Automatic small transformer detection device

Abstract

The invention relates to an automatic small transformer detection device, and relates to the technical field of transformer detection, the automatic small transformer detection device comprises a shell, the shell comprises an upper layer and a lower layer, the center of the upper layer is provided with a detection host, and one side of the outer wall of the detection host is provided with a visual identification system; a conveying mechanism is arranged below the detection host, a sorting mechanism is arranged on one side of the conveying mechanism, a transition plate is arranged on the other side of the conveying mechanism, a hopper is arranged on one side of the transition plate, and a sorting storage box is arranged on one side of the sorting mechanism. And the detection stability is improved through a temperature and humidity compensation mechanism and an automatic calibration function. The device realizes the full automation of the detection process, has the advantages of high detection precision, good stability and high detection efficiency, and ensures the stable operation and long service life of the device through the reinforced design of key nodes.

Description

Technical Field

[0001] The present application relates to the technical field of transformer detection, and in particular to an automated small transformer detection device. Background Art

[0002] In today's era of high reliance on electronic devices, small transformers, as a vital electronic component, have been widely used in various electronic devices. Whether it is the portable electronic devices such as smartphones and tablets we use in daily life, or the complex and precise automation control systems in the industrial field, or professional equipment such as medical equipment that have extremely high requirements for stability and reliability, small transformers play an indispensable role. The performance of small transformers directly determines whether the electronic equipment can operate stably and reliably. For example, in the power supply system of electronic equipment, the small transformer is responsible for reasonably transforming and adjusting the input voltage to provide a voltage value suitable for the normal operation of the various circuits of the equipment. If there is a problem with the performance of the small transformer, such as unstable inductance or excessive loss, it may cause abnormal power output, which in turn affects the normal operation of the entire electronic equipment, and may even cause damage to the equipment, causing unnecessary losses to users. Therefore, in order to ensure the quality and performance of electronic equipment, it is particularly important to accurately and stably detect small transformers; However, the existing small transformer detection devices have some problems in actual use. First, there are obvious deficiencies in detection accuracy. Due to the structural characteristics of the small transformer itself, the number of coil turns is relatively small, which makes its inductance value at a low level. Secondly, the detection stability of the existing detection device is poor. In the actual detection process, changes in environmental factors such as temperature and humidity will have a significant impact on the test results. When the ambient temperature rises, the material properties inside the small transformer may change. For example, changes in resistivity will cause fluctuations in inductance value; at the same time, temperature changes may also affect the performance of electronic components in the detection device, causing changes in their working state, thereby affecting the accuracy of the measurement.

[0003] In view of the above-mentioned related technologies, a solution is now proposed. Summary of the invention

[0004] The purpose of this application is to provide an automated small transformer detection device to solve the technical problems in the prior art of poor detection accuracy and stability and the inability to automate the detection process.

[0005] The present application provides an automated small transformer detection device, which adopts the following technical solution: An automated small transformer detection device comprises a shell, wherein the shell comprises an upper layer and a lower layer, a detection host is arranged at the center of the upper layer, a visual identifier is arranged on one side of the outer wall of the detection host, a transmission mechanism is arranged below the detection host, a sorting mechanism is arranged on one side of the transmission mechanism, a transition plate is arranged on the other side of the transmission mechanism, a hopper is arranged on one side of the transition plate, and a sorting storage box is arranged on one side of the sorting mechanism.

[0006] By adopting the above technical scheme, the shell of the device is divided into an upper layer and a lower layer. A detection host is set at the center of the upper layer, and a visual identifier is equipped on one side of its outer wall for accurate identification and positioning of small transformers. A transmission mechanism is provided under the detection host, which is responsible for smoothly transporting the transformer to be inspected to the detection area. One side of the transmission mechanism is connected to the sorting mechanism to classify the transformer according to the test results; the other side is connected to the transition plate, and a hopper is placed on one side of the transition plate for collecting or temporarily storing the transformer to be inspected. In addition, a sorting storage box is also provided on one side of the sorting mechanism for storing qualified or unqualified products after inspection. This design not only improves the detection efficiency, but also facilitates subsequent processing and analysis. From the technical effect point of view, it realizes an automated and intelligent detection process, reduces manual intervention, and reduces the error rate. From the assembly direction, the entire device has a compact and reasonable structure, the various components cooperate well, and are easy to install and maintain, providing reliable technical support for the quality inspection of small transformers.

[0007] Preferably, the detection host includes a touch screen, a control unit is provided on one side of the touch screen, a measuring circuit module is provided on one side of the control unit, a clamp is provided on one side of the measuring circuit module, the lower part of the clamp is in contact with the transmission mechanism, a temperature and humidity sensor is provided on the other side of the measuring circuit module, an automatic calibration module is provided on one side of the temperature and humidity sensor, a power supply module is provided on one side of the automatic calibration module, and a communication interface is provided on one side of the power supply module.

[0008] By adopting the above scheme, this design not only realizes the accurate measurement of various parameters of small transformers, but also provides an intuitive and easy-to-use operation interface through the touch screen, allowing users to easily set detection parameters, monitor the detection process and obtain detection results. At the same time, the combination of the measurement circuit module and the fixture ensures the accuracy and stability of the measurement; the temperature and humidity sensor monitors the environmental conditions in real time to ensure the reliability of the test results. In addition, the existence of the automatic calibration module and the power supply module respectively ensures the long-term accuracy and stable operation of the equipment, while the communication interface facilitates data exchange and integration with other devices or systems. From the assembly direction, these components are reasonably laid out and tightly connected in the detection host, which is not only convenient for installation and maintenance, but also conducive to the optimization and improvement of the overall performance of the equipment, fully reflecting the design concept of automation and intelligence.

[0009] Preferably, the transmission mechanism includes a belt, guide wheels are provided on both sides of the belt, a roller is provided on one side of the guide wheel, a drive motor is provided on one side of the roller, a tensioning wheel is provided on the other side of the roller, a support roller is provided on one side of the tensioning wheel, and side plates are provided on both sides of the support roller.

[0010] By adopting the above solution, the belt is used as the transmission medium, and the guide wheels on both sides ensure the accurate running track of the belt, effectively avoiding the deviation or shaking of the belt, thereby ensuring the stability and accuracy of the transmission process. The cooperation between the roller and the drive motor provides strong power support for the transmission mechanism, so that the belt can smoothly and efficiently transmit small transformers. At the same time, the presence of the tensioning wheel ensures the tension of the belt and prevents the influence of the belt being too loose or too tight on the transmission effect. The support roller enhances the carrying capacity of the entire transmission mechanism, ensuring that it will not be deformed or damaged due to heavy pressure during the transmission process. The setting of the side plate not only enhances the overall structural stability of the transmission mechanism, but also plays a role in protection and support.

[0011] Preferably, the sorting mechanism includes a mechanical claw, a microprocessor is provided on one side of the mechanical claw, a sensor is provided on one side of the microprocessor, a servo motor is provided below the sensor, a support frame is provided on one side of the servo motor, a discharge port is provided on one side of the support frame, the discharge port includes a qualified product discharge port and an unqualified product discharge port, an unqualified product discharge port is provided on one side of the qualified product discharge port, and a protective plate is provided on one side of the discharge port.

[0012] By adopting the above solution, the microprocessor controls the precise movement of the mechanical claw, and cooperates with the real-time monitoring of the sensor to ensure the accuracy and efficiency of sorting. The servo motor provides stable power, the support frame ensures the stability of the equipment structure, the discharge port is reasonably designed, qualified products and unqualified products can be accurately separated, and the protective plate ensures safe operation. In terms of actual installation, the layout of each component is compact, which is easy to integrate and maintain. The overall design takes into account practicality and convenience, making the sorting mechanism perform well in actual applications.

[0013] Preferably, the measurement circuit module adopts a differential measurement method, including a differential amplifier, a low-noise operational amplifier is provided on one side of the differential amplifier, and a high-precision ADC is provided on one side of the low-noise operational amplifier. The measurement circuit module amplifies the input signal through the differential amplifier, and optimizes the input signal through the low-noise operational amplifier and the high-precision ADC.

[0014] By adopting the above solution, the differential amplifier effectively amplifies the input signal, and the low-noise operational amplifier and high-precision ADC further optimize the signal, ensuring high precision and stability of the measurement. During the actual installation, the layout of each component is reasonable, which is convenient for integration and debugging. The overall design is compact and efficient, which not only improves the measurement performance, but also simplifies the installation process, showing excellent practicality and convenience.

[0015] Preferably, the ambient temperature and humidity are detected in real time by the temperature and humidity sensor, and the measurement results are corrected by a dynamic compensation algorithm. The temperature and humidity sensor collects data at a frequency of 1 Hz, and one side of the temperature and humidity sensor is transmitted to the control unit via an SPI interface.

[0016] By adopting the above solution, 1Hz frequency data acquisition ensures the timeliness and continuity of monitoring, while the SPI interface transmission ensures the efficient transmission of data to the control unit. In terms of actual installation, the connection between the temperature and humidity sensor and the control unit is simple and easy, and the application of the dynamic compensation algorithm does not require additional complex configuration. The overall design not only improves the accuracy of environmental monitoring, but also simplifies the installation and maintenance process, showing good practicality and convenience.

[0017] Preferably, the automatic calibration module has built-in resistors and inductors as calibration references, and the control unit controls the automatic calibration module to measure the standard element, and adjusts the parameters of the measurement circuit module according to the error value to correct the measurement result.

[0018] By adopting the above solution, the automatic calibration module has built-in resistors and inductors as calibration references, and the control unit accurately controls its measurement of standard components, and intelligently adjusts the parameters of the measurement circuit module according to the error value to correct the measurement results. In terms of technical effect, this design ensures high accuracy and stability of measurement and effectively reduces measurement errors.

[0019] Preferably, a clamp is provided below the detection host, the clamp comprises an upper clamp, a lower clamp is provided on one side of the upper clamp, a clamp driving power supply is provided on one side of the lower clamp, a linear guide is provided on one side of the clamp driving power supply, and a position sensor is provided on one side of the linear guide.

[0020] By adopting the above solution, the clamping jaw drive power supply drives the upper clamping jaw to move precisely along the linear guide rail, and cooperates with the lower clamping jaw to achieve firm clamping of the coil. The position sensor ensures the accuracy of the clamping position and improves the stability and reliability of the detection. In terms of actual installation, the layout of each component is reasonable and the installation is simple. The combination of the clamping jaw drive power supply and the linear guide rail also simplifies the debugging process. The overall design not only improves the performance of the equipment, but also reduces the installation and maintenance costs.

[0021] Preferably, spring shock absorbers are provided at the four corners of the bottom of the shell, and the spring shock absorbers include a telescopic sleeve, a No. 1 spring is provided inside the telescopic sleeve, a No. 2 spring is provided outside the telescopic sleeve, and a roller is provided at the bottom of the telescopic sleeve.

[0022] By adopting the above solution, excellent shock absorption effect and mobility are achieved. In terms of technical effect, the dual shock absorption structure of spring No. 1 and spring No. 2 effectively absorbs vibration energy, while the built-in design of the telescopic sleeve ensures the stability and durability of the spring. The addition of the bottom roller greatly improves the mobility and flexibility of the equipment. In terms of actual installation, the integrated design of the spring shock absorber and the shell simplifies the installation process, and the setting of the roller also facilitates quick positioning and adjustment. The overall design not only enhances the stability of the equipment, but also improves the convenience of use and maintenance.

[0023] In summary, the present application includes at least one of the following beneficial technical effects: 1. Ensure the accuracy of the test results through measuring circuit modules and temperature and humidity compensation mechanisms; 2. Ensure the stability of test results through automatic calibration and environmental compensation; 3. Fully automated testing process greatly improves testing efficiency and reduces labor costs; 4. Strengthen the design of the small and fragile important nodes such as the high and low voltage terminals of the transformer to ensure the stable operation and long life of the device; 5. Adopt anti-seismic design to reduce the impact of external vibration on the test results; adopt modular design to facilitate maintenance and upgrade. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a schematic diagram of the overall structure of an automated small transformer detection device of the present application; Figure 2 This is a partial top view structural diagram of a transmission mechanism and a sorting mechanism of an automated small transformer detection device of the present application; Figure 3 This is a partial front view structural diagram of a detection host of an automated small transformer detection device of the present application; Figure 4 This is a three-dimensional schematic diagram of the overall appearance of an automated small transformer detection device of the present application; Figure 5 This is a partial structural diagram of a transmission mechanism of an automated small transformer detection device of the present application; Figure 6 This is a schematic diagram of the partial structure of a spring shock absorber of an automated small transformer detection device of the present application; Figure 7It is a partial cross-sectional structural schematic diagram of a sorting mechanism of an automated small transformer detection device of the present application.

[0025] Description of reference numerals: 1. housing; 2. upper layer; 3. lower layer; 4. detection host; 401. touch screen; 402. control unit; 403. measurement circuit module; 4031. differential amplifier; 4032. low noise operational amplifier; 4033. high precision ADC; 404. fixture; 40401. upper clamp; 40402. lower clamp; 40403. clamp driving power supply; 40404. linear guide; 40405. position sensor; 405. temperature and humidity sensor; 406. automatic calibration module; 407. power module; 408. communication interface; 409. telescopic motor; 5. visual identifier; 6 , transmission mechanism; 601, belt; 602, guide wheel; 603, roller; 604, driving motor; 605, tensioning wheel; 606, supporting roller; 607, side plate; 7, sorting mechanism; 701, mechanical claw; 702, microprocessor; 703, sensor; 704, servo motor; 705, supporting frame; 706, discharge port; 7061, qualified product discharge port; 7062, unqualified product discharge port; 707, protective plate; 8, transition plate; 9, hopper; 10, sorting storage box; 11, roller; 12, spring shock absorber; 1201, telescopic sleeve; 1202, spring No. 1; 1203, spring No. 2. DETAILED DESCRIPTION

[0026] The following is combined with Figure 1 - Attachment Figure 7 , further details of this application are given.

[0027] Embodiment 1 of the present application discloses an automated small transformer detection device.

[0028] Reference Figure 1 An automated small transformer detection device comprises a shell 1, the shell 1 comprises an upper layer 2 and a lower layer 3, a detection host 4 is arranged at the center of the upper layer 2, a visual identifier 5 is arranged on one side of the outer wall of the detection host 4, a transmission mechanism 6 is arranged below the detection host 4, a sorting mechanism 7 is arranged on one side of the transmission mechanism 6, a transition plate 8 is arranged on the other side of the transmission mechanism 6, a hopper 9 is arranged on one side of the transition plate 8, and a sorting storage box 10 is arranged on one side of the sorting mechanism 7.

[0029] Specifically, the detection host 4 is fixed to the upper layer 2 frame of the housing 1 by bolts, and has an integrated measurement circuit module 403, a temperature and humidity sensor 405, and an automatic calibration module 406. The visual identifier 5 includes an industrial camera and a ring fill light, and the camera is connected to the control unit 402 of the detection host 4 by a cable to capture the position and direction information of the transformer in real time.

[0030] The transmission mechanism 6 includes a belt 601 and a drive motor 604. The belt 601 is connected to the drive motor 604 through a drive roller 603. The drive motor 604 is fixed to the support frame of the lower layer 3 by bolts. The surface of the belt 601 is designed with an anti-slip texture to ensure that the transformer does not slide during transportation. Guide strips are installed on both sides of the belt 601 and fixed to the support frame by bolts to ensure that the transformer is transported in the center.

[0031] The sorting mechanism 7 includes a mechanical claw 701 and a discharge port 706. The mechanical claw 701 is driven by a servo motor 704. The servo motor 704 is connected to the mechanical arm through a belt 601. The mechanical claw 701 is installed at the end of the mechanical arm. The discharge port 706 is fixed to the supporting frame of the lower layer 3 by bolts. A sorting storage box 10 is placed below. The sorting storage box 10 is detachable for easy cleaning and replacement.

[0032] The transition plate 8 is fixed to the support frame by bolts, and its surface is smooth and level with the transmission mechanism 6, ensuring that the transformer will not get stuck or vibrate when sliding from the hopper 9 to the transmission mechanism 6. The hopper 9 is fixed to the support frame of the lower layer 3 by bolts, and its inclination angle is 30°~45°. The transmission mechanism 6 is installed at the outlet of the hopper 9, so that the material passes through the hopper 9 and enters the transmission mechanism 6 and then passes through the sorting mechanism 7 for the next operation. The sorting mechanism 7 is driven by a servo motor 704, and the servo motor 704 is fixed to the support frame 705.

[0033] The sorting storage box 10 is connected to the supporting frame of the lower layer 3 through a slide rail, which is convenient for removal and replacement. When assembling, it is first necessary to process each part according to the design drawings, including the shell 1, the detection host 4, the transmission mechanism 6, the sorting mechanism 7, etc., and then assemble the parts together according to the above connection method. During installation, it is necessary to ensure the horizontality and verticality of each part to avoid affecting the operation of the equipment due to installation errors. After the assembly is completed, debugging is carried out, including calibration of the detection host 4, speed adjustment of the transmission mechanism 6, action test of the sorting mechanism 7, etc., to ensure that the equipment can operate stably. Finally, it is put into use in an actual production environment, and regular maintenance and maintenance are carried out to ensure the long-term stable operation of the equipment.

[0034] Reference Figure 1 and Figure 3The detection host 4 includes a touch screen 401, a control unit 402 is provided on one side of the touch screen 401, a measuring circuit module 403 is provided on one side of the control unit 402, a fixture 404 is provided on one side of the measuring circuit module 403, and the fixture 404 is a precision fixture. The lower side of the fixture 404 is in contact with the transmission mechanism 6, a temperature and humidity sensor 405 is provided on the other side of the measuring circuit module 403, an automatic calibration module 406 is provided on one side of the temperature and humidity sensor 405, a power module 407 is provided on one side of the automatic calibration module 406, and a communication interface 408 is provided on one side of the power module 407.

[0035] Specifically, the touch screen 401 is connected to the control unit 402 through a flat cable. The touch screen 401 is used to display the test results and equipment status, and provide an operation interface for user interaction; the control unit 402 is connected to the measurement circuit module 403 through a bus interface. The control unit 402 is responsible for coordinating the test process, processing the test data and managing the peripheral equipment; the measurement circuit module 403 is connected to the clamp 404 through a shielded wire. The measurement circuit module 403 includes a differential amplifier 4031, a low-noise operational amplifier 4032 and a high-precision ADC 4033, which are used to measure the inductance, resistance and insulation performance of the transformer. The clamp 404 is fixed to the bottom of the detection host 4 by bolts, and its clamp is driven by a pneumatic device to ensure good electrical contact when clamping the transformer coil; the bottom of the clamp 404 is in contact with the transmission mechanism 6 to ensure that the transformer can The other side of the measuring circuit module 403 is connected to the temperature and humidity sensor 405 through the I2C interface. The temperature and humidity sensor 405 monitors the ambient temperature and humidity data in real time, and dynamically compensates the measurement results through the control unit 402; one side of the temperature and humidity sensor 405 is connected to the automatic calibration module 406 through a relay. The automatic calibration module 406 has built-in standard resistors and inductors. The calibration process is regularly started through the control unit 402 to ensure measurement accuracy; one side of the automatic calibration module 406 is connected to the power module 407 through a power line. The power module 407 includes a voltage-stabilized power supply and a filtering circuit to provide a stable power supply for the detection host 4; one side of the power module 407 is connected to the communication interface 408 through a cable. The communication interface 408 includes a USB interface and an Ethernet interface for data transmission and remote control.

[0036] When the detection host 4 is implemented in real life, it is first necessary to process various parts according to the design drawings, including the touch screen 401, the control unit 402, the measurement circuit module 403, the fixture 404, etc., and then assemble the various parts together according to the above-mentioned connection method. During installation, it is necessary to ensure that the electrical connection of each part is reliable to avoid affecting the operation of the equipment due to poor contact. After the assembly is completed, debugging is carried out, including calibration of the measurement circuit module 403, action test of the fixture 404, data collection of the temperature and humidity sensor 405, etc., to ensure that the detection host 4 can operate stably. Finally, it is put into use in an actual production environment, and regular maintenance and maintenance are carried out to ensure the long-term stable operation of the equipment.

[0037] Reference Figure 1 and Figure 5 The transmission mechanism 6 includes a belt 601, guide wheels 602 are arranged on both sides of the belt 601, a roller 603 is arranged on one side of the guide wheel 602, a driving motor 604 is arranged on one side of the roller 603, a tensioning wheel 605 is arranged on the other side of the roller 603, a supporting roller 606 is arranged on one side of the tensioning wheel 605, and side plates 607 are arranged on both sides of the supporting roller 606.

[0038] Specifically, guide wheels 602 are installed on both sides of the belt 601 through bearings, and the guide wheels 602 are fixed to the support frame through bolts to ensure that the transformer is transported in the center of the belt 601 to avoid deviation; one side of the guide wheel 602 is connected to a roller 603 through the belt 601, and the roller 603 is installed on the support frame through bearings. The surface of the roller 603 is designed with an anti-slip texture to ensure that the friction between the belt 601 is large enough to avoid slipping; one side of the roller 603 is connected to the drive motor 604 through the belt 601, and the drive motor 604 is fixed to the support frame through bolts. The drive motor 604 adopts a stepper motor or a servo motor, which is accurately controlled by the control unit 402 Control the running speed and position of the belt 601; a tensioning wheel 605 is installed on the other side of the roller 603 through a bearing, and the tensioning wheel 605 is connected to the support frame through an adjusting bolt, which is used to adjust the tension of the belt 601 to prevent the belt 601 from loosening or slipping; a support roller 606 is installed on one side of the tensioning wheel 605 through a bearing, and the support rollers 606 are evenly distributed under the belt 601 and fixed to the support frame by bolts, which are used to support the belt 601 and reduce friction; side plates 607 are fixed on both sides of the support roller 606 by bolts, and the side plates 607 are connected to the support frame by bolts, which are used to protect the belt 601 and the guide wheel 602, and prevent external objects from entering the interior of the transmission mechanism 6.

[0039] When realizing the transmission mechanism 6 in actual life, it is first necessary to process various parts according to the design drawings, including the belt 601, the guide wheel 602, the roller 603, the drive motor 604, etc., and then assemble the various parts together according to the above-mentioned connection method. During installation, it is necessary to ensure that the tension of the belt 601 is moderate to avoid excessive tightness or looseness affecting the operation. After assembly, debugging is carried out, including speed adjustment of the drive motor 604, position calibration of the guide wheel 602, horizontality check of the support roller 606, etc., to ensure that the transmission mechanism 6 can operate stably. Finally, it is put into use in an actual production environment, and regular maintenance and maintenance are carried out to ensure the long-term stable operation of the equipment.

[0040] Reference Figure 1 and Figure 7 The sorting mechanism 7 includes a mechanical claw 701, a microprocessor 702 is arranged on one side of the mechanical claw 701, a sensor 703 is arranged on one side of the microprocessor 702, a servo motor 704 is arranged below the sensor 703, a support frame 705 is arranged on one side of the servo motor 704, a discharge port 706 is arranged on one side of the support frame 705, the discharge port 706 includes a qualified product discharge port 7061 and a failed product discharge port 7062, a failed product discharge port 7062 is arranged on one side of the qualified product discharge port 7061, and a protective plate 707 is arranged on one side of the discharge port 706.

[0041] Specifically, the model of microprocessor 702 is STM32F4 series, and the model of sensor 703 is TCRT5000. Mechanical claw 701 is connected to servo motor 704 through belt 601, and servo motor 704 is fixed to support frame 705 through bolts. Servo motor 704 drives mechanical claw 701 to perform multi-degree-of-freedom movement to ensure that the transformer can be accurately grasped and placed; one side of mechanical claw 701 is connected to microprocessor 702 through cable, and microprocessor 702 is fixed to support frame 705 through bolts. Microprocessor 702 is responsible for controlling the movement of mechanical claw 701 and adjusting the sorting strategy according to the data of sensor 703; one side of microprocessor 702 is connected to sensor 703 through cable, and sensor 703 includes position sensor and photoelectric sensor, which is installed near mechanical claw 701 and discharge port 706 through bracket, and is used to detect the position and sorting status of transformer in real time; the lower part of sensor 703 is connected to servo motor 704 through belt 601, and servo motor 70 The servo motor 704 is fixed to the support frame 705 by bolts, and the mechanical claw 701 is driven by the mechanical claw 701 to move precisely; the support frame 705 is fixed to one side of the servo motor 704 by bolts, and the support frame 705 is made of high-rigidity material to ensure the stability of the sorting mechanism 7; a discharge port 706 is installed on one side of the support frame 705 by bolts, and the discharge port 706 includes a qualified product discharge port 7061 and a failed product discharge port 7062, and the qualified product discharge port 7061 and the failed product discharge port 7062 are connected to the support frame 705 by slide rails, and a qualified product storage box and a failed product storage box are placed below them respectively, which are convenient for taking out and replacing; a protective plate 707 is fixed to one side of the discharge port 706 by bolts, and the protective plate 707 wraps the two sides and the top of the sorting mechanism 7, and is used to protect the mechanical claw 701 and the servo motor 704, and prevent external objects from entering the interior of the sorting mechanism 7.

[0042] When the sorting mechanism 7 is realized in actual life, it is first necessary to process various parts according to the design drawings, including the mechanical claw 701, the microprocessor 702, the sensor 703, the servo motor 704, etc., and then assemble the various parts together according to the above-mentioned connection method. During installation, it is necessary to ensure that the movement range of the mechanical claw 701 covers the discharge port 706 to avoid affecting the sorting effect due to position deviation. After the assembly is completed, debugging is carried out, including the action test of the servo motor 704, the data collection of the sensor 703, the control logic verification of the microprocessor 702, etc., to ensure that the sorting mechanism 7 can operate stably.

[0043] Reference Figure 3The measurement circuit module 403 adopts a differential measurement method, including a differential amplifier 4031, a low-noise operational amplifier 4032 and a high-precision ADC 4033. The low-noise operational amplifier 4032 is arranged on one side of the differential amplifier 4031, and the high-precision ADC 4033 is arranged on one side of the low-noise operational amplifier 4032. The measurement circuit module 403 amplifies the input signal through the differential amplifier 4031, and optimizes the input signal through the low-noise operational amplifier 4032 and the high-precision ADC 4033.

[0044] Specifically, the model of the differential amplifier 4031 is AD620, which is a low-power, high-precision instrument amplifier with adjustable gain, suitable for low-noise and high-precision measurement. The model of the low-noise operational amplifier 4032 is OPA1612, which is an ultra-low noise, low-distortion operational amplifier suitable for high-precision audio and measurement applications. The model of the high-precision ADC is ADS1256, a 24-bit Σ-Δ ADC with high precision and low noise, suitable for precision measurement and data acquisition systems. The measurement circuit module 403 adopts a differential measurement method, including a differential amplifier 4031, a low-noise operational amplifier 4032 and a high-precision ADC 4033. The differential amplifier 4031 is connected to the fixture 404 through a shielded wire. The differential amplifier 4031 is used to preliminarily amplify the input signal and suppress common-mode interference, thereby providing High signal-to-noise ratio; one side of the differential amplifier 4031 is connected to a low-noise operational amplifier 4032 through a shielded wire, and the low-noise operational amplifier 4032 is used to perform secondary amplification on the signal output by the differential amplifier 4031 to further reduce the noise level and ensure measurement accuracy; one side of the low-noise operational amplifier 4032 is connected to a high-precision ADC 4033 through a shielded wire, and the high-precision ADC 4033 adopts a 24-bit Σ-Δ type ADC to convert analog signals into digital signals and improve measurement resolution through sampling and digital filtering technology; the measurement circuit module 403 amplifies the input signal through the differential amplifier 4031, and optimizes the input signal through the low-noise operational amplifier 4032 and the high-precision ADC 4033 to ensure the accuracy and stability of the measurement result.

[0045] The measurement circuit module 403 adopts contactless magnetic suspension technology to eliminate mechanical friction and achieve up and down displacement with nanometer-level positioning accuracy. The permanent magnet array and the electromagnetic coil group constitute a suspension unit, and vertical contactless driving is achieved through the Lorentz force. At the same time, a high-sensitivity Hall sensor such as Melexis MLX90393 is integrated to achieve accurate monitoring of the up and down displacement of the measurement circuit module 403.

[0046] When implementing the measurement circuit module 403 in real life, it is first necessary to select high-quality electronic components according to the design drawings, including the differential amplifier 4031, the low-noise operational amplifier 4032 and the high-precision ADC 4033, and then solder the components on the circuit board according to the above connection method. During soldering, it is necessary to ensure that the connection of the shielded wire is reliable to avoid affecting the signal transmission due to poor contact. After assembly, debugging is performed, including gain adjustment of the differential amplifier 4031, noise testing of the low-noise operational amplifier 4032, accuracy calibration of the high-precision ADC 4033, etc., to ensure that the measurement circuit module 403 can operate stably.

[0047] Reference Figure 3 The ambient temperature and humidity are detected in real time through the temperature and humidity sensor 405, and the measurement results are corrected by a dynamic compensation algorithm. The temperature and humidity sensor 405 collects data at a frequency of 1 Hz, and one side of the temperature and humidity sensor 405 is transmitted to the control unit 402 through the SPI interface.

[0048] Specifically, the ambient temperature and humidity are detected in real time by the temperature and humidity sensor 405. The temperature and humidity sensor 405 adopts a high-precision, low-drift sensor, the model of which is the SHT series of Sensirion or the HTU series of TE Connectivity. The temperature and humidity sensor 405 is fixed to the inside of the detection host 4 by bolts, close to the measurement circuit module 403, to ensure the accuracy of the detection data; the temperature and humidity sensor 405 collects ambient temperature and humidity data at a frequency of 1 Hz, and the collected data is transmitted to the control unit 402 through the SPI interface. The SPI interface connects the temperature and humidity sensor 405 and the control unit 402 through a shielded cable to ensure the stability and anti-interference ability of data transmission; after receiving the temperature and humidity data, the control unit 402 adopts a dynamic compensation algorithm to correct the measurement result. The dynamic compensation algorithm is based on the temperature and humidity-error relationship model established based on experimental data, and calculates the measurement error under the current temperature and humidity through polynomial fitting or piecewise linear fitting method, and dynamically adjusts the measurement result.

[0049] When implementing the temperature and humidity sensor 405 in actual life, first, it is necessary to select a high-quality temperature and humidity sensor 405 according to the design drawings, and then install the temperature and humidity sensor 405 inside the detection host 4 according to the above-mentioned connection method, and connect it to the control unit 402 through a shielded cable. During installation, it is necessary to ensure that the position of the temperature and humidity sensor 405 is close to the measurement circuit module 403 to avoid affecting the accuracy of the detection data due to position deviation. After assembly, debugging is carried out, including data acquisition testing of the temperature and humidity sensor 405, communication verification of the SPI interface, accuracy calibration of the dynamic compensation algorithm, etc., to ensure that the temperature and humidity sensor 405 can operate stably. Finally, it is put into use in an actual production environment, and regular maintenance and maintenance are carried out to ensure the long-term stable operation of the equipment.

[0050] Reference Figure 3 The automatic calibration module 406 has built-in resistors and inductors as calibration references, wherein the resistors are high-precision standard resistors and the inductors are standard inductors. The control unit 402 controls the automatic calibration module 406 to measure the standard components, and adjusts the parameters of the measurement circuit module 403 according to the error value to correct the measurement results.

[0051] Specifically, the automatic calibration module 406 has built-in resistors and inductors as calibration references, and the accuracy level of the standard resistors and inductors needs to be higher than the accuracy requirements of the measurement circuit module 403, such as 0.01% accuracy, to ensure the accuracy of the calibration reference; the automatic calibration module 406 is connected to the control unit 402 via a relay, and the relay is connected to the measurement circuit module 403 via a shielded cable. The control unit 402 regularly starts the automatic calibration process, controls the relay to switch to the standard resistor or inductor, and the measurement circuit module 403 measures the standard component to obtain the standard value; the control unit 402 calculates the measurement error based on the error between the standard value and the value to be measured, and corrects the measurement result by dynamically adjusting the gain, bias and other parameters of the measurement circuit module 403.

[0052] When implementing the automatic calibration module 406 in real life, it is first necessary to select high-quality standard resistors and inductors according to the design drawings, and then install the standard resistors, inductors and relays inside the automatic calibration module 406 according to the above-mentioned connection method, and connect them to the control unit 402 and the measurement circuit module 403 through a shielded cable. During installation, it is necessary to ensure that the contact resistance of the relay is low and the reliability is high to avoid affecting the calibration accuracy due to poor contact. After assembly, debugging is performed, including measurement and testing of standard components, switching verification of relays, calibration logic verification of the control unit 402, etc., to ensure that the automatic calibration module 406 can operate stably.

[0053] Reference Figure 3 A clamp 404 is arranged below the detection host 4, and the clamp 404 includes an upper clamp 40401, a lower clamp 40402 is arranged on one side of the upper clamp 40401, a clamp driving power supply 40403 is arranged on one side of the lower clamp 40402, a linear guide rail 40404 is arranged on one side of the clamp driving power supply 40403, and a position sensor 40405 is arranged on one side of the linear guide rail 40404.

[0054] Specifically, the upper clamping jaw 40401 and the lower clamping jaw 40402 are fixed to the slider of the linear guide 40404 by bolts, and the clamping surfaces of the upper clamping jaw 40401 and the lower clamping jaw 40402 are designed with anti-slip textures to ensure good electrical contact when clamping the transformer coil and not damaging the coil; one side of the lower clamping jaw 40402 is connected to the clamping jaw driving power supply 40403 through the linear guide 40404, and the clamping jaw driving power supply 40403 is fixed to the supporting frame by bolts, and the clamping jaw driving power supply 40403 drives the upper clamping jaw 40401 and the lower clamping jaw 40402 to move precisely along the linear guide 40404 to ensure moderate clamping force; one side of the clamping jaw driving power supply 40403 A linear guide 40404 is fixed to the side by bolts, and the linear guide 40404 is fixed to the supporting frame by bolts. The linear guide 40404 ensures that the upper clamp 40401 and the lower clamp 40402 remain stable during movement to avoid deviation; a position sensor 40405 is installed on one side of the linear guide 40404 through a bracket. The model of the position sensor 40405 is the MTS-E series, which is a compact magnetostrictive linear position sensor suitable for a variety of industrial scenarios with high cost performance. The position sensor 40405 is connected to the control unit 402 through a cable, and is used to detect the positions of the upper clamp 40401 and the lower clamp 40402 in real time to ensure the accuracy of the clamping action.

[0055] When realizing the clamp 404 in actual life, it is first necessary to process each part according to the design drawings, including the upper clamp 40401, the lower clamp 40402, the clamp drive power supply 40403, the linear guide 40404, etc., and then assemble the parts together according to the above-mentioned connection method. During installation, it is necessary to ensure the horizontality and verticality of the linear guide 40404 to avoid affecting the clamping action due to installation errors. After assembly, debugging is performed, including the action test of the clamp drive power supply 40403, the data collection of the position sensor 40405, the clamping force adjustment of the upper clamp 40401 and the lower clamp 40402, etc., to ensure that the clamp 404 can operate stably.

[0056] Reference Figure 1 and Figure 6 Spring shock absorbers 12 are arranged at the four corners of the bottom of the shell 1. The spring shock absorber 12 includes a telescopic sleeve 1201. A No. 1 spring 1202 is arranged inside the telescopic sleeve 1201, a No. 2 spring 1203 is arranged outside the telescopic sleeve 1201, and a roller 11 is arranged at the bottom of the telescopic sleeve 1201.

[0057] Specifically, the telescopic sleeve 1201 is fixed to the four corners of the bottom of the outer shell 1 by bolts, and a No. 1 spring 1202 is arranged inside the telescopic sleeve 1201, and the No. 1 spring 1202 is fixed to the inner wall of the telescopic sleeve 1201 by welding, so as to absorb vibration in the vertical direction; a No. 2 spring 1203 is arranged outside the telescopic sleeve 1201, and the No. 2 spring 1203 is fixed to the outer wall of the telescopic sleeve 1201 by welding, so as to absorb vibration in the horizontal direction; a roller 11 is installed at the bottom of the telescopic sleeve 1201 by bolts, and the roller 11 adopts a universal wheel design, so as to facilitate the movement and fixation of the equipment.

[0058] When realizing the spring shock absorber 12 in actual life, it is first necessary to process various parts according to the design drawings, including the telescopic sleeve 1201, the No. 1 spring 1202, the No. 2 spring 1203 and the roller 11, and then assemble the various parts together according to the above-mentioned connection method. During installation, it is necessary to ensure that the elastic coefficients of the No. 1 spring 1202 and the No. 2 spring 1203 are moderate to avoid affecting the shock absorption effect due to excessive or insufficient elasticity. After assembly, debugging is carried out, including shock absorption effect testing of the spring shock absorber 12, movement and fixing function verification of the roller 11, etc., to ensure that the spring shock absorber 12 can operate stably.

[0059] Embodiment 2 of the present application discloses an automated small transformer detection device.

[0060] Reference Figure 3In the specific implementation process, the measuring circuit module 403 adopts an electric telescopic structure to detect the material below. Specifically, the measuring circuit module 403 drives the electronic components above to detect. The measuring circuit module 403 adopts a liftable structure design to achieve fine detection of the clamped material. A telescopic motor 409 is arranged inside the detection host 4. The telescopic motor 409 can drive the differential amplifier 4031, the low-noise operational amplifier 4032 and the high-precision ADC 4033 below to move up and down along the vertical direction of the device. The position signal is fed back by the absolute encoder. The telescopic motor 409 drives the measuring circuit module 403 to move up and down in the vertical direction of the device. 0mm / s speed steadily descends, based on the preset program and the signal feedback of the position sensor 40405 below, the high-precision ADC4033 contacts the material for measurement without damaging the material. After the transformer to be inspected is positioned by the fixture 404, the control unit 402 sends a descending command to the telescopic motor 409. After completing the detection of parameters such as inductance and Q value, the control unit 402 issues an ascending command, and the measuring circuit module 403 returns to the initial position at a speed of 50mm / s; during the lifting and lowering process of the measuring circuit module 403, a flexible cable drag chain is provided to synchronously retract and release the power supply / signal cable to ensure that the line is free of wear within 2 million strokes. The high-precision ADC4033 probe connector adopts MIL-DTL-83513 standard gold-plated contacts, which can still maintain a contact resistance of less than 5mΩ under repeated plugging and unplugging conditions. Unlike Example 1, the measuring circuit module 403 of Example 2 can achieve the stability of the input signal of the high-precision ADC4033 during the displacement process through the lifting function, and automatically adjust the contact force through pressure feedback to solve the measurement error caused by contact pressure fluctuations in traditional detection.

[0061] The implementation principle of the embodiment of the present application is as follows: the outer shell 1 is divided into an upper layer 2 and a lower layer 3, the upper layer 2 is mainly used for the detection host 4 and the visual identifier 5, and the lower layer 3 is used for the transmission mechanism 6, the sorting mechanism 7 and the hopper 9, etc. The modular design makes the functions of each part independent, which is convenient for maintenance and upgrading; the detection host 4 integrates a touch screen 401, a control unit 402, a measurement circuit module 403, a fixture 404, a temperature and humidity sensor 405, an automatic calibration module 406, a power module 407 and a communication interface 408 to form a complete detection unit; the transmission mechanism 6 includes a belt 601, a guide wheel 602, a roller 603, a drive motor 604, etc., which is responsible for transporting the transformer from the hopper 9 to the detection position; the sorting mechanism 7 includes a mechanical claw 701, a microprocessor 702, a sensor 703, etc., which is responsible for classifying the transformer according to the detection results; The high-precision measurement of the device is as follows: the measurement circuit module 403 uses a differential amplifier 4031, a low-noise operational amplifier 4032 and a high-precision ADC 4033, and suppresses common-mode interference through differential measurement to ensure measurement accuracy. The temperature and humidity sensor 405 monitors the ambient temperature and humidity in real time, and corrects the measurement results through a dynamic compensation algorithm to eliminate the influence of environmental factors on the measurement accuracy. The automatic calibration module 406 has built-in resistors and inductors, and regularly calibrates the measurement circuit to ensure long-term measurement accuracy. In the automatic control, the control unit 402 serves as the core control unit and is responsible for coordinating the operation of the detection host 4, the transmission mechanism 6 and the sorting mechanism 7. The control unit 402 interacts with the user through the touch screen 401 and communicates with the external device through the communication interface 408. The position and direction information of the transformer is captured in real time through the industrial camera and the annular fill light to ensure the correct positioning of the transformer at the detection position. The upper clamping jaw 40401 and the lower clamping jaw 40402 are driven by the clamping jaw driving power supply 40403 to ensure that the transformer coil has good electrical contact during the detection process. The four corners of the bottom of the housing 1 are provided with spring shock absorbers 12, including a telescopic sleeve 1201, a No. 1 spring 1202 and a No. 2 spring 1203, which are used to absorb vibrations in the vertical and horizontal directions to ensure that the equipment can still operate stably under external vibration environments; The working process is as follows: the transformer slides from the hopper 9 through the transition plate 8 onto the belt 601 of the transmission mechanism 6, the transmission mechanism 6 transports the transformer to the detection position, the visual identifier 5 adjusts the transformer position, the clamp 404 clamps the transformer coil, the detection host 4 measures the inductance value, resistance value and insulation performance, and according to the detection results, the sorting mechanism 7 classifies the transformer and places it at the qualified product discharge port 7061 or the unqualified product discharge port 7062. The detection results are displayed in real time on the touch screen 401 and stored in the system.

[0062] The embodiments of this specific implementation are all preferred embodiments of the present application, and are not intended to limit the protection scope of the present application. The same components are represented by the same figure marks. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. An automated small transformer detection device, comprising a housing (1), characterized in that: The housing (1) comprises an upper layer (2) and a lower layer (3); a detection host (4) is arranged at the center of the upper layer (2); a visual identifier (5) is arranged on one side of an outer wall of the detection host (4); a transmission mechanism (6) is arranged below the detection host (4); a sorting mechanism (7) is arranged on one side of the transmission mechanism (6); a transition plate (8) is arranged on the other side of the transmission mechanism (6); a hopper (9) is arranged on one side of the transition plate (8); and a sorting storage box (10) is arranged on one side of the sorting mechanism (7).

2. An automated small transformer detection device according to claim 1, characterized in that: The detection host (4) comprises a touch screen (401), a control unit (402) is arranged on one side of the touch screen (401), a measurement circuit module (403) is arranged on one side of the control unit (402), a fixture (404) is arranged on one side of the measurement circuit module (403), the lower side of the fixture (404) is in contact with the transmission mechanism (6), a temperature and humidity sensor (405) is arranged on the other side of the measurement circuit module (403), an automatic calibration module (406) is arranged on one side of the temperature and humidity sensor (405), a power supply module (407) is arranged on one side of the automatic calibration module (406), and a communication interface (408) is arranged on one side of the power supply module (407).

3. An automated small transformer detection device according to claim 1, characterized in that: The transmission mechanism (6) comprises a belt (601), guide wheels (602) are provided on both sides of the belt (601), a roller (603) is provided on one side of the guide wheel (602), a driving motor (604) is provided on one side of the roller (603), a tensioning wheel (605) is provided on the other side of the roller (603), a supporting roller (606) is provided on one side of the tensioning wheel (605), and side plates (607) are provided on both sides of the supporting roller (606).

4. The automatic small transformer detection device according to claim 1 is characterized in that: The sorting mechanism (7) comprises a mechanical claw (701), a microprocessor (702) is arranged on one side of the mechanical claw (701), a sensor (703) is arranged on one side of the microprocessor (702), a servo motor (704) is arranged below the sensor (703), a support frame (705) is arranged on one side of the servo motor (704), a discharge port (706) is arranged on one side of the support frame (705), the discharge port (706) comprises a qualified product discharge port (7061) and a failed product discharge port (7062), a failed product discharge port (7062) is arranged on one side of the qualified product discharge port (7061), and a protective plate (707) is arranged on one side of the discharge port (706).

5. The automatic small transformer detection device according to claim 2 is characterized in that: The measurement circuit module (403) adopts a differential measurement method, comprising a differential amplifier (4031), a low-noise operational amplifier (4032) being provided on one side of the differential amplifier (4031), and a high-precision ADC (4033) being provided on one side of the low-noise operational amplifier (4032), the measurement circuit module (403) amplifies an input signal through the differential amplifier (4031), and optimizes the input signal through the low-noise operational amplifier (4032) and the high-precision ADC (4033).

6. An automated small transformer detection device according to claim 2, characterized in that: The temperature and humidity of the environment are monitored in real time by the temperature and humidity sensor (405), and the measurement result is corrected by using a dynamic compensation algorithm. The temperature and humidity sensor (405) collects data at a frequency of 1 Hz, and one side of the temperature and humidity sensor (405) is transmitted to the control unit (402) via an SPI interface.

7. An automated small transformer detection device according to claim 2, characterized in that: The automatic calibration module (406) has built-in resistors and inductors as calibration references. The control unit (402) controls the automatic calibration module (406) to measure the standard element, and adjusts the parameters of the measurement circuit module (403) according to the error value to correct the measurement result.

8. An automated small transformer detection device according to claim 2, characterized in that: A clamp (404) is arranged below the detection host (4), and the clamp (404) comprises an upper clamp (40401), a lower clamp (40402) is arranged on one side of the upper clamp (40401), a clamp driving power supply (40403) is arranged on one side of the lower clamp (40402), a linear guide rail (40404) is arranged on one side of the clamp driving power supply (40403), and a position sensor (40405) is arranged on one side of the linear guide rail (40404).

9. The automatic small transformer detection device according to claim 1, characterized in that: Spring shock absorbers (12) are arranged at the four corners of the bottom of the housing (1), and the spring shock absorber (12) comprises a telescopic sleeve (1201), a No. 1 spring (1202) is arranged inside the telescopic sleeve (1201), a No. 2 spring (1203) is arranged outside the telescopic sleeve (1201), and a roller (11) is arranged at the bottom of the telescopic sleeve (1201).

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