Quality control device of gas alarm automatic production line

Abstract

The invention provides a quality control device of a gas alarm automatic production line, and mainly relates to the technical field of gas alarm production. A quality control device of a gas alarm automatic production line comprises an aging line body assembly, a detection calibration assembly, a detection line body assembly, an automatic sorting area, a feeding area and a control host. The aging line body assembly is used for storing a gas alarm circuit board and realizing power-on aging in a set time through natural circulation of an assembly line, and the detection calibration assembly is used for enabling a set number of gas alarm circuit boards subjected to power-on aging to be in a closed space with a set volume and applying calibration gas with a set concentration. The gas alarm concentration of the alarm signal sent by the gas alarm circuit board is calibrated through the control host. According to the scheme, the process is realized through an automatic assembly line, the quality of the gas alarm is automatically detected in batches, related detection records are generated, and the production efficiency is improved.

Description

Technical Field

[0001] The invention mainly relates to the technical field of gas alarm production, and in particular to a quality control device for an automated production line of gas alarms. Background Art

[0002] The most important process in the production of gas alarms is aging gas calibration and the judgment of the calibration results. Aging means to continuously power on the sensor to keep it in a stable working state. Calibration means to place the gas alarm under a predetermined gas concentration and let the alarm record the voltage value corresponding to the current gas concentration as the basic value for future alarms. The predetermined gas concentration can be adjusted according to the different alarms to meet the needs of products with different parameters, such as 4000ppm or 5000ppm methane gas. The judgment of the calibration results is usually called retesting, which is to detect whether the alarm reaches the expected alarm threshold value. The generally allowable error range is ±1000ppm. When the calibration value of the alarm is 5000ppm, its qualified alarm range is 5000±1000ppm.

[0003] Existing gas alarm production equipment is mostly manually operated, and the calibration and retesting steps of the alarm are prone to errors, which may result in users not being able to alarm in time during use, generating false alarms, or insufficient aging time, which may lead to unstable performance of the alarm. Summary of the invention

[0004] In order to address the deficiencies of the prior art, the present invention provides a quality control device for an automated production line of gas alarms, which can ensure sufficient aging time to effectively improve the efficiency of gas alarm calibration and retesting, thereby ensuring product quality. This solution implements the above process through an automated assembly line, thereby automatically and batch-wise testing the quality of gas alarms, and generating relevant test records, thereby improving production efficiency.

[0005] In order to achieve the above object, the present invention is implemented through the following technical solutions: A quality control device for an automated production line of a gas alarm comprises an aging line assembly, a detection and calibration assembly, a detection line assembly, an automatic sorting area, a loading area and a control host, wherein the detection and calibration assembly, the detection line assembly, the automatic sorting area and the loading area are arranged in sequence according to an S-shaped assembly line assembly, the automatic sorting area is provided with a manipulator, the loading area is provided with a lift, the detection and calibration assembly comprises a gas-filling and calibration box, the detection line assembly comprises a gas-filling and retesting box, the gas alarm circuit board is conveyed from the aging line assembly to the S-shaped assembly line assembly by a conveying device, the manipulator transfers the gas alarm circuit board to the S-shaped assembly line assembly and then automatically passes through the above-mentioned functional areas in sequence.

[0006] The aging line assembly is used to store the gas alarm circuit board and realize power-on aging for a set time through natural circulation of the assembly line.

[0007] The gas-filling calibration box is used to place a set number of gas alarm circuit boards that have been powered on and aged in a closed space of a set volume, and apply calibration gas of a set concentration, so as to calibrate the gas alarm concentration of the gas alarm circuit board to send out an alarm signal through the control host; the detection and calibration assembly also includes temperature and humidity control equipment, which can achieve consistency in the performance of products produced throughout the year and avoid the influence of air quality due to the technical characteristics of the sensor; the temperature and humidity control can be set in the air purifier.

[0008] The gas-filling retest box is used to place the calibrated gas alarm circuit board in a set closed space and gradually increase the internal gas concentration until the gas concentration rises to the highest concentration at which all gas alarm circuit boards send out alarm signals. During this process, the control host will record the gas concentration when each gas alarm circuit board sends out an alarm signal.

[0009] Under the control of the control host, the automatic sorting area separates qualified products that send out alarm signals within the set concentration range from other unqualified products, and automatically transmits them to the corresponding storage area or the next detection step.

[0010] The loading area is used for temporarily storing and transporting the gas alarm circuit boards to be tested.

[0011] During operation, the tooling board on which the product under test is installed is powered continuously, so that the gas alarm circuit board of the product under test is continuously in working condition to meet the test requirements.

[0012] Compared with the prior art, the beneficial effects of the present invention are: 1. Through the various inspection and test steps of the assembly line, the power-on aging of the set time is automatically realized to prevent errors in manual recording; 2. Gas calibration and retesting, no manual participation is required, which improves production efficiency and automatically records relevant production data; 3. By analyzing the production data (sensor alarm threshold), the quality of the sensor can be further analyzed; 4. Automatically configure the gas concentration according to the production process and form a closed-loop feedback to meet the requirements of the standards; 5. The device automatically sorts qualified products and unqualified products; 6. Use special tooling boards to monitor the products under test, greatly improve detection efficiency and ensure shipment quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a schematic diagram of the overall top view of the structure of the present invention; Figure 2 It is a schematic diagram of the overall main structure of the present invention; Figure 3 It is a schematic diagram of the overall side structure of the present invention.

[0014] The numbers shown in the accompanying drawings are: 1. Aging line assembly; 2. Detection and calibration assembly; 3. Detection line assembly; 4. Elevator; 5. Manipulator; 6. S-type assembly line; 7. Assembly line assembly. DETAILED DESCRIPTION

[0015] The present invention will be further described with reference to the accompanying drawings and specific embodiments. It should be understood that these embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention. In addition, it should be understood that after reading the content taught by the present invention, those skilled in the art may make various changes or modifications to the present invention, and these equivalent forms also fall within the scope limited by the application.

[0016] Combined with Figure 1-Figure 3 , including an aging line assembly 1, a detection and calibration assembly 2, a detection line assembly 3, an automatic sorting area, a loading area and a control host. The detection and calibration assembly 2, the detection line assembly 3, the automatic sorting area, and the loading area are arranged in sequence according to the S-type assembly line assembly 6. The automatic sorting area is provided with a manipulator 5, and the loading area is provided with a lift 4. The detection and calibration assembly 2 includes a gas-filled calibration box, and the detection line assembly 3 includes a gas-filled retest box. The gas alarm circuit board is assembled by the aging line assembly 1 through the assembly line assembly 7 and is transmitted to the S-type assembly line assembly through a conveying device. The manipulator transfers the gas alarm circuit board to the S-type assembly line assembly and then automatically passes through the above-mentioned functional areas in sequence; the S-type assembly line is a double-speed chain transmission assembly line, which can achieve uninterrupted power supply during the transmission process.

[0017] The aging line assembly 1 is used to store the gas alarm circuit board and realize power-on aging for a set time through natural circulation of the assembly line.

[0018] The gas-filling calibration box is used to place a set number of gas alarm circuit boards that have been powered on and aged in a closed space of a set volume, and apply calibration gas of a set concentration, so as to calibrate the gas alarm circuit board and send out an alarm signal through the control host; the detection and calibration assembly 2 also includes temperature and humidity control equipment, which can achieve consistency in the performance of products produced throughout the year and avoid the influence of air quality on the technical characteristics of the sensor.

[0019] The gas-filling retest box is used to place the calibrated gas alarm circuit board in a set closed space and gradually increase the internal gas concentration until the gas concentration rises to the highest concentration at which all gas alarm circuit boards send out alarm signals. During this process, the control host will record the gas concentration when each gas alarm circuit board sends out an alarm signal.

[0020] Under the control of the control host, the automatic sorting area separates qualified products that send out alarm signals within the set concentration range from other unqualified products, and automatically transmits them to the corresponding storage area or the next detection step.

[0021] The loading area is used for temporarily storing and transporting the gas alarm circuit boards to be tested.

[0022] During operation, the tooling board on which the product under test is installed is powered continuously, so that the gas alarm circuit board of the product under test is continuously in working condition to meet the test requirements.

[0023] The assembly line is set up as follows: aging line assembly (to achieve power-on aging for a set time), gas-filling calibration box, gas-filling retest box, automatic sorting machine (to sort qualified and unqualified products), loading area (to place new tested alarms), and control host, which is used to control the operation of the assembly line and display test results and test records.

[0024] The aging line assembly is the power-on aging zone described above. It adopts an uninterrupted cycle method, which is beneficial to the rhythm of the assembly line and forms natural power-on aging.

[0025] Gas-filled calibration box and gas-filled retest box: The structures of the two are exactly the same, but they have different purposes and the concentrations of applied gases are different.

[0026] Its basic components include: gas box, infrared analyzer, gas injection machine, exhaust blower, fan, and air purifier interface.

[0027] Air box: The bottom is open and the top is hood-shaped. It forms a sealed fixed space with the lifting tooling board. The calculated gas is injected into it and the gas is stirred evenly by the internal fan. Connect the input and output pipelines of the infrared analyzer and the exhaust port. The air box is suspended and fixed on the upper part of the assembly line without affecting the normal flow of the tooling board.

[0028] At the position of the corresponding assembly line of the gas box, there is a mechanical structure for lifting the tooling plate. When the tooling plate is in place, the lifting device lifts it up and fits closely with the edge of the gas box to form a closed space inside the gas box. To ensure the sealing of the gas box, the lower edge of the gas box is made of soft elastic rubber.

[0029] Infrared analyzer: used to monitor the gas concentration in the gas box in order to adjust the input of the gas injection machine.

[0030] Gas injection machine: According to the production process parameters, it automatically injects the required gas into the gas box. And it can automatically fine-tune the gas injection volume according to the monitoring results of infrared analysis.

[0031] Exhaust fan: It is convenient to quickly exhaust the gas in the air box to restore the air box to a normal space environment.

[0032] Fans: On the top of the air box, evenly distributed in multiple locations to quickly stir the high-concentration gas injected inside.

[0033] Air purifier interface: Connect to the air purifier. The calibration and retest gas in the device will pass through the air purifier and then be mixed with the test gas, and the temperature and humidity will be adjusted.

[0034] Automatic sorting machine: According to the retest results, qualified products and unqualified products are separated and placed, and flow into different production nodes.

[0035] Loading area: After the sorting machine, the tooling board is free, and new products can be placed. The products can be placed manually to facilitate observation of whether there are any abnormalities in the products.

[0036] The control host is used to control the operation rhythm of the entire assembly line, as well as record and display test results, production statistics, etc.

[0037] Data communication of tooling board: The tooling board is in contact with the external AC power supply only through the track on the assembly line. Since the tooling board keeps running on the assembly line, it is not convenient to use wired method to exchange information with the control host through the data collected by the built-in MCU of the tooling board, and wireless communication is required. This data interaction is only required when the gas box is added, and the wireless communication distance does not need to be very far, and in order to avoid interference with wireless communication with other tooling boards, the closer the communication distance, the better.

[0038] The wireless communication adopts infrared mode and is a two-way communication. Infrared communication is a mature technology. In the small space of the gas box, it is not easily affected by external interference and is not easy to interfere with other equipment.

[0039] When the tooling board runs to the gas tank, it starts infrared communication and exchanges data with the main controller. For example: when the gas concentration in the gas tank reaches the predetermined concentration, the control host informs the tooling board through infrared communication. After receiving the information, the tooling board informs the tested products one by one and records the current voltage value as the threshold value for future alarms. When retesting, when the gas tank reaches the predetermined low concentration of gas, the control host reads the status of each tested product, and no alarm should be generated at this time; when the gas tank reaches the predetermined high concentration of gas, the control host reads the status of each tested product, and an alarm should be generated at this time; products that meet the requirements for both states are qualified, otherwise they are unqualified products.

[0040] Household gas alarms generally use semiconductor sensors or catalytic combustion sensors. Due to their technical characteristics, they should be fully powered on and aged before gas testing, and the power should not be cut off.

[0041] The tooling board is powered by dual rails, and each rail is connected to the live and neutral wires of the AC power supply to power the product under test on the tooling board. There are cams on both sides of the assembly line, which respectively import the live and neutral wires of the AC power supply. The spacing between the cams on the same side is less than 1 / 2 the length of the tooling board to ensure that the tooling board is continuously powered when it moves forward on the assembly line, thereby ensuring that the circuit board of the gas alarm under test is always powered on.

[0042] The calibration / retest process takes about 10 minutes. According to the technical requirements of the sensor, it usually takes 24 hours to age. When 24x6=144 tooling boards are sequentially transferred to the calibration / retest process, they have also undergone 24 hours of ageing.

[0043] The assembly line is generally set up in a ring shape, and the tooling boards required for testing are continuously cycled back and forth.

[0044] Introduction to pipeline actions: 1. Place the product to be tested; observe whether there is any abnormality while placing the product to be tested, and select the abnormal product; 2. When the tooling board filled with the tested products is run to the gas-filled test box through the assembly line, it has undergone power-on aging and meets the basic requirements of the test; 3. The tooling board enters the gas filling calibration box and is lifted up, and the gas box forms a closed space. The gas injection machine automatically starts to inject gas according to the production process, and the infrared analyzer automatically detects the gas concentration in the gas box to form a closed-loop control. When the concentration reaches the required production process, the tooling board is informed through infrared communication. After receiving the information, the tooling board informs each tested product and records the current corresponding voltage value.

[0045] 4. The gas-filling calibration box starts the exhaust fan to exhaust the gas in the gas box, then the jacking device descends, the tooling plate returns to the horizontal flow of the assembly line, and enters the re-test process.

[0046] 5. The tooling board enters the gas filling retest box and is lifted up, and the gas box forms a closed space. The gas injection machine automatically injects low-concentration test gas according to the production process and reads the status of the current product under test. Then the gas injection machine injects high-concentration test gas and reads the status of the current product under test. The control host determines whether the product under test is qualified or not.

[0047] 6. The gas-filling and retesting box starts the exhaust fan to exhaust the gas in the gas box, then the jacking device descends, the tooling plate returns to the horizontal flow of the assembly line, and enters the sorting process.

[0048] 7 The control host sorts qualified products from unqualified products according to the test results. After all the sorting is completed, the tooling board is free and ready to be loaded with new products to be tested.

[0049] other: The gas box can determine whether there is a product to be tested on the tooling board through infrared communication. If not, it will not lift or add gas to save resources, but still run according to the beat. This situation is mainly used in the initial state of the assembly line operation.

[0050] The assembly line in this device has emergency stop function, anti-electric shock function, etc. The control host has the function of data recording and display and can automatically control the operation of various electrical components according to the set conditions. The device can detect natural gas, liquefied gas, carbon monoxide, hydrogen and other products according to the different types of gases detected. These gases use multi-way switches to switch the gas supply channels. Different gases correspond to different infrared analyzers.

[0051] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A quality control device for an automated production line of a gas alarm, comprising an aging line assembly, a detection and calibration assembly, a detection line assembly, an automatic sorting area, a loading area and a control host, characterized in that: The detection and calibration assembly, the detection line assembly, the automatic sorting area, and the loading area are arranged in sequence according to the S-type assembly line. The automatic sorting area is provided with a robot, and the loading area is provided with a lift. The detection and calibration assembly includes a gas-filled calibration box, and the detection line assembly includes a gas-filled retest box. The gas alarm circuit board is conveyed from the aging line assembly to the S-type assembly line assembly through a conveying device. After the robot transfers the gas alarm circuit board to the S-type assembly line assembly, it automatically passes through the above-mentioned functional areas in sequence.

2. The quality control device for the automated production line of gas alarms according to claim 1 is characterized by: The aging line assembly is used to store the gas alarm circuit board and realize power-on aging for a set time through natural circulation of the assembly line.

3. The quality control device for the automated production line of gas alarms according to claim 1 is characterized by: The gas-filled calibration box is used to place a set number of power-on aged gas alarm circuit boards in a closed space of a set volume, and apply calibration gas of a set concentration, and calibrate the gas alarm concentration of the gas alarm circuit board to send an alarm signal through the control host.

4. The quality control device for the automated production line of gas alarms according to claim 1 is characterized by: The gas-filling retest box is used to place the calibrated gas alarm circuit board in a set closed space and gradually increase the internal gas concentration until the gas concentration rises to the highest concentration at which all gas alarm circuit boards send out alarm signals. During this process, the control host will record the gas concentration when each gas alarm circuit board sends out an alarm signal.

5. The quality control device for the automated production line of gas alarms according to claim 1 is characterized by: Under the control of the control host, the automatic sorting area separates qualified products that send out alarm signals within the set concentration range from other unqualified products, and automatically transmits them to the corresponding storage area or the next detection step.

6. The quality control device for the automated production line of gas alarms according to claim 1 is characterized by: The loading area is used for temporarily storing and transporting the gas alarm circuit boards to be tested.

7. The quality control device for the automated production line of gas alarms according to claim 1 is characterized by: During operation, the tooling board on which the product under test is installed is powered continuously, so that the gas alarm circuit board of the product under test is continuously in working condition to meet the test requirements.

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