding mechanism-610, flexible vibration plate-611, upper shell feeding bin-612, material picking robot VIII-620, pressing mechanism-621, pressing cylinder-621a, pressure sensor-621b, pressing detection displacement sensor-621c, four-axis manipulator IV-622, upper shell picking claw-623, flipping mechanism II-630;

[0039] Laser coding unloading station-700, laser coding equipment-710, material picking robot Ⅸ-720, finished product unloading mechanism-730;

[0040] Reflow double-speed chain station-800, jig pallet handling assembly-810, pallet lifting cylinder-820, pallet belt line-830. DETAILED DESCRIPTION

[0041] 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.

[0042] Reference Figure 1-16, an electrochemical gas sensor automated production line, comprising a lower shell loading station 100, an electrolyte injection station 200, a counter electrode reference electrode assembly station 300, an isolation membrane assembly station 400, a working electrode assembly station 500, an upper shell assembly station 600, a laser coding blanking station 700 and a reflux double-speed chain station 800, wherein the lower shell loading station 100, the electrolyte injection station 200, the counter electrode reference electrode assembly station 300, the isolation membrane assembly station 400, the working electrode assembly station 500, the upper shell assembly station 600 and the laser coding blanking station 700 are sequentially arranged on one side of the reflux double-speed chain station 800, the lower shell loading station 100 is used to realize automatic loading of the sensor lower shell and to shape the PIN pin on the sensor lower shell; the electrolyte injection station 200 is used to inject liquid into the sensor A predetermined amount of electrolyte is added into the lower shell; the counter electrode reference electrode assembly station 300 is used to realize automatic loading, cutting and installation of the counter electrode reference electrode of the sensor into the lower shell of the sensor, and realize the bending of the PIN foot of the counter electrode reference electrode of the sensor; the isolation membrane assembly station 400 is used to realize automatic loading, cutting and installation of the isolation membrane of the sensor into the lower shell of the sensor, and realize the bending of the PIN foot of the working electrode of the sensor; the working electrode assembly station 500 is used to realize automatic loading, cutting and installation of the working electrode of the sensor into the upper shell of the sensor; the upper shell assembly station 600 is used to realize automatic loading of the upper shell of the sensor and press-fit sealing of the upper and lower shells of the sensor; the laser coding unloading station 700 is used to realize sensor number printing and finished product offline; the reflux speed chain station 800 is used for the transportation of materials to realize the series connection of all stations.

[0043] In this embodiment, the lower shell loading station 100 includes a lower shell loading mechanism 110, a lower shell shaping mechanism 120, a material picking robot I 130, a CCD module I 140 and a flipping mechanism I 150, the lower shell loading mechanism 110 includes a lower shell feeding area 111, a lower shell picking area 112 and an empty tray receiving area 113; the lower shell feeding area 111 includes a first conveyor belt 111a and a lower shell support seat 111b placed on the first conveyor belt, the lower shell support seat 111b is placed with a plurality of lower shell trays 111c filled with lower shells, and L-shaped guide columns 111d are arranged around the lower shell tray 111c, and the first A first pallet lifting mechanism 111e is provided at the bottom of the conveyor belt 111a, which is lifted and lowered along the L-shaped guide column 111d. At the same time, a first pallet separating mechanism 111f is arranged at the edge of the L-shaped guide column 111d to separate the pallets filled with the lower shell; the lower shell material taking area 112 includes a second conveyor belt 112a and a first material taking positioning mechanism 112b, which are used to operate and position the lower shell pallet; the empty pallet receiving area 113 includes a third conveyor belt 113a and an empty pallet 113b of the lower shell placed on the third conveyor belt, L-shaped guide columns 113c are arranged around the empty pallet of the lower shell, and a second pallet lifting mechanism is provided at the bottom of the third conveyor belt 113a 113d, lifts and lowers along the L-shaped guide column 113c; the L-shaped guide column 113c is arranged with an empty pallet stacking hanging plate tongue 113e, which is used to hang the pallet after stacking; the first conveyor belt 111a and the second conveyor belt 112a cooperate to convey the lower shell pallet to the lower shell picking area 112, and the second conveyor belt 112a and the third conveyor belt 113a cooperate to convey the lower shell empty pallet to the empty pallet receiving area 113; the picking robot Ⅰ130 includes a four-axis manipulator Ⅰ131 and a lower shell picking claw 132, which are used to take the sensor lower shell out of the lower shell picking area 112 and place it on the jig pallet handling assembly 810, and the picking and placing process is carried out by The camera visual detection component 133 performs visual correction, the CCD module Ⅰ140 is used to perform appearance inspection and defect detection on the lower shell of the sensor. When a defective product is detected, the material picking robot Ⅰ140 transfers the shell to the defective product area. The flipping claw 152 in the flipping mechanism Ⅰ150 is driven by the driving cylinder 153 and clamps the lower shell of the sensor, and is driven by the servo motor 151 to flip the shell in the loading tray 180° to adjust the posture of the lower shell of the sensor; the lower shell shaping mechanism 120 includes a shaping positioning fixture 121, which is used for positioning when trimming the lower shell, and the PIN feet on the lower shell of the sensor are shaped by the shaping cylinder 122.

[0044] The lower shell includes a shell and an electrode PIN pin, wherein the electrode PIN pin is a filamentary metal material, and the electrode PIN pin and the shell are formed at one time during injection molding. During the molding and material transfer process, the filamentary PIN pin is prone to deformation, resulting in inaccurate alignment in subsequent assembly. The main function of the lower shell loading station is to load the lower shell to the assembly station. In order to solve the problem of PIN pin deformation, the present invention provides a lower shell shaping mechanism at the lower shell loading station to shape the electrode PIN pin, and the electrode PIN pin after shaping is required to be perpendicular to the lower shell. In order to prevent the filamentary PIN pin from breaking during the shaping process, the lower shell needs to be positioned first, and shaping cylinders are provided on both sides of the PIN pin. The shaping cylinders on both sides clamp the electrode PIN pin synchronously upward or downward, so that the PIN pin is perpendicular to the lower shell.

[0045] In this embodiment, the electrolyte injection station 200 includes an XYZ cantilever module 210, an injection mechanism 220, and a CCD module II 230. The injection mechanism is installed at the output end of the XYZ cantilever module. The XYZ cantilever module 210 is used to drive the injection mechanism to move above the fixture tray; the injection mechanism 220 includes an intake and discharge pipe 221, which is used to absorb electrolyte and quantitatively inject it into the sensor lower shell of the fixture tray. The intake or discharge of the electrolyte in the intake and discharge pipe 221 is controlled by a linear slide rail 222 and an injection valve 223; the CCD module II 230 is used to confirm the relative position of the intake and discharge pipe and the sensor lower shell during the injection process and perform visual correction.

[0046] The traditional electrochemical gas sensor is provided with a liquid filling hole. After the internal assembly of the sensor and the packaging of the upper and lower shells are completed, liquid is added through the liquid filling hole, and finally the liquid filling hole is blocked with a plug and sealed with glue. In order to simplify the liquid filling process of the electrochemical gas sensor, the electrochemical gas sensor of the present invention is filled with liquid before the upper and lower shells are packaged. The electrolyte of the electrochemical gas sensor is usually a corrosive inorganic acid solution, which needs to be quantitatively injected into the sensor shell, and it is particularly necessary to prevent excessive filling and dripping on the wire body. The cleanliness of the electrolyte has a great influence on the stability of the product. In the present invention, an electrolyte filling station is set up. In order to prevent the inorganic acid solution from corroding the suction pump for a long time, resulting in a short life, the injection mechanism uses a suction and discharge pipeline. The inorganic acid solution only reciprocates in the pipeline. The piston in the pipeline is fixed on the linear slide rail and driven by a servo motor to ensure its injection accuracy. It is controlled by the injection valve to reciprocate, which avoids the corrosion of the driving components by the inorganic acid solution and reduces the contamination of the solution caused by corrosion. To achieve the liquid adding action, the electrolyte injection station includes an XYZ cantilever module, an injection mechanism, and a CCD module II. The XYZ cantilever module is used to move the injection mechanism above the fixture tray; the injection mechanism is used to inject the electrolyte into the lower sensor housing of the fixture tray. In the present invention, the CCD module II is set to improve the position accuracy of the injection mechanism during injection, prevent over-filling, and prevent dripping on the wire body.

[0047] In this embodiment, the electrode reference electrode assembly station 300 includes an electrode reference electrode loading mechanism 310, a picking robot II 320, an electrode reference electrode cutting assembly 330, a picking robot III 340, and a CCD module III 350. The electrode reference electrode loading mechanism 310 has the same structure as the lower shell loading mechanism 110, and is used to load the sensor electrode reference electrode to the electrode reference electrode picking area one by one. The picking robot II 320 includes a four-axis manipulator II 321, a CCD visual guide device I 322, and an electrode reference electrode suction nozzle assembly 323. The operating end of the four-axis manipulator II 321 is equipped with a z-axis mechanism and a CCD visual guide device I 322. The z-axis mechanism is used to increase the four-axis machine The z-axis travel of the manipulator II 321, the electrode reference electrode suction nozzle assembly 323 is installed on the z-axis assembly, the electrode reference electrode suction nozzle assembly 323 is used to adsorb the electrode reference electrode and transfer the electrode reference electrode from the electrode reference electrode material collection area to the electrode reference electrode cutting station, the electrode reference electrode suction nozzle assembly 323 can be connected to the vacuum generator, the electrode reference electrode cutting assembly 330 includes a laser cutter 331, which is used to cut the electrode reference electrode into the required size of the sensor, the laser cutter 331 is connected to the base through the Z-axis module 332, and the height of the laser cutter 331 is adjusted through the Z-axis module 332; a disc mechanism 334 is arranged under the laser cutter 331, and the disc mechanism 334 is connected to the base through a hollow rotating platform I 335. The disc mechanism 334 is used for replacing the counter electrode reference electrode after trimming, so that the material picking robot II 320 can place the untrimmed counter electrode reference electrode. The material picking robot III 340 can remove the trimmed counter electrode reference electrode. The processed micropores on the working surface of the disc mechanism 334 are used to adsorb the counter electrode reference electrode before trimming and the single counter electrode reference electrode after trimming. The material picking robot III 340 includes a four-axis manipulator III 341 and a counter electrode reference electrode single suction nozzle assembly 342 installed at the operating end of the four-axis manipulator III 341, which is used to absorb and install the trimmed counter electrode reference electrode into the sensor lower shell of the fixture tray. The operation of the four-axis manipulator III 341 The end is equipped with a counter electrode reference electrode PIN foot bending mechanism 344 through a lifting cylinder 345, which is used to bend the PIN foot of the counter electrode reference electrode corresponding to the lower shell of the sensor in the fixture tray, so that the PIN foot of the counter electrode reference electrode is pressed above the counter electrode reference electrode. The operating end of the four-axis manipulator III 341 is also equipped with a CCD visual guidance device II 343, which is used for visual correction and positioning during assembly of the counter electrode reference electrode, and completes post-assembly inspection at the same time. When defective products are detected, the material picking robot III transfers the lower shell of the sensor on the fixture tray to the defective product area, and the CCD module III 350 is used to provide visual guidance and positioning for the material picking robot II 320 and the counter electrode reference electrode loading mechanism 310 when picking up materials.

[0048] In this embodiment, the isolation film assembly station 400 includes an isolation film feeding mechanism 410, a picking robot IV420, an isolation film cutting component 430, a picking robot V440, and a CCD module IV450. The isolation film feeding mechanism 410 includes a rotating component 411, and the rotating component 411 includes a hollow rotating platform II411a. The hollow rotating platform II411a is connected to the base, and an isolation film clip 411b is installed on the hollow rotating platform II411a. The sensor isolation film is placed inside the isolation film clip 411b. A lifting module 412 is arranged below the isolation film clip 411b. The lifting module 412 is used to push the sensor isolation film upward to the picking height. A double-sided separation air knife 413 is arranged on the top of the isolation film clip 411b for layering the sensor isolation film. The picking robot IV420 has the same structure as the picking robot II320. The picking robot IV42 0 is used to take out the sensor isolation membrane from the isolation membrane feeding mechanism 410 and place it in the isolation membrane cutting station. The isolation membrane cutting component 430 has the same structure as the counter electrode reference electrode cutting component 330 and is used to cut the isolation membrane into the required size of the sensor. The material picking robot V440 has the same structure as the material picking robot III340 and is used to install the cut isolation membrane into the sensor lower shell in the fixture tray, so that the isolation membrane is placed in the sensor lower shell and pressed above the counter electrode reference electrode PIN pin; the material picking robot V440 is used to bend the working electrode PIN pin so that the working electrode PIN needle is pressed above the isolation membrane. The CCD module IV450 is used for correcting the deviation and positioning during the isolation membrane assembly and completing the inspection after assembly. When a defective product is detected, the material picking robot V440 transfers the sensor lower shell on the fixture tray to the defective product area.

[0049] In this embodiment, the working electrode assembly station 500 includes a working electrode loading mechanism 510, a picking robot VI 520, a working electrode cutting assembly 530, a picking robot VII 540 and a CCD module V 550. The working electrode loading mechanism 510 has the same structure as the lower shell loading mechanism 110 and is used to load the sensor working electrode to the working electrode picking area one by one. The picking robot VI 520 has the same structure as the picking robot II 320 and is used to place the working electrode on the working electrode. The working electrode cutting station, the working electrode cutting component 530 has the same structure as the counter electrode reference electrode cutting component 330, and is used to cut the working electrode to the required size of the sensor, the material picking robot Ⅶ540 has the same structure as the material picking robot III340, and is used to transfer the cut working electrode to the sensor upper shell on the working electrode mounting fixture, and the CCD module V550 is used to provide visual guidance and positioning for the material picking robot Ⅵ520 when the working electrode loading mechanism 510 picks up materials.

[0050] In this embodiment, the upper shell assembly station 600 includes an upper shell feeding mechanism 610, a picking robot VIII 620, and a flipping mechanism II 630. The upper shell feeding mechanism 610 includes a flexible vibration plate 611 and an upper shell feeding bin 612, which are used to evenly arrange the scattered sensor upper shells for grabbing by the picking robot VIII 620. The picking robot VIII 620 includes a four-axis manipulator IV 622 and an upper shell picking claw 623, which are used to take the sensor upper shell out of the upper shell feeding mechanism 610 and place it on the flipping mechanism II 630, and the picking robot VII 620 installs the working electrode of the sensor into the upper shell of the sensor, and the flipping mechanism II 630 flips the upper shell of the sensor 180°. The pressing mechanism 621 arranged at the end of the material picking robot Ⅶ 620 installs the flipped upper shell of the sensor to the lower shell of the sensor. The pressing mechanism 621 includes a pressing cylinder 621a, which is used to press the upper shell of the sensor and the lower shell of the sensor into a whole. The pressing mechanism 621 is equipped with a pressure sensor 621b and a pressing detection displacement sensor 621c, which are used to detect whether the upper and lower shells are pressed in place while preventing excessive pressure from damaging the shells.

[0051] The upper and lower shells of traditional electrochemical gas sensors are sealed by sealants (such as rings, sealants, etc.), and the upper and lower shells are usually connected and fixed by ultrasonic welding and sealants to prevent leakage. In order to simplify the packaging process, the electrochemical gas sensor in the present invention uses the working electrode breathable membrane in the upper shell as a sealant, and the upper and lower shells are connected by snaps, and the structure is simpler. However, when using this process for sealing, the size of the breathable membrane and the installation position have a great influence on the sealing of the product. In the present invention, a high-precision robot is used in combination with a visual correction system to install the working electrode breathable membrane into the upper shell of the sensor with minimal error. At the same time, the robot has its own contoured pressure head to pre-press the working electrode breathable membrane to improve the accuracy of the upper and lower shell packaging.

[0052] In this embodiment, the laser coding unloading station 700 includes a laser coding device 710, a picking robot IX 720, and a finished product unloading mechanism 730. The laser coding device 710 is used to laser mark the sensor after the upper and lower shells are packaged and assign a product number. The picking robot IX 720 has the same structure as the picking robot I 130, and is used to transfer the sensor after the upper and lower shells are pressed together to the finished product unloading mechanism 730. The finished product unloading mechanism 730 has the same structure as the lower shell loading mechanism 110, and is used to transfer the assembled finished products off the line.

[0053] In this embodiment, the reflow speed chain workstation 800 includes a jig pallet transport assembly 810, a pallet lifting cylinder 820 and a pallet belt line 830. The jig pallet transport assembly 810 is arranged at both ends of the pallet belt line 830, and is used for transporting and changing lines after the jig pallet flows back and forth to the terminal to form a closed loop operation. The pallet lifting cylinder 820 is used for positioning the jig pallet at each workstation to facilitate the robot to assemble the product.

[0054] Compared with manual assembly, the automated production line of the present invention not only has higher assembly efficiency, but also the assembly process can be more standardized, and the leakage rate and poor contact rate of the finished sensor are significantly reduced. The leakage rate and poor contact rate are the leakage rate and poor contact rate of the sensor after simulating the high and low temperature, high and low humidity, vibration, drop and impact tests that may be encountered during transportation, storage and use. The specific parameters can be found in the following table:

[0055]

[0056] It can be seen from the data in the above table that the efficiency of assembling sensors using the automated growth line of the present invention is 3-4 times that of manual assembly, while the leakage rate of the assembled finished product is only 1 / 30 of that of manual assembly, and the poor contact rate is only 1 / 50 of that of manual assembly. That is, the sensors produced by the automated production line of the present invention have significantly improved production efficiency and finished product qualification rate.

[0057] The above description is only a preferred embodiment of the present invention and does not limit the technical scope of the present invention. Therefore, any slight modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. An automated production line for electrochemical gas sensors, characterized in that: It includes a lower shell loading station, an electrolyte injection station, a counter electrode reference electrode assembly station, an isolation membrane assembly station, a working electrode assembly station, an upper shell assembly station, a laser coding unloading station and a reflux double-speed chain station. The lower shell loading station, the electrolyte injection station, the counter electrode reference electrode assembly station, the isolation membrane assembly station, the working electrode assembly station, the upper shell assembly station and the laser coding unloading station are sequentially arranged on one side of the reflux double-speed chain station. The lower shell loading station is used to realize automatic loading of the sensor lower shell and to shape the PIN pin on the sensor lower shell; the electrolyte injection station is used to add a predetermined amount of electrolyte into the sensor lower shell; the counter electrode reference electrode assembly station is used to The sensor counter electrode and reference electrode are automatically loaded, cut and installed into the lower shell of the sensor, and the PIN pin of the sensor counter electrode and reference electrode are bent; the isolation membrane assembly station is used to automatically load, cut and install the sensor isolation membrane into the lower shell of the sensor, and the PIN pin of the sensor working electrode is bent; the working electrode assembly station is used to automatically load, cut and install the sensor working electrode into the upper shell of the sensor; the upper shell assembly station is used to automatically load the upper shell of the sensor and press and seal the upper and lower shells of the sensor; the laser coding unloading station is used to print the sensor number and unload the finished product; the reflux speed chain station is used for the transportation of materials to realize the series connection of all stations.

2. The electrochemical gas sensor automated production line according to claim 1, characterized in that: The lower shell loading station includes a lower shell loading mechanism, a lower shell shaping mechanism, a picking robot I, a CCD module I and a flipping mechanism I. The lower shell loading mechanism includes a lower shell feeding area, a lower shell picking area and an empty pallet receiving area; the lower shell feeding area includes a first conveyor belt and a lower shell support placed on the first conveyor belt, the lower shell support is placed with a number of lower shell pallets filled with lower shells, and L-shaped guide columns I are arranged around the lower shell pallets. A first pallet lifting mechanism is arranged at the bottom of the first conveyor belt, which rises and falls along the L-shaped guide columns I. At the same time, a first pallet dividing mechanism is arranged on the edge of the L-shaped guide columns I to divide the pallets filled with lower shells; the lower shell picking area includes a second conveyor belt and a first picking positioning mechanism, which is used to operate and position the lower shell pallet; the empty pallet receiving area includes a third conveyor belt and an empty pallet of the lower shell placed on the third conveyor belt, and L-shaped guide columns II are arranged around the empty pallet of the lower shell. A second pallet lifting mechanism is arranged at the bottom, which is lifted and lowered along the L-shaped guide column II; the L-shaped guide column II is provided with an empty pallet stacking hanging plate tongue, which is used to hang the pallet after stacking; the first conveyor belt and the second conveyor belt cooperate to convey the lower shell pallet to the lower shell material picking area, and the second conveyor belt and the third conveyor belt cooperate to convey the lower shell empty pallet to the empty pallet receiving area; the picking robot I includes a four-axis manipulator I and a lower shell picking clamp, which is used to take the sensor lower shell out of the lower shell material picking area and place it on the jig pallet handling assembly. The picking and placing process is visually corrected by the camera visual detection assembly. The CCD module I is used to perform appearance inspection and defect detection on the sensor lower shell. When a defective product is detected, the picking robot I transfers the shell to the defective product area. The flipping clamp in the flipping mechanism I is driven by a driving cylinder and clamps the sensor lower shell, and is driven by a servo motor to flip the shell in the loading tray 180° to adjust the posture of the sensor lower shell; The lower shell shaping mechanism includes a shaping positioning fixture, which is used for positioning when trimming the lower shell, and shaping the PIN pins on the lower shell of the sensor through a shaping cylinder.

3. The electrochemical gas sensor automated production line according to claim 1, characterized in that: The electrolyte injection station includes an XYZ cantilever module, an injection mechanism, and a CCD module II. The injection mechanism is installed at the output end of the XYZ cantilever module. The XYZ cantilever module is used to drive the injection mechanism to move above the fixture tray; the injection mechanism includes an intake and discharge pipeline, which is used to absorb electrolyte and quantitatively inject it into the sensor lower shell of the fixture tray. The suction or discharge of electrolyte in the intake and discharge pipeline is controlled by a linear slide rail and an injection valve; the CCD module II is used to confirm the relative position of the intake and discharge pipeline and the sensor lower shell during the injection process and perform visual correction.

4. The electrochemical gas sensor automated production line according to claim 2, characterized in that: The counter electrode reference electrode assembly station includes a counter electrode reference electrode loading mechanism, a picking robot II, a counter electrode reference electrode cutting component, a picking robot III, and a CCD module III. The counter electrode reference electrode loading mechanism has the same structure as the lower shell loading mechanism and is used to load the sensor counter electrode reference electrode plate by plate to the counter electrode reference electrode picking area. The picking robot II includes a four-axis manipulator II, a CCD visual guidance device I, and a counter electrode reference electrode suction nozzle component, which is used to transfer the counter electrode reference electrode from the counter electrode reference electrode picking area to the counter electrode The counter electrode reference electrode cutting station, the counter electrode reference electrode cutting assembly includes a laser cutting machine, which is used to cut the counter electrode reference electrode into the size required by the sensor, the laser cutting machine is connected to the base through a Z-axis module, and the height of the laser cutting machine is adjusted by the Z-axis module; a disc mechanism is arranged under the laser cutting machine, and the disc mechanism is connected to the base through a hollow rotating platform I, and the disc mechanism is used to replace the counter electrode reference electrode after cutting, so that the material picking robot II can place the uncut counter electrode reference electrode, and the material picking robot III can remove the cut counter electrode reference electrode. The counter electrode reference electrode, the processed micropores on the working surface of the disc mechanism are used to adsorb the counter electrode reference electrode before trimming and the single counter electrode reference electrode after trimming. The material-picking robot III includes a four-axis manipulator III and a counter electrode reference electrode single suction nozzle assembly installed at the operating end of the four-axis manipulator III, which is used to absorb the trimmed counter electrode reference electrode and install it into the sensor lower shell of the fixture tray. The operating end of the four-axis manipulator III is equipped with a counter electrode reference electrode PIN foot bending mechanism through a lifting cylinder, which is used to bend the sensor lower shell in the fixture tray. The PIN pin of the corresponding counter electrode and reference electrode is bent so that the PIN pin of the counter electrode and reference electrode is pressed above the counter electrode and reference electrode. The operating end of the four-axis manipulator III is also equipped with a CCD visual guidance device II, which is used for visual correction and positioning during assembly of the counter electrode and reference electrode, and completes the post-assembly inspection at the same time. When a defective product is detected, the material picking robot III transfers the lower shell of the sensor on the fixture tray to the defective product area. The CCD module III is used to provide visual guidance and positioning for the material picking robot II and the counter electrode and reference electrode loading mechanism when picking up materials.

5. The electrochemical gas sensor automated production line according to claim 4, characterized in that: The isolation film assembly station includes an isolation film feeding mechanism, a picking robot IV, an isolation film cutting component, a picking robot V, and a CCD module IV. The isolation film feeding mechanism includes a rotating component, and the rotating component includes a hollow rotating platform II. The hollow rotating platform II is connected to the base. An isolation film clip is installed on the hollow rotating platform II. A sensor isolation film is placed inside the isolation film clip. A lifting module is arranged below the isolation film clip. The lifting module is used to push the sensor isolation film upward to the picking height. A double-sided separation air knife is arranged on the top of the isolation film clip to layer the sensor isolation film. The picking robot IV has the same structure as the picking robot II. The picking robot IV is used to take out the sensor isolation film from the isolation film feeding mechanism and place it on the isolation film The cutting station, the isolation membrane cutting component has the same structure as the counter electrode reference electrode cutting component, and is used to cut the isolation membrane into the required size of the sensor. The material picking robot V has the same structure as the material picking robot III, and is used to install the cut isolation membrane into the sensor lower shell in the jig tray, so that the isolation membrane is placed in the sensor lower shell and pressed above the counter electrode reference electrode PIN pin; the material picking robot V is used to bend the working electrode PIN pin so that the working electrode PIN needle is pressed above the isolation membrane. The CCD module IV is used for correcting the positioning during the isolation membrane assembly and for inspection after assembly. When a defective product is detected, the material picking robot V transfers the sensor lower shell on the jig tray to the defective product area.

6. The electrochemical gas sensor automated production line according to claim 4, characterized in that: The working electrode assembly station includes a working electrode loading mechanism, a picking robot VI, a working electrode cutting component, a picking robot VII and a CCD module V. The working electrode loading mechanism has the same structure as the lower shell loading mechanism and is used to load the sensor working electrode one by one to the working electrode picking area. The picking robot VI has the same structure as the picking robot II and is used to place the working electrode in the working electrode cutting station. The working electrode cutting component has the same structure as the counter electrode and reference electrode cutting component and is used to cut the working electrode to the required size of the sensor. The picking robot VII has the same structure as the picking robot III and is used to transfer the cut working electrode to the upper shell of the sensor on the working electrode mounting fixture. The CCD module V is used to provide visual guidance and positioning for the picking robot VI when picking up materials from the working electrode loading mechanism.

7. The electrochemical gas sensor automated production line according to claim 1, characterized in that: The upper shell assembly station includes an upper shell feeding mechanism, a picking robot VIII, and a flipping mechanism II. The upper shell feeding mechanism includes a flexible vibration plate and an upper shell feeding bin, which is used to evenly arrange and feed the scattered sensor upper shells for the picking robot VIII to grab. The picking robot VIII includes a four-axis manipulator IV and an upper shell picking claw, which is used to take the sensor upper shell from the upper shell feeding mechanism and place it on the flipping mechanism II. The picking robot VII installs the sensor working electrode into the sensor upper shell. The flipping mechanism II flips the sensor upper shell 180°. The pressing mechanism arranged at the end of the picking robot VII installs the flipped sensor upper shell onto the sensor lower shell. The pressing mechanism includes a pressing cylinder, which is used to press the sensor upper shell and the sensor lower shell into a whole. The pressing mechanism is equipped with a pressure sensor and a pressing detection displacement sensor, which is used to detect whether the upper and lower shells are pressed in place while preventing excessive pressure from damaging the shells.

8. The electrochemical gas sensor automated production line according to claim 2, characterized in that: The laser coding unloading station includes a laser coding device, a picking robot IX, and a finished product unloading mechanism. The laser coding device is used to laser mark the sensor after the upper and lower shells are packaged and assign a product number. The picking robot IX has the same structure as the picking robot I and is used to transfer the sensor after the upper and lower shells are pressed together to the finished product unloading mechanism. The finished product unloading mechanism has the same structure as the lower shell loading mechanism and is used to transfer the assembled finished product off the line.

9. The electrochemical gas sensor automated production line according to claim 1, characterized in that: The reflow speed chain workstation includes a jig pallet transport assembly, a pallet lifting cylinder and a pallet belt line. The jig pallet transport assembly is arranged at both ends of the pallet belt line and is used for transporting and changing lines after the jig pallet flows back and forth to the terminal to form a closed loop operation. The pallet lifting cylinder is used for positioning the jig pallet at each workstation to facilitate the robot to assemble the product.

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