IPM error-proofing test system and method

Abstract

The invention discloses an IPM error-proofing test system and method, and belongs to the field of intelligent power module IPM electronic installation, the system comprises a computer, a switch, a camera IO control panel, an IPM automatic feeding tool, an intelligent camera and an LCD touch screen, the computer is connected with an NET module in the camera IO control panel through the switch; an MES system is arranged in the computer; a PWR module of the camera IO control panel is in communication connection with the intelligent camera, and the intelligent camera is embedded in the IPM automatic feeding tool. The intelligent camera is in communication connection with the LCD touch screen. According to the invention, the MES traces back to the IPM model according to the currently selected model, compares the model with the model identified by the camera, and gives an alarm immediately when inconsistency is found, so that the problem of wrong material use caused by errors of manual checking at present is solved, the working effect and efficiency are improved, the frequency of errors of manual detection is reduced, and the safety is improved.

Description

Technical Field

[0001] The invention relates to the field of electronic assembly of intelligent power modules (IPMs), and in particular to an IPM error-proofing test system and method. Background Art

[0002] Intelligent power module IPM uses insulated gate bipolar transistor IGBT, a power switching device. IPM is composed of high-speed, low-power IGBT chip and optimized gate-level drive and protection circuit. It has the advantages of high current density, low saturation voltage and high voltage resistance of high-power transistor GTR, as well as the advantages of high input impedance, high switching frequency and low drive power of field effect transistor MOSFET. IPM integrates logic, control, detection and protection circuits, which is easy to use. It not only reduces the size and development time of the system, but also greatly enhances the reliability of the system. It adapts to the development direction of today's power devices - modularization, compounding and power integrated circuit PIC, and is increasingly widely used in the field of power electronics.

[0003] Because the area of ​​the intelligent power module IPM is too small, and the model and other identification characters on the intelligent power module IPM are too small, when the intelligent power module IPM is packaged, manual inspection and checking is time-consuming and labor-intensive, and at the same time inefficient, and it is not possible to check and trace it well, which affects the work effect and efficiency. Summary of the invention

[0004] With regard to the above problems existing in the prior art, the object of the present invention is to provide an IPM error-proofing test system and method to solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] An IPM error-proofing test system includes a computer, a switch, a camera IO control board, an IPM automatic feeding tool, a smart camera and an LCD touch screen, wherein the computer is connected to a NET module in the camera IO control board through the switch; an MES system is provided inside the computer;

[0007] The PWR module of the camera IO control board is connected to the smart camera for communication, and the smart camera is embedded in the IPM automatic feeding tooling;

[0008] The smart camera is communicatively connected with the LCD touch screen.

[0009] As a further solution of the present invention: the output power interface of the camera IO control board is connected to a power plug through a power adapter, and the power plug is connected to an external power supply.

[0010] As a further solution of the present invention: a panel is obliquely provided on the IPM automatic feeding tooling, a slide groove is provided on the panel, a material tube is provided on the slide groove, and an intelligent power module IPM is installed in the material tube.

[0011] As a further solution of the present invention: the panel is arranged at an inclination angle of 30°-45°.

[0012] As a further solution of the present invention: an opening is provided at the bottom end of the panel of the IPM automatic feeding tool.

[0013] As a further solution of the present invention: the smart camera is arranged below the bottom of the inclined chute of the IPM automatic feeding tooling.

[0014] As a further solution of the present invention: the smart camera is fixedly arranged parallel to the panel, and the lens of the smart camera is aimed at the opening position of the panel of the IPM automatic feeding tooling.

[0015] As a further solution of the present invention: the panel material tube of the IPM automatic feeding tool is made of transparent material.

[0016] As a further solution of the present invention: enclosures are arranged around the IPM automatic feeding tooling.

[0017] An IPM error-proofing test method, the method steps are as follows:

[0018] S1. Loading the tooling: put the tubular intelligent power module IPM into the card slot of the IPM automatic loading tooling, and two tubular intelligent power modules IPM will automatically slide down to the material removal port;

[0019] S2, information scanning and transmission, the intelligent camera automatically starts detection when powered on, scans the bottom screen of the tubular intelligent power module IPM at a frequency of S intervals through the opening reserved by the IPM automatic feeding tooling, and converts the recognized characters into strings and outputs them to the computer;

[0020] S3. Comparative testing: The MES system installed on the computer checks whether the model of the tubular intelligent power module IPM currently used in production is consistent with the model output by the smart camera. If not, a voice alarm and pop-up window reminder will be issued, and the system will be bundled with the product barcode for traceability.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] The MES of the present invention traces back to the IPM model according to the currently selected machine model, and compares it with the model recognized by the camera. When inconsistency is found, an alarm is immediately sounded to improve the current problem of wrong materials caused by manual verification errors, improve work effectiveness and efficiency, reduce the frequency of manual detection errors, and increase safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 A schematic diagram of the framework of an IPM error-proofing test system disclosed in an embodiment.

[0024] Figure 2 The present invention is a schematic diagram of a camera IO control board in an IPM error-proofing test system disclosed in an embodiment.

[0025] Figure 3 The present invention is a flowchart of the steps of an IPM error prevention test method disclosed in an embodiment.

[0026] The reference numerals in the figure are: 1. computer; 2. switch; 3. power plug; 4. power adapter; 5. camera IO control board; 6. IPM automatic feeding tooling; 7. smart camera; 8. LCD touch screen. DETAILED DESCRIPTION

[0027] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention; it is obvious that 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.

[0028] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "provided with", "connected", and "connected" should be understood in a broad sense; for example, it can be a fixed connection, a detachable connection, or an integral connection, a mechanical connection, or an electrical connection, a direct connection, or an indirect connection through an intermediate medium, or the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0029] See also Figure 1-3, an IPM error-proofing test system, including a computer 1, a switch 2, a camera IO control board 5, an IPM automatic feeding tool 6, an intelligent camera 7 and an LCD touch screen 8, wherein the computer 1 is connected to the NET module in the camera IO control board 5 through the switch 2; an MES system is provided inside the computer 1; during operation, the device can be conveniently controlled through the MES system in the computer 1, which is beneficial to the operation of the system; the MES system can identify the IPM model of the intelligent power module according to the production scheduling model, and compare it with the camera output content, bundle barcode traceability, and realize the error alarm function. Select the production schedule, click to start production, and the MES will trace back to the IPM model according to the currently selected model, and compare it with the model recognized by the camera. When inconsistency is found, an alarm will be sounded immediately, and a pop-up window will be displayed on the software interface to report an error "IPM verification exception" to improve the current problem of using the wrong material due to manual verification errors.

[0030] The automatic feeding tool 6 of the intelligent power module IPM can slide down automatically to improve efficiency; the intelligent power module IPM is packaged in a material tube, one end of the material tube is fixed with a latch and the other end is fixed with a rubber plug. Pull out the rubber plug of the material tube, tilt the material tube, and the intelligent power module IPM can slide out freely.

[0031] The PWR module of the camera IO control board 5 is connected to the smart camera 7 for communication, and the smart camera 7 is embedded in the automatic feeding tooling 6 of the intelligent power module IPM; the camera IO control board 5 is convenient for controlling and adjusting the smart camera 7; when the intelligent power module IPM is in the waiting area, the high-speed camera can scan the code from the bottom. Since the high-frequency flicker of the camera LED hurts the eyes, the camera can be placed inside the tooling.

[0032] The smart camera 7 is connected to the LCD touch screen 8 for communication; the LCD touch screen 8 is used to display the results of the smart camera 7 shooting when loading materials, so that people can view them conveniently; the camera IO control board 5, the smart camera 7 and the LCD touch screen 8 cooperate with each other to realize the automatic recognition and transmission of the characters at the bottom of the intelligent power module IPM.

[0033] The output power interface of the camera IO control board 5 is connected to the power plug 3 through the power adapter 4, and the power plug 3 is connected to the external power supply. When working, the power plug 3 is used to conveniently power the camera IO control board 5 to ensure the normal operation of the device; the power adapter 4 is used to adjust the voltage of the power supply, facilitate the power supply of the camera IO control board 5, and increase safety.

[0034] An IPM automatic feeding tool 6 is provided with a panel inclined thereon, a slide groove is provided on the panel, a material tube is provided on the slide groove, and an intelligent power module IPM is installed in the material tube.

[0035] The panel is set at an inclination angle of 30°-45°.

[0036] An opening is provided at the bottom end of the panel of the IPM automatic feeding tool 6.

[0037] The smart camera 7 is arranged below the bottom of the inclined chute of the IPM automatic feeding tool 6; the smart camera 7 is fixedly arranged parallel to the panel, and the lens of the smart camera 7 is aimed at the opening position, with a focal length of 100 mm.

[0038] The material tube is made of transparent material, which is convenient for the subsequent intelligent camera 7 to scan the intelligent power module IPM.

[0039] The intelligent power module IPM is packaged in a material tube, one end of the material tube is fixed with a latch and the other end is fixed with a rubber plug. Pull out the rubber plug of the material tube, tilt the material tube, and the intelligent power module IPM can slide out freely. Therefore, a placement tool with an inclined angle can be designed, and the material tube is placed in the IPM automatic feeding tool 6 to clamp it. The intelligent power module IPM in the tube slides to the waiting area. When the first intelligent power module IPM is taken away, the next intelligent power module IPM automatically slides to the waiting area until the material tube is used up and the next material tube is replaced.

[0040] When the intelligent power module IPM is in the waiting area, a high-speed camera can scan the code from the bottom. Since the high-frequency flickering of the camera LED hurts the eyes, the camera can be placed inside the tooling to scan the second intelligent power module IPM in the waiting area. A pressure cover is added above the second intelligent power module IPM to prevent it from lifting.

[0041] Add fences around the tooling to block the high-frequency flashing LED light when the camera is shooting and protect the operator's eyes.

[0042] The trigger mode of the smart camera 7 is internal triggering, and the trigger time is set to 3000ms, that is, one shot every 3 seconds. It can be increased or decreased according to actual conditions, and the shooting frequency must be less than the material collection interval.

[0043] An IPM error-proofing test method, the method steps are as follows:

[0044] S1. Loading of tooling: Put the tubular intelligent power module IPM into the card slot of the IPM automatic loading tooling 6. The tubular intelligent power module IPM will automatically slide down two pieces to the material taking port, reducing manual contact and subcontracting;

[0045] S2, information scanning and transmission, the intelligent camera 7 automatically starts detection when powered on, scans the bottom screen of the tubular intelligent power module IPM at a frequency of 3S intervals through the opening reserved by the IPM automatic feeding tooling 6, and converts the recognized characters into a string and outputs it to the computer 1;

[0046] S3. Comparative testing: The MES system installed on computer 1 checks whether the model of the tubular intelligent power module IPM currently used in production is consistent with the model output by the smart camera. If not, a voice alarm and pop-up window reminder will be issued, and the system will be bundled with the product barcode for traceability.

[0047] The specific adjustment parameters in the MES system are as follows:

[0048] Exposure time (1-10000ms): The larger the value, the higher the brightness of the image, the longer the dynamic response time, and the worse the image detection effect during motion.

[0049] Gain (1-4): Adjust the brightness. The larger the value, the higher the brightness and the more noise.

[0050] Contrast (1-100): The difference between the brightest and darkest parts of the image. The higher the value, the greater the difference, and the clearer and more prominent the image will be.

[0051] Sharpness (1-100): The higher the value, the higher the detail contrast and the clearer the image, but the corresponding imaging will be distorted.

[0052] Color saturation (1-100): The purity of the color. The higher the value, the brighter it is, and the lower the value, the darker it is.

[0053] Gamma (1-4): Auxiliary function of brightness and contrast. This value adjusts the brightness and contrast of the image.

[0054] Light source brightness: Manually adjust the brightness value of the light source.

[0055] Adjust position: Adjust the effective detection range of character recognition.

[0056] Adjust Angle: Adjust the angle of the character recognition detection area.

[0057] Horizontal reset: reset the detection area angle to the horizontal direction.

[0058] Vertical reset: reset the detection area angle to vertical.

[0059] Character Extraction: Base Characters: Automatically identify the extracted base characters.

[0060] Set extraction rules: Set the rules for character recognition extraction.

[0061] Similarity: Adjust the similarity value of character recognition judgment. It will be judged OK only when the similarity value is met.

[0062] Default: system built-in model detection

[0063] Online Model: The model library can be updated online.

[0064] Standard: When identifying, the recognition accuracy is average and the detection speed is fast.

[0065] High precision: When identifying, the recognition accuracy is high and the detection speed is slow

[0066] Character preprocessing: closed by default, you can set related parameters when it is turned on.

[0067] Font Color: Select the color of the font you want to identify.

[0068] Dot matrix font processing: Optimize the recognition success rate for dot matrix character detection.

[0069] Threshold: Manually adjust the black and white threshold for segmenting characters.

[0070] The communication mode of the present invention: supports serial port and network port, we use the network port / TCP client mode

[0071] TCP client: the smart camera acts as the client, the computer acts as the server, and the camera sends data to the computer;

[0072] TCP server: the smart camera acts as a server, the computer acts as a client, and the computer actively requests data;

[0073] Modbus-TCP: Data exchange is carried out through the network port modbus protocol;

[0074] Server IP address: Computer IP address, which is in the same network segment as the camera.

[0075] Local IP address: Camera IP address, which is in the same network segment as the computer.

[0076] Server IP port: The computer and the camera are set to the same port.

[0077] Number of sent data frames: The data format that the camera sends to the computer after recognizing the character string.

[0078] The IPM automatic feeding tooling of the present invention can realize automatic sliding of IPM to improve efficiency. The camera IO control board, smart camera, and LCD touch screen can realize automatic recognition and transmission of the characters at the bottom of IPM. The MES system can recognize the IPM model according to the production scheduling model, and compare it with the camera output content, bundle barcode traceability, and realize the error alarm function. Select production scheduling, click to start production, and MES will trace the IPM model according to the currently selected model and compare it with the model recognized by the camera. When inconsistency is found, an alarm will be sounded immediately, and a pop-up window will be displayed on the software interface to report an error "IPM verification exception" to improve the current problem of wrong materials caused by manual verification errors.

[0079] The above are only preferred embodiments of the present application and are not intended to limit the present application. For those skilled in the art, the present application may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

[0080] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential features of the present invention. Therefore, the embodiments should be viewed from all points of view as exemplary and non-restrictive. The scope of the present invention is defined by the appended claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims be included in the present invention, and any reference numerals in the claims should not be considered as limiting the claims involved.

[0081] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. An IPM error-proofing test system, characterized in that: The invention comprises a computer (1), a switch (2), a camera IO control board (5), an IPM automatic feeding tool (6), a smart camera (7) and an LCD touch screen (8), wherein the computer (1) is connected to a NET module in the camera IO control board (5) via the switch (2); and an MES system is arranged inside the computer (1); The PWR module of the camera IO control board (5) is connected to the intelligent camera (7) for communication, and the intelligent camera (7) is embedded in the IPM automatic feeding tooling (6); The smart camera (7) is communicatively connected to the LCD touch screen (8).

2. An IPM error-proofing test system according to claim 1, characterized in that: The output power interface of the camera IO control board (5) is connected to a power plug (3) via a power adapter (4), and the power plug (3) is connected to an external power source.

3. An IPM error-proofing test system according to claim 2, characterized in that: The IPM automatic feeding tool (6) is provided with a panel inclined thereon, a slide groove is provided on the panel, a material tube is provided on the slide groove, and an intelligent power module IPM is installed in the material tube.

4. An IPM error-proofing test system according to claim 3, characterized in that: The panel is arranged at an inclination angle of 30°-45°.

5. An IPM error-proofing test system according to claim 4, characterized in that: The bottom end of the panel of the IPM automatic feeding tool (6) is provided with an opening.

6. An IPM error-proofing test system according to claim 1, characterized in that: The intelligent camera (7) is arranged below the bottom of the inclined chute of the IPM automatic feeding tool (6).

7. An IPM error-proofing test system according to claim 6, characterized in that: The smart camera (7) is fixedly arranged parallel to the panel, and the lens of the smart camera (7) is aligned with the opening position of the panel of the IPM automatic feeding tool (6).

8. An IPM error-proofing test system according to claim 7, characterized in that: The panel material pipe of the IPM automatic feeding tool (6) is made of transparent material.

9. An IPM error-proofing test system according to claim 8, characterized in that: The IPM automatic feeding tool (6) is provided with enclosures around it.

10. An IPM error-proofing test method according to any one of claims 1 to 9, characterized in that: The method steps are as follows: S1, loading of tooling, placing the tubular intelligent power module IPM into the card slot of the IPM automatic loading tooling (6), and the tubular intelligent power module IPM will automatically slide two pieces to the material removal port; S2, information scanning and transmission, the intelligent camera (7) automatically starts detection when powered on, and scans the bottom screen of the tubular intelligent power module IPM at a frequency of (3) S intervals through the opening reserved by the IPM automatic feeding tooling (6), and converts the recognized characters into a character string and outputs it to the computer (1); S3. Comparative testing: The MES system installed on the computer (1) checks whether the model of the tubular intelligent power module IPM currently used in production is consistent with the model output by the smart camera. If not, a voice alarm and pop-up window reminder are issued, and the system is bundled with the product barcode for traceability.

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