Flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters

Abstract

The present invention discloses a flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters, which is equipped with an integrated welding tool, covering units such as an automatic feeding unit for terminal boxes, a welding piece feeding and positioning unit, and a laser welding unit; a three-dimensional positioning subsystem based on a laser interferometer is used to achieve submicron positioning and adjust the trajectory in combination with an algorithm; the multifunctional welding integrated equipment intelligently selects welding methods and parameters; the low heat input welding and thermal deformation compensation subsystem ensures welding accuracy and reliability; a special welding piece feeding mechanism, a smooth feeding channel, a high-precision photoelectric sensor to prevent stacking and jamming, and a vacuum adsorption and precise pushing device; an intelligent recognition and adaptive grasping device to achieve precise grasping; the integrated welding tool integrates multiple processes and completes welding of multiple parts with one clamping; it realizes the hard connection of sampling components of various smart meter products, the fully automatic welding, assembly, and inspection integrated molding, improves processing efficiency, welding accuracy and reliability, and effectively solves the problems of complex parts processing.

Description

Technical Field

[0001] The present invention relates to the technical field of equipment, and in particular to a flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters. Background Art

[0002] 1. Development and application requirements of smart meters

[0003] Smart meters are a new type of power system energy dual-carbon background, the basis for carbon, energy efficiency, electricity consumption, and billing measurement. They are large in number and have a wide range of applications. Their reliability and accuracy are crucial to the safe operation of the power grid and users, as well as the economic and property interests.

[0004] Popularization of smart meters: With the advancement of intelligent power systems, traditional meters are gradually being replaced by smart meters. Smart meters can monitor electricity consumption in real time, realize remote meter reading, two-way communication, support time-of-use electricity prices and other functions, which has brought great convenience to power management and user use. Globally, countries are vigorously promoting the installation and application of smart meters, and its market size continues to expand, which puts higher requirements on the production efficiency and quality of smart meters. There are many difficulties in the technical implementation of fully automatic processing equipment for smart meters, covering multiple dimensions such as component characteristics, welding process, equipment operation, etc., as follows:

[0005] 1. The challenge of specifications and compatibility for small and complex components: Smart meters on the market require robotic arms or mechanical air grippers (nozzles) to grasp and automatically load components such as switch units (relays or circuit breakers), transformers, terminal blocks, and solder lugs. These components are extremely complex and come in a wide variety of sizes, shapes, and interface configurations. This requires highly flexible production capabilities for fully automated processing equipment. Hardware components such as robotic arms, fixtures, robotic arms, or mechanical air grippers (nozzles) must be able to quickly adjust to accommodate components of varying specifications. Furthermore, the control system must be equipped with adaptive algorithms and parameter configurations, enabling flexible, multi-component adaptable robotic arms (grippers) with multiple components. Otherwise, equipment changeovers will be difficult, significantly increasing equipment costs and production changeover time. In addition, the tiny size and complex structure of these components pose great challenges. Existing robots or mechanical air grippers cannot adapt to different shapes, positioning and grasping are difficult, and the accuracy is poor. Relays, circuit breakers, transformers, terminal boxes, etc. have delicate internal structures. During automatic processing, the equipment needs to accurately operate each component. For example, the coil winding and welding of relays, circuit breakers, transformers, transformers, etc., any slight deviation will affect the performance; the spacing between the terminal box terminals is small, and the electrodes must be precisely contacted during welding to avoid short circuits or cold welds.

[0006] 2. Difficulties in Solder Pad Processing: Due to the extremely thin thickness of solder pads ranging from 0.05mm to 3mm, the automated positioning system must achieve micron-level accuracy or even higher, overcoming factors such as equipment vibration and external airflow interference to quickly and accurately identify the pad's position and posture. Traditional visual recognition and mechanical positioning technologies struggle to meet these requirements. During the loading process, thin solder pads are prone to stacking and jamming during transportation and loading. This requires the loading mechanism to have a carefully designed feeding channel, equipped with a suction device with moderate and stable suction, and a push mechanism with precise speed and force control to ensure consistent and accurate loading each time, avoiding processing interruptions or defective products caused by loading problems. Heat input control is crucial during welding. Excessive heat can cause the pad to melt excessively or even burn through, while insufficient heat can result in a weak weld. Precise selection of welding process parameters such as welding current, voltage, and time is crucial, and the welding equipment must possess fast response and precise control capabilities to increase welding speed while ensuring weld quality and avoid defects such as cold and leaky welds.

[0007] 3. Special Positioning and Welding Process Challenges: When the switch unit (relay or circuit breaker) and the transformer are not aligned on the same plane, positioning and assembly become more challenging. Automated processing equipment must be equipped with a high-precision three-dimensional positioning system, combined with complex motion control algorithms, to accurately identify and adjust the position and angle of the two, ensuring an accurate and stable connection. During the welding process, the welding angle, heat distribution, and welding sequence must be strictly controlled to prevent problems such as deformation and poor connection. Furthermore, different solder filler materials, shapes, and sizes have significantly different welding process requirements. The equipment must be able to automatically adjust welding parameters based on the filler type and select the appropriate soldering method, such as wave soldering, reflow soldering, laser soldering, or resistance soldering. The heat generated during welding can cause thermal stress and deformation in the filler and weldment, affecting welding accuracy and reliability. Low-heat-input welding techniques and precise temperature control are essential, along with real-time monitoring and compensation for thermal deformation. Furthermore, the operating environment of smart meters is complex. After welding, good electrical connections and mechanical strength must be ensured, and the filler must be resistant to external factors such as electromagnetic interference and mechanical vibration, enhancing stability and reliability in various environments. Laser welding of weld seams is challenging, especially for welds as thin as 0.05mm, where the seams are narrow and indistinct. This requires a high-resolution and high-sensitivity visual inspection system to accurately identify the weld's location, shape, and direction. Furthermore, while ensuring high-precision positioning required for welding quality, production efficiency must be balanced, achieving a balance between high precision and high speed. Effective protection and filtering measures must also be implemented to mitigate interference from arc light, smoke, and spatter during the laser welding process.

[0008] 4. Bottlenecks in Automatic Grasping and Inspection Technology: Smart meter components are small and irregular in shape. Automatic grasping devices must demonstrate extremely high precision and stability to accurately grasp components such as switch units (relays or circuit breakers), transformers, and solder lugs, avoiding mishandling or damage. This places high demands on the grasping device's mechanical structure design, drive control technology, and sensor accuracy and reliability. Automatic inspection requires comprehensive inspection of component appearance, dimensions, and electrical performance. Appearance inspection relies on high-resolution image acquisition equipment and advanced image processing algorithms to identify minor defects such as cracks and scratches. Electrical performance testing requires high-precision testing equipment and fast, accurate testing methods to monitor and determine in real time whether component electrical parameters meet standards. Automatic inspection generates large amounts of data. How to quickly and accurately process and analyze this data to determine component conformance and classify and trace unqualified products requires the development of efficient data processing models and algorithms, combined with artificial intelligence and machine learning technologies, to enable intelligent analysis and management of inspection data.

[0009] 5. Equipment coordination and troubleshooting: Smart meter fully automated processing equipment consists of multiple modules, including feeding, welding, and testing. Each module's operating speed and cadence must be precisely matched to prevent production bottlenecks and reduce overall efficiency. Failures are inevitable with long-term equipment operation, so a fast and accurate fault diagnosis system is crucial. This system must be able to locate faults promptly. Leveraging remote monitoring and intelligent diagnostic technologies, this system can reduce equipment downtime and improve production efficiency.

[0010] 6. Safety hazards caused by welding quality: Defects such as cold joints, cracks, and delamination during welding are major causes of safety incidents such as smart meter failures, metering and billing errors, and fires. Cold joints lead to unreliable electrical connections, increased resistance, and heat generation, affecting meter operation. Cracks and delamination weaken the mechanical strength and electrical performance of welds, and can cause failures over time. Addressing these issues requires strengthening quality control and inspection of the welding process, focusing on welding material selection, welding process optimization, and welding equipment accuracy and stability.

[0011] 7. Processing difficulties faced by specific smart meter structures: The sampling components of smart meters include switch units (relays or circuit breakers), transformers, and terminal strips. Bare soldering is required between the switch units and the terminal strips, and between the transformers and the terminal strips. This requires at least two sets of welding equipment and fixtures, resulting in multiple steps, long turnaround times, low efficiency, and high costs. Existing processing methods combine manual processing with assembly line operations to complete the welding of related components. However, this processing method suffers from low efficiency. Furthermore, as labor costs increase, reducing labor while improving efficiency to reduce processing costs has become an urgent issue for those skilled in the art. Summary of the Invention

[0012] Therefore, the technical problem to be solved by the present invention is how to overcome the problem of complex parts processing, improve welding accuracy and efficiency, and optimize equipment coordination for flexible, high-precision, fully automated processing. To this end, a flexible manufacturing and high-precision welding system for fully automated processing equipment of smart meters is provided, comprising:

[0013] The integrated welding tooling is arranged in sequence around the circulation line from right to left and then from left to the starting right through the lifting cycle. The integrated welding tooling goes from right to left through the terminal box automatic loading unit, the welding piece loading and positioning unit, the laser welding unit, the opening detection unit, the welding inspection integration unit, the closing detection unit, and the comprehensive detection unit; the laser welding unit includes a welding piece loading mechanism;

[0014] Multi-component automatic loading and grabbing mechanism;

[0015] Vibration and airflow monitoring feedback subsystem;

[0016] Intelligent recognition and adaptive grasping device, efficient data processing and analysis subsystem outputs big data and artificial intelligence analysis for quality judgment, realizes automatic path planning and real-time monitoring of grasping force through collaborative vision and force sensors;

[0017] Laser interferometer-based 3D positioning subsystem: achieves submicron positioning accuracy and adjusts motion trajectory in conjunction with model predictive control algorithms. This laser interferometer-based 3D positioning subsystem works closely with the multi-component automatic feeding and gripping mechanism, the soldering sheet feeding mechanism, the vibration and airflow monitoring and feedback subsystem, and the functional welding integrated equipment to form a flexible manufacturing and high-precision welding system for fully automatic processing equipment for smart meters.

[0018] Multifunctional welding integrated equipment, integrating multiple welding methods, intelligently selecting welding methods and adjusting parameters;

[0019] The low heat input welding and thermal deformation compensation subsystem uses a low heat input laser welding process and uses high-precision temperature sensors and closed-loop control to achieve protection and reduce welding interference;

[0020] A comprehensive intelligent detection subsystem uses high-resolution industrial cameras and deep learning image processing for appearance inspection, while also utilizing high-precision instruments (optional instruments for real-time monitoring of electrical parameters include power monitors, multi-function digital ammeters, AOB19 intelligent programmable digital display meters, three-phase power quality analyzers, and lightning arrester comprehensive testers) to monitor electrical parameters in real time.

[0021] An efficient data processing and analysis subsystem enables real-time data collection and storage, and uses big data and artificial intelligence analysis for quality judgment and traceability;

[0022] Equipment collaborative control software, which monitors and matches module operation data in real time, includes intelligent recognition and adaptive gripping device module, laser interferometer-based 3D positioning subsystem module, multi-component automatic loading and gripping mechanism module, solder sheet loading mechanism module, multi-functional welding integrated equipment module, low heat input welding and thermal deformation compensation subsystem module, vibration and airflow monitoring and feedback subsystem module, and comprehensive intelligent detection subsystem module.

[0023] The distributed control subsystem architecture ensures communication coordination; the distributed control subsystem architecture ensures the coordination of communication coordination, including: multi-component automatic loading and grasping mechanism, welding piece loading mechanism, vibration and airflow monitoring feedback subsystem, multi-functional welding integrated equipment, low heat input welding and thermal deformation compensation subsystem, comprehensive intelligent detection subsystem and laser interferometer-based three-dimensional positioning subsystem.

[0024] The fault diagnosis subsystem based on the Internet of Things and artificial intelligence collects operating data through sensors in key locations to realize remote monitoring center and fault prediction and positioning.

[0025] It also includes: the circulation line is fixed with an integrated welding tool; the integrated welding tool is used to install and fix the terminal box unit, switch unit, and mutual inductor;

[0026] The terminal box automatic loading unit is located on one side of the circulation line;

[0027] The solder piece loading and positioning unit is located on one side of the circulation assembly line. The solder piece loading and positioning unit adopts a smooth feeding channel. A high-precision photoelectric sensor is set on the channel to prevent stacking and jamming of materials, as well as a vacuum adsorption and precise pushing device to form the loading of the solder piece. The solder piece cooperates with the terminal box unit; the vacuum adsorption and precise pushing device includes a high-precision pressure sensor and an intelligent control chip, which automatically adjusts the suction force according to the thickness and material characteristics of the solder piece. The vacuum adsorption and precise pushing device includes a high-precision motor and a screw transmission mechanism, which can accurately control the pushing speed and force.

[0028] The laser welding unit is located on one side of the circulation line. It is used to weld the welding piece to the copper terminals of the switch unit and the copper terminals of the transformer. The laser welding unit uses a welding process to form welds, forming a π-shaped weld between the corresponding welding piece and the copper terminal of the switch unit; and a π-shaped weld between the corresponding welding piece and the copper terminal of the transformer. The welding process adopts a welding piece composite laser welding process, combining pulse and continuous laser, and adopting a multi-axis linkage welding process. The welding angle sequence is controlled through coordinated motion in three-dimensional space, and the parameters are adjusted in real time through real-time monitoring and feedback.

[0029] The vibration and airflow monitoring feedback subsystem automatically adjusts operating parameters or activates vibration reduction devices by installing high-precision vibration sensors and airflow sensors at key locations on the equipment.

[0030] Also includes:

[0031] The switch unit is fixed with a second conductive member, and the mutual inductor is fixed with a third conductive member; the welding and inspection integrated unit welds the second conductive member to the copper terminal of the switch unit; the welding and inspection integrated unit welds the third conductive member to the copper terminal of the mutual inductor;

[0032] The closing detection unit closes the switch unit for detection, including transformer communication detection, transformer current detection, switch unit opening and closing detection, and switch unit current detection;

[0033] Comprehensive detection unit, which detects the terminal box unit where the switch unit and transformer are welded and fixed;

[0034] The multi-component automatic loading and gripping mechanism includes a terminal box automatic loading unit, a switch unit automatic loading unit, and a transformer automatic loading unit. The multi-component automatic loading and gripping mechanism adopts a joint modular design to achieve rapid replacement of various end effectors.

[0035] Adaptive clamp subsystem: The adaptive clamp subsystem intelligently adjusts the clamping position and force. The adaptive clamp subsystem adopts a flexible material surface damage-resistant design and monitors the clamping status in real time through sensors.

[0036] Intelligent recognition and adaptive gripping device, used for solder sheet feeding mechanism, multi-component automatic loading and gripping mechanism's manipulator or mechanical air gripper, realizes automatic grasping path planning and real-time monitoring of grasping force through the collaboration of vision and force sensors.

[0037] The vacuum adsorption and precise pushing device also includes an adaptive suction adjustment subsystem and a flexible adsorption surface:

[0038] Adaptive suction adjustment subsystem: Equipped with a high-precision pressure sensor and intelligent control chip, the pressure sensor monitors the vacuum level in the adsorption chamber in real time. The intelligent control chip uses a pre-recorded database of the corresponding relationships between different solder sheet thicknesses, materials, and suction forces, combined with high-precision pressure sensor data, to quickly and accurately adjust the power of the vacuum pump located at the bottom or side of the vacuum adsorption and precision pushing device, or in a shock-absorbing base or box, thereby achieving automatic adjustment of the suction force.

[0039] The flexible adsorption surface of the adsorption head and the gripper or finger surface is made of a special flexible silicone material with tiny nano-scale pores on the surface. It is manufactured by 3D printing-assisted method, and the diameter, depth and distribution density of the pores are precisely set in the 3D model design;

[0040] Multi-adsorption head collaborative working mechanism: The device is equipped with multiple independently controllable adsorption heads, each of which can independently adjust the suction force and control the working status. The working combination of different adsorption heads is controlled by rule-based algorithms, heuristic algorithms, or machine learning algorithms. When facing a large-area solder wafer array, the multi-adsorption head collaborative working mechanism simultaneously starts multiple adsorption heads for collaborative adsorption. For small and scattered solder wafers, some adsorption heads are selectively enabled for separate adsorption, and the working combination of different adsorption heads is controlled by intelligent algorithms.

[0041] The integrated welding tooling is fixed with welding fixtures.

[0042] Welding fixture includes:

[0043] The bottom plate is provided with a first concave cavity and a first fixing cavity, the first fixing cavity is used to fix the terminal button box unit; the bottom plate is provided with a slide groove, the slide groove is provided with a first horizontal groove and a first inclined groove, and the first horizontal groove is connected to the first inclined groove; or, the bottom plate further includes a protrusion, the protrusion is connected to the bottom plate, the protrusion is provided with a slide groove, the slide groove is provided with a first horizontal groove and a first inclined groove, and the first horizontal groove is connected to the first inclined groove;

[0044] The sixth connecting plate is accommodated in the first concave cavity, and the sixth connecting plate slides relative to the first concave cavity; the sixth connecting plate is provided with a second fixed cavity, and the second fixed cavity is used to fix the switch unit; the sixth connecting plate is provided with a first protrusion, and the first protrusion is located in the sliding groove and slides; the sixth connecting plate is provided with a first opening groove and a second opening groove.

[0045] When the first protrusion slides in the slide groove, it cooperates with the first inclined groove to form an inclined downward pressing action, so that better welding cooperation is achieved between the switch unit and the terminal box unit, and between the mutual inductor and the terminal box unit.

[0046] The welding fixture also includes,

[0047] The clamping unit is slidably connected to the sixth connecting plate, and the clamping unit is provided with a third fixed cavity, which is used to fix the mutual inductor; the clamping unit includes a fixed claw and a rotating claw, one end of the rotating claw rotates relative to the fixed claw, and the other end of the rotating claw cooperates with the fixed claw to form a third fixed cavity; a pressure spring is provided between the fixed claw and the rotating claw, the fixed claw is provided with an inner arc, and the rotating claw is provided with a first L-shaped step groove, a first arc, a second arc, and a third arc, and the first L-shaped step groove, the first arc, the second arc, and the third arc are connected in sequence;

[0048] A positioning frame and a return spring. The positioning frame is provided with a first U-shaped groove and a first fixed column. A double-sided L-shaped first step opening groove and a second step opening groove are symmetrically provided on both sides of the forearm of the first U-shaped groove. The first step opening groove and the second step opening groove are used for positioning and supporting the third conductive member. A 7-shaped step surface is provided on the bottom surface of the positioning frame. A linear ball guide is installed between one side surface of the positioning frame and the first opening groove, and a linear ball guide is installed between the other side surface of the positioning frame and the first opening groove. The positioning frame slides relative to the sixth connecting plate, and the clamping unit is fixed to the positioning frame. The bottom plate is provided with a second fixed column, one end of the return spring cooperates with the first fixed column, and the other end of the return spring cooperates with the second fixed column.

[0049] The second conductive member is connected to the copper terminal of the switch unit by welding; the third conductive member is connected to the copper terminal of the mutual inductor by welding.

[0050] The fixed claw and rotating claw of the clamping unit cooperate with each other, and the clamping unit clamps and fixes the transformer. After welding is completed, the rotating claw can be rotated to easily remove the terminal box unit, switch unit, and transformer integrated structure for the next step of detection operation.

[0051] The floating pressure gate opening support unit is also included. The floating pressure gate opening support unit includes a T-plate, and the T-plate is provided with a T-shaped opening groove and a giving L-shaped opening;

[0052] The opening and closing mechanism is accommodated in the T-shaped opening slot, and is provided with a chamber, which is open at the front and rear. The opening and closing mechanism includes a base and an eighteenth U-shaped slot plate, and the base and the eighteenth U-shaped slot plate cooperate to form a chamber, and the base is provided with a partition portion, and the partition portion is provided with a first waist-shaped hole; the base is provided with a first I-shaped slot and a second I-shaped slot, the first I-shaped slot is connected to the second I-shaped slot, and the bottom surface of the first I-shaped slot is provided with a first groove;

[0053] There are two sliding tongue plates, which are accommodated in the cavity. The two sliding tongue plates are symmetrically arranged, and the front end of the sliding tongue plate extends to the outside of the front end of the cavity, and is used to cooperate with the first pin of the switch unit; the rear end of the sliding tongue plate extends to the outside of the rear end of the cavity, and the rear end of the sliding tongue plate cooperates with the driving source and the power cord; the sliding tongue plate is provided with a first positioning hole and a second lower step, and the second lower step is provided with a step portion;

[0054] A sliding rod extending between the two sliding tongue plates to form a sliding pair;

[0055] An elastic reset member, one end of which abuts against one of the sliding tongue plates, and the other end of which abuts against the other sliding tongue plate. The elastic reset member is located at the front end of the chamber and passes through the first waist-shaped hole. The two sliding tongue plates are respectively arranged on both sides of the partition portion.

[0056] A first positioning pin, the first positioning pin passes through the first positioning hole and is linked to the sliding tongue plate, the first positioning hole is located at the rear end of the chamber, and a convex point is provided at the lower end of the first positioning pin;

[0057] In the first state, the sliding tongue plate moves toward the switch unit, and the front end of the sliding tongue plate cooperates with the first pin to disconnect the switch unit;

[0058] In the second state, the front end of the sliding tongue plate cooperates with the first pin to form a connection effect of the switch unit; the sliding tongue plate moves away from the switch unit; in the initial position, the protrusion cooperates with the first groove, the sliding tongue plate slides, and the step portion abuts against the first I-shaped groove.

[0059] The first positioning pin passes through the first positioning hole of the sliding tongue plate. When the front end of the sliding tongue plate cooperates with the first pin, the elastic reset member is compressed and tightened, and the rear end of the sliding tongue plate rotates around the first positioning pin. At the same time, the tension of the elastic reset member drives the front end of the sliding tongue plate to move outward, so that the sliding tongue plate and the first pin can better cooperate.

[0060] The system achieves intelligent, automatic, high-precision lap assembly, welding connection, and post-weld performance testing between terminal box units, switch units, transformers, and welding pieces through the coordination of multiple machines, vision, force, vibration sensors, laser interferometer's three-dimensional positioning, motion trajectory and algorithm, as well as flexible adaptive manipulators, automatic loading and grabbing of welding pieces, and welding fixtures.

[0061] The welding fixtures include welding fixture A, welding fixture B, and welding fixture C. Welding fixture A, welding fixture B, and welding fixture C respectively form independent and integrated welding fixtures for cyclic welding fixation between the terminal box unit, the switch unit, and the transformer unit.

[0062] Flexible manufacturing, high-precision welding systems and fully automatic processing equipment for smart meters work together to complete welding connections and performance testing, realizing the fully automatic welding, assembly, inspection and integrated molding of hard-connected sampling components for smart single-phase, two-phase or three-phase fee-controlled meters.

[0063] The adaptive fixture subsystem with flexible structure monitors the clamping status in real time through sensors and intelligently adjusts the clamping position and force. The three-dimensional positioning subsystem based on laser interferometer combined with model predictive control algorithm can predict the deviation in the equipment movement process in advance and quickly and accurately adjust the movement trajectory of the processing equipment to ensure that when the welding switch unit and the mutual inductor are not in the same plane, they can achieve precise connection and improve processing accuracy. The equipment collaborative control software monitors the operating data of each module in real time, accurately matches the operating speed and beat of each module, ensures the smooth progress of the entire production process, and improves overall production efficiency. The multifunctional welding integrated equipment can be adjusted according to the different components and different welding Requirements, intelligently select welding methods and adjust parameters; the low heat input welding and thermal deformation compensation subsystem uses high-precision temperature sensors to monitor welding temperature in real time, and uses closed-loop control to promptly compensate for thermal deformation caused by heat input; the comprehensive intelligent detection subsystem uses high-resolution industrial cameras and deep learning image processing to perform appearance inspection, and uses high-precision instruments to monitor electrical parameters in real time; the efficient data processing and analysis subsystem collects and stores data in real time, and uses big data and artificial intelligence analysis to judge and trace product quality; the fault diagnosis subsystem based on the Internet of Things and artificial intelligence collects operating data through sensors at key locations, enabling the remote monitoring center to predict and locate equipment faults;

[0064] The vibration and airflow monitoring feedback subsystem installs high-precision vibration sensors and airflow sensors at key locations on the robotic arm joints and welding workbench to accurately monitor the equipment's own vibration and ambient airflow changes in real time. When an anomaly is detected, the system automatically adjusts the equipment's operating parameters, such as reducing the movement speed and adjusting the motor's output power. If the vibration is severe, the system activates the vibration reduction device to ensure the stability of the automatic positioning system and meet the requirements of welding sheet processing, which requires extremely high positioning accuracy.

[0065] After the visual sensor in the intelligent recognition adaptive grasping device captures the shape, position and posture information of various components such as switch units, transformers and mutual inductors, the system automatically plans the optimal grasping path based on the multi-factor fusion grasping path automatic planning and grasping force collaborative control algorithm. The force sensor continuously monitors the grasping force during the grasping process. When the grasping force is abnormal, it immediately feeds back to the control system to adjust the grasping force of the robotic arm.

[0066] The fully automatic processing equipment for smart meters aims to solve the problems of processing complex parts, improving welding accuracy and efficiency, and optimizing equipment coordination for flexible, high-precision, fully automated processing. Its inventive features are mainly reflected in the following aspects:

[0067] (1) Innovative design of hardware system

[0068] Flexible mechanical structure:

[0069] The system includes a multi-component automatic loading and gripping mechanism, terminal box automatic loading unit, relay automatic loading unit, circuit breaker automatic loading unit, and transformer automatic loading unit. The integrated welding fixture loading and automatic gripping unit, as well as the multiple suction heads of the soldering sheet feeding mechanism, feature a modular joint design, enabling rapid replacement of various end effectors (electromagnetic suction and mechanical snaps). The adaptive gripper subsystem intelligently adjusts gripping position and force, utilizes a flexible material surface design to prevent damage, and uses sensors to monitor gripping status in real time.

[0070] High-precision positioning and motion control:

[0071] The three-dimensional positioning subsystem based on laser interferometer can achieve sub-micron positioning accuracy and adjust the motion trajectory in combination with the model predictive control algorithm.

[0072] The vibration and airflow monitoring feedback subsystem automatically adjusts operating parameters or activates vibration reduction devices by installing sensors at key locations.

[0073] Efficient loading and automatic grabbing device:

[0074] The solder sheet feeding mechanism adopts a smooth feeding channel, a high-precision photoelectric sensor to prevent stacking and jamming, as well as a vacuum adsorption and precise pushing device.

[0075] The intelligent recognition and adaptive grasping device uses an efficient data processing and analysis subsystem to output big data and artificial intelligence analysis for quality judgment. Through the collaboration of vision and force sensors, it realizes automatic grasping path planning and real-time monitoring of grasping force.

[0076] Optimized welding equipment:

[0077] The multifunctional welding integrated equipment integrates multiple welding methods and can intelligently select welding methods and adjust parameters.

[0078] The low heat input welding and thermal deformation compensation subsystem adopts low heat input laser welding process and implements protective devices to reduce welding interference through high-precision temperature sensors and closed-loop control.

[0079] Intelligent detection equipment:

[0080] The comprehensive intelligent detection subsystem uses high-resolution industrial cameras and deep learning image processing for appearance inspection, while using high-precision instruments to monitor electrical parameters in real time.

[0081] The efficient data processing and analysis subsystem realizes real-time data collection and storage, and uses big data and artificial intelligence analysis for quality judgment and traceability.

[0082] Equipment collaboration and fault diagnosis subsystem:

[0083] The equipment collaborative control software ensures communication collaboration through real-time monitoring and beat matching of module operation data and distributed control subsystem architecture.

[0084] The fault diagnosis subsystem based on the Internet of Things and artificial intelligence collects operating data through sensors in key locations to realize remote monitoring center and fault prediction and positioning.

[0085] Processing innovation for specific structures and processes of smart meters:

[0086] The integrated welding tooling integrates multiple welding processes, ensures relative position accuracy through high-precision positioning, and improves efficiency through automated welding processes.

[0087] Improved welding process: A hybrid laser welding process is used, combining pulsed and continuous lasers to precisely control parameters to ensure quality and efficiency. Furthermore, a multi-axis linkage welding process is used to control the welding angle sequence through coordinated motion in three-dimensional space, with real-time monitoring and feedback to adjust parameters.

[0088] 2. Technical Effect Analysis

[0089] Improve production efficiency:

[0090] Through the integrated welding tooling, multiple welding processes are integrated into one tooling platform. The welding operations of multiple parts can be completed with one clamping, which reduces the positioning error caused by multiple clamping and greatly improves the production efficiency.

[0091] The equipment collaborative control software monitors the operating data of each module in real time, accurately matches the operating speed and rhythm of each module, ensures the smooth progress of the entire production process, and improves overall production efficiency.

[0092] Improve welding accuracy:

[0093] The three-dimensional positioning subsystem based on laser interferometer achieves submicron positioning accuracy. Combined with the model predictive control algorithm, it adjusts the motion trajectory to ensure precise connection when welding switch units (relays or circuit breakers) and components such as transformers that are not on the same plane, thereby improving processing accuracy.

[0094] The high-precision positioning device ensures that the relative position accuracy of each component during the welding process can reach the micron level, effectively ensuring the welding quality and product performance stability.

[0095] The low heat input welding and thermal deformation compensation subsystem adopts a low heat input laser welding process. Through high-precision temperature sensors and closed-loop control, it achieves precise control of the welding temperature, timely compensates for thermal deformation caused by heat input, and ensures welding accuracy and reliability.

[0096] Enhance the adaptability and flexibility of equipment:

[0097] The flexible mechanical structure reconfigurable robotic arm system adopts a joint modular design, which can realize the rapid replacement of various end effectors. The adaptive clamp subsystem can intelligently adjust the clamping position and force to meet the processing requirements of parts of different specifications.

[0098] The multifunctional welding integrated equipment integrates multiple welding methods and can intelligently select welding methods and adjust parameters to meet the diverse needs of different components and different welding requirements of smart meters.

[0099] Improve equipment reliability and stability:

[0100] The vibration and airflow monitoring feedback subsystem automatically adjusts operating parameters or activates vibration reduction devices by installing sensors at key locations, ensuring the stability of the automatic positioning system and meeting the requirements of processes such as welding processing that require extremely high positioning accuracy.

[0101] 3. The technical solution of the present invention also has the following advantages:

[0102] (1) The flexible manufacturing and high-precision welding system of the fully automatic processing equipment of the smart meter provided by the present invention forms an intelligent automatic high-precision lap assembly, welding connection and post-welding performance detection between the terminal box unit, switch unit, mutual inductor and welding piece through the cooperation of multiple machines, vision and force, vibration sensors, three-dimensional positioning, motion trajectory and algorithm of laser interferometer, flexible adaptive manipulator (mechanical air claw), automatic feeding and grasping of welding pieces, welding fixture A, welding fixture B and welding fixture C. Compared with the manual processing in the prior art, this processing method can greatly improve the processing efficiency, welding accuracy and reliability, and reduce production costs.

[0103] (2) The flexible manufacturing and high-precision welding system of the fully automatic processing equipment for smart meters provided by the present invention has a very thin thickness of the welding piece. Conventional welding methods will cause the welding piece to vaporize, affecting subsequent processing. The pulse spot welding method can form an intermittent cooling effect to prevent the welding piece from overheating during the welding process. The setting of the π-shaped weld increases the overall welding length, optimizes the welding route, and improves the welding quality.

[0104] (3) The flexible manufacturing and high-precision welding system of the fully automatic processing equipment for smart electric meters provided by the present invention has a very thin thickness of the welding sheet. During the suction process, the welding sheet is easily affected by static electricity, resulting in static adsorption, which causes unilateral force to tear the welding sheet during the suction process. A U-shaped suction nozzle forms a structure with two suction nozzle openings, and the welding sheet is sucked by the two suction nozzle openings. Compared with the single-point suction, this structure has higher stability. At the same time, the U-shaped suction nozzle is driven to move in different directions by the V-shaped air rotating clamp. When the welding sheet generates static dislocation, the U-shaped suction nozzle can be driven by the V-shaped air rotating clamp to adjust the position of the welding sheet, thereby making subsequent processing more convenient.

[0105] (4) The flexible manufacturing and high-precision welding system of the fully automatic processing equipment for smart meters provided by the present invention forms the terminal box unit, the switch unit, and the mutual inductor unit independently (flexible implementation of resistance brazing from 2 to 4 stations) and the single-process cycle welding fixation with the matching carrier through welding fixtures A, welding fixtures B, and welding fixtures C, making the processing more flexible and convenient.

[0106] (5) The flexible manufacturing and high-precision welding system of the fully automatic processing equipment for smart meters provided by the present invention has the following characteristics: since the contact surfaces of the switch unit and the terminal box unit are not at the same level as the contact surfaces of the transformer and the terminal box unit, the first driving mechanism drives the sixth connecting plate to move. When the first protrusion cooperates with the first inclined groove, an inclined downward pressing action is formed, so that the welding between the switch unit and the terminal box unit, and between the transformer and the terminal box unit is coordinated.

[0107] (6) The flexible manufacturing and high-precision welding system of the fully automatic processing equipment for smart meters provided by the present invention is mainly designed to solve the problem that the positioning clamping and welding of the third conductive part on the transformer cannot be separated in the existing technology during assembly, and the positioning frame is easy to be welded with the copper terminal of the transformer and the third conductive part, resulting in poor welding. By moving the positioning frame, a relative movement effect can be formed.

[0108] (7) The flexible manufacturing and high-precision welding system of the fully automatic processing equipment for smart meters provided by the present invention has a clamping unit that clamps and fixes the transformer. Since the main body of the transformer is annular, it is clamped and fixed by the clamping mechanism. Secondly, after welding is completed, the terminal box unit, the switch unit, and the transformer form an integrated structure. By rotating the rotating claw, the entire structure can be removed and the next step of detection can be carried out, which is highly convenient to operate. Moreover, this structural setting forms a fixing effect for different transformers. This clamping unit can be applied to both the Southern Power Grid and the State Grid transformers.

[0109] (8) The flexible manufacturing and high-precision welding system of the fully automatic processing equipment of the smart meter provided by the present invention has an opening and closing mechanism to prevent the moving and static contacts inside the switch unit from being in a connected state. During the welding process, if the moving and static contacts inside the switch unit are in a connected state, welding is performed at this time. The large welding current causes the moving and static contacts of the switch unit to stick and melt, resulting in the mechanism being stuck, the mutual inductor being de-energized, etc., and the remote opening and closing and electricity fee control functions of the low-voltage user cannot be realized; and shunts will be formed during the welding process, resulting in the generation of cold welding, affecting the welding quality; with the above structure, in the first state (the switch unit is disconnected), the risk of welding shunt cold welding and melting of the moving and static contacts of the switch unit is eliminated; in the second state (the switch unit is connected), the closing of the switch unit after welding realizes the requirements of the smart meter welding power detection resistance and meter performance; the opening and closing mechanism ensures that the moving and static contacts inside the switch unit are in a disconnected state, thereby improving the stability and welding quality of subsequent welding.

[0110] (9) The flexible manufacturing and high-precision welding system of the fully automatic processing equipment for smart electric meters provided by the present invention has a first positioning pin that forms a fixing effect on the sliding tongue plate. When the front end of the sliding tongue plate is matched with the first pin, the elastic reset member will be compressed and tightened. At this time, the rear end of the sliding tongue plate will form a rotation effect around the first positioning pin. At the same time, the tension of the elastic reset member will drive the front end of the sliding tongue plate to move outward, so that the sliding tongue plate and the first pin are better matched.

[0111] (10) The flexible manufacturing and high-precision welding system of the fully automatic processing equipment for smart meters provided by the present invention has a left-right separation setting to prevent creepage between the two sliding tongue plates, and the setting of the first waist-shaped hole better realizes the sliding effect of the elastic reset member. It should be noted here that the elastic reset member will not electrically connect the two sliding tongue plates, that is, no short circuit will occur between the two sliding tongue plates. Here, when the elastic reset member is a compression spring, an insulating pad or an insulating sleeve can be installed at the position where the elastic reset member and the sliding tongue plate cooperate to form an insulating effect; in addition, an insulating separation can also be formed by an elastic reset member whose outer surface is an insulating material, such as a rainbow ring structure.

[0112] (11) The flexible manufacturing and high-precision welding system of the fully automatic processing equipment for smart meters provided by the present invention has the following characteristics: in the initial position, the protrusion and the first groove are matched to form a limiting effect; when the step portion is moved to the first I-shaped groove, the sliding tongue plate cannot continue to move toward the front end, thereby achieving a limiting and fixing effect to prevent the sliding tongue plate from excessive movement. BRIEF DESCRIPTION OF THE DRAWINGS

[0113] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0114] Figure 1 An exploded diagram of the terminal box unit, switch unit, and transformer provided by the present invention;

[0115] Figure 2 A schematic diagram of the structure of the flexible manufacturing and high-precision welding system of the fully automatic processing equipment for smart meters provided by the present invention;

[0116] Figure 3 This is a control diagram of the automatic adaptive recognition and grabbing of the soldering sheet feeding mechanism provided by the present invention;

[0117] Figure 4 A schematic diagram of the control of high-precision positioning and movement of the flexible robotic arm and gripper provided by the present invention;

[0118] Figure 5 A schematic structural diagram of four second transition prefabricated grooves in the welding sheet feeding and positioning unit provided by the present invention;

[0119] Figure 6 This is a structural schematic diagram of the welding sheet feeding mechanism on the laser welding unit provided by the present invention;

[0120] Figure 7 A schematic diagram of the structure of the integrated welding tool provided by the present invention, which can be fixed with welding fixtures A;

[0121] Figure 8 A schematic diagram of the structure of the integrated welding tool provided by the present invention, wherein the welding fixture B can be fixed respectively;

[0122] Figure 9 This is a schematic structural diagram of the clamping claws in the welding fixture A and the welding fixture B in the clamping unit provided by the present invention;

[0123] Figure 10 A schematic structural diagram of the opening and closing mechanism provided by the present invention;

[0124] Figure 11 This is a schematic diagram of the assembly of the terminal box unit, switch unit (circuit breaker), and transformer of the ultra-high current smart meter provided by the present invention;

[0125] Figure 12 This is a schematic diagram of the structure of the cooperation between the fixed claw and the rotating claw of the welding fixture C in the clamping unit provided by the present invention;

[0126] Figure 13 A schematic diagram of the assembly structure of the clamping claws of the circuit breaker and the mutual inductor in the single-phase, two-phase, and three-phase clamping units provided by the present invention;

[0127] Figure 14 This is a structural schematic diagram of the floating pressure gate opening support unit provided by the present invention.

[0128] Description of reference numerals:

[0129] 11. Bottom plate; 12. First pressing mechanism; 14. First driving mechanism; 15. Terminal box unit; 16. Switch unit; 17. Mutual inductor; 25. Rotating claw I; 26. Fixed claw I; 29. Second driving mechanism; 30. Buffer mechanism; 32. First side plate; 33. Fourth sliding pair; 40. Third driving mechanism; 41. Fifth driving mechanism; 105. Second fixed column; 111. Sixth connecting plate; 112. Slide groove; 113. First concave cavity; 114. First fixed cavity; 115. First protrusion; 120. Return spring; 121. First pressing member; 124. Tenth connecting plate; 125. Outer arc I; 128. First arc I; 129. Second arc I; 131. Second fixed cavity; 132. Three fixed cavities I; 133, through hole; 151, switch unit copper terminal; 152, transformer copper terminal; 161, second conductive member; 162, first pin; 171, third conductive member; 235, floating pressure release support unit; 237, T-plate; 238, U-shaped slide; 316, support plate; 244, second U-shaped groove; 246, third U-shaped groove; 247, second clearance groove; 256, first protrusion; 258, inner arc I; D249, clearance L-shaped opening; 250, T-shaped opening groove; 251, clamping groove; 253, eighth U-shaped groove; 254, second waist-shaped hole; 260, rotating shaft I; 261, first L-shaped step groove I; 262, driving unit I; 1121, first horizontal groove; 1122, first inclined groove 264, 18th U-shaped groove plate; 265, sliding tongue plate; 267, sliding rod; 268, first positioning pin; 269, motor connection hole; 270, power line connection hole; 271, first lower step; 273, fourth U-shaped groove; 274, second lower step; 276, third lower step; 27, L-shaped groove; 278, fourth arc; 279, "X"-shaped step; 281, first groove; 282, first I-shaped groove; 283, second I-shaped groove; 284, first through hole; 272, first positioning hole; 285, second positioning hole; 287, first square groove; 291, base; 292, first waist-shaped hole; 293, countersunk hole; 295, fifth U-shaped groove; 294, sixth U-shaped groove; 296, seventh U-shaped groove; 297, L-shaped clearance groove; 300, partition portion; 301, step portion; 302, step surface; 560, L-shaped front groove; 134, second square groove; 136, rear groove; 313, first mounting plate; 530, U-shaped plate; 529, 7-type adjustment plate; 526, second side plate; 614, spring hole; 612, first groove; 607, first sliding pair; 606, second sliding pair; D135, second concave cavity; 616, L-shaped groove; 613, inverted L-shaped groove; 608, pad; 583, first U-shaped groove plate; 574, first threaded hole; 118, first U-shaped groove; 531, second mounting plate; 570, second through hole; 609, U-shaped rotating plate; 620, second threaded hole; 617, first hole; 618, second hole;611, third hole; 615, sixth hole; 571, slide rod hole; 582, pin hole; D24, spring; B563, clamping claw; 569, third threaded hole; 527, fourth hole; 524, fifth hole; D111, slot plate; 627, slide plate; 252, first square slot; D112, second square slot; D14, cylinder; D132, fourth fixed cavity; 598, upper cover; 619, slide column; D620, bump; 621, straight slot; 622, curved slot; D121, pressing unit; 576, fourth open slot; 577, fifth open slot; 578, twelfth U-shaped slot; 565, rotating floating pressure head; 585, L-shaped second U-shaped slot plate; 586, thirteenth U-shaped slot; 588, fourteenth U-shaped groove; 590, third U-shaped groove plate; 592, fifteenth U-shaped groove; 596, sixteenth U-shaped groove; 666, seventeenth U-shaped groove; 610, slide; 649, machine; 650, first fixture lifting unit; 648, integrated welding tooling; 647, first circulating conveyor belt; 651, shift stopper; 652, terminal box automatic loading unit; 653, loading robot; 654, circulating hopper; 655, welding piece loading and positioning unit; 656, laser welding unit; 666, binocular vision inspection; 667, reserved laser welding position; 669, stopper mechanism; 668, transformer discharge; 680, switch unit automatic loading unit; 670, second circulating conveyor belt; 683, switch unit first point welding Unit; 684, transformer second point welding unit; 682, first welding unit; 687, second welding unit; 688, switch unit second point welding unit; 689, transformer first point welding unit; 690, welding energy temperature detection unit; 691, gate opening detection; 692, temperature control unit; 693, intelligent control system; 694, comprehensive detection unit; 695, comprehensive test instrument unit; 696, unloading unit; 697, finished product defect storage unit; 698, flow transfer unit; 699, second fixture lifting unit; 708, first air duct; 702, first L-shaped plate; 707, second L-shaped plate; 709, V-type air transfer clamp; 700, quick joint; 701, second air duct; 718, first main welding Seam; 716, auxiliary weld; 710, fourth air channel; 720, pipe joint; 723, first suction nozzle; 722, second suction nozzle; 721, third suction nozzle; 716, fourth suction nozzle; 712, first air hole; 713, second air hole; 714, third air hole; 715, fourth air hole; 711, third air channel; 706, first vacuum generator; 703, second vacuum generator; 719, welding piece; 717, second main weld; A119, positioning frame; A120, first step opening groove; A123, 7-type step surface; A124, second step opening groove; A127, third arc I; A255, first opening groove; A126, third opening groove; A132, middle groove; A257, ninth U-shaped groove;B33, first clamping claw; C33, second clamping claw; D33, third clamping claw; B115, first vacuum hole; B116, second vacuum hole; B117, third vacuum hole; B118, fourth vacuum hole; B700, first turning plate; B701, second turning plate; B114, T-plate; B131, front threaded hole; A118, second opening slot; A105, second positioning pin; B257, tenth U-shaped Groove; C257, eleventh U-shaped groove; D110, lower base; D105, fourth threaded hole; B25, rotating claw II; B26, fixed claw II; B125, outer arc II; B128, first arc II; B129, second arc II; B132, third fixed cavity II; B258, inner arc II; B260, rotating shaft II; B261, first L-shaped step groove II; B262, driving part II; B127, third arc II. DETAILED DESCRIPTION

[0130] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0131] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0132] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0133] In addition, the technical features involved in different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0134] Example 1

[0135] This embodiment provides a flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters, as shown in the attached Figures 1-14 As shown,

[0136] The fully automated processing equipment for smart meters includes multiple units, including a multi-component automatic loading and gripping mechanism, a terminal box automatic loading unit 652, a switch automatic loading unit, and a transformer automatic loading unit. It also includes an integrated welding fixture 648, multiple suction heads for loading and automatic gripping, a soldering unit, a laser welding unit, a switch-opening detection unit, an integrated welding inspection unit, a switch-closing detection unit, a comprehensive inspection unit 694, and a material unloading and turnover unit. Solder loading is achieved through a smooth feeding channel, high-precision photoelectric sensors, vacuum suction, and a precise pushing mechanism. Intelligent recognition and adaptive gripping are achieved through the collaboration of vision and force sensors. The integrated welding fixture integrates multiple welding processes, and a three-dimensional positioning subsystem based on a laser interferometer ensures submicron positioning accuracy. Pulsed spot welding is used to create a π-shaped weld seam on the soldering unit, effectively preventing solder vaporization. The system can realize the fully automatic welding, assembly, inspection and integrated molding of hard-connected sampling components of various types of smart meters. Through the cooperation of multiple units, the welding connection and performance testing of various components can be completed, which greatly improves the processing efficiency and welding accuracy, reduces costs, enhances the adaptability, reliability and stability of the equipment, and solves the problems of complex parts processing.

[0137] The integrated welding tooling is arranged in sequence around the circulation line from right to left and then from left to the starting right through the lifting cycle. The integrated welding tooling goes from right to left through the terminal box automatic loading unit, the welding piece loading and positioning unit, the laser welding unit, the opening detection unit, the welding inspection integration unit, the closing detection unit, and the comprehensive detection unit; the laser welding unit includes a welding piece loading mechanism;

[0138] Multi-component automatic loading and grabbing mechanism;

[0139] Vibration and airflow monitoring feedback subsystem;

[0140] Intelligent recognition and adaptive grasping device, efficient data processing and analysis subsystem outputs big data and artificial intelligence analysis for quality judgment, realizes automatic path planning and real-time monitoring of grasping force through collaborative vision and force sensors;

[0141] Laser interferometer-based 3D positioning subsystem: achieves submicron positioning accuracy and adjusts motion trajectory in conjunction with model predictive control algorithms. This laser interferometer-based 3D positioning subsystem works closely with the multi-component automatic feeding and gripping mechanism, the soldering sheet feeding mechanism, the vibration and airflow monitoring and feedback subsystem, and the functional welding integrated equipment to form a flexible manufacturing and high-precision welding system for fully automatic processing equipment for smart meters.

[0142] Multifunctional welding integrated equipment, integrating multiple welding methods, intelligently selecting welding methods and adjusting parameters;

[0143] The low heat input welding and thermal deformation compensation subsystem uses a low heat input laser welding process and uses high-precision temperature sensors and closed-loop control to achieve protection and reduce welding interference;

[0144] A comprehensive intelligent detection subsystem uses high-resolution industrial cameras and deep learning image processing for appearance inspection, while also utilizing high-precision instruments (optional instruments for real-time monitoring of electrical parameters include power monitors, multi-function digital ammeters, AOB19 intelligent programmable digital display meters, three-phase power quality analyzers, and lightning arrester comprehensive testers) to monitor electrical parameters in real time.

[0145] An efficient data processing and analysis subsystem enables real-time data collection and storage, and uses big data and artificial intelligence analysis for quality judgment and traceability;

[0146] Equipment collaborative control software, which monitors and matches module operation data in real time, includes intelligent recognition and adaptive gripping device module, laser interferometer-based 3D positioning subsystem module, multi-component automatic loading and gripping mechanism module, solder sheet loading mechanism module, multi-functional welding integrated equipment module, low heat input welding and thermal deformation compensation subsystem module, vibration and airflow monitoring and feedback subsystem module, and comprehensive intelligent detection subsystem module.

[0147] The distributed control subsystem architecture ensures communication coordination; the distributed control subsystem architecture ensures the coordination of communication coordination, including: multi-component automatic loading and grasping mechanism, welding piece loading mechanism, vibration and airflow monitoring feedback subsystem, multi-functional welding integrated equipment, low heat input welding and thermal deformation compensation subsystem, comprehensive intelligent detection subsystem and laser interferometer-based three-dimensional positioning subsystem.

[0148] The fault diagnosis subsystem based on the Internet of Things and artificial intelligence collects operating data through sensors in key locations to realize remote monitoring center and fault prediction and positioning.

[0149] It also includes: the circulation line is fixed with an integrated welding tool; the integrated welding tool is used to install and fix the terminal box unit 15, the switch unit 16, and the mutual inductor 17;

[0150] The terminal box automatic loading unit is located on one side of the circulation line;

[0151] The solder piece loading and positioning unit is located on one side of the circulation assembly line. The solder piece loading and positioning unit adopts a smooth feeding channel. A high-precision photoelectric sensor is set on the channel to prevent stacking and jamming of materials, as well as a vacuum adsorption and precise pushing device to form the loading of the solder piece. The solder piece cooperates with the terminal box unit 15; the vacuum adsorption and precise pushing device includes a high-precision pressure sensor and an intelligent control chip, which automatically adjusts the suction force according to the thickness and material characteristics of the solder piece. The vacuum adsorption and precise pushing device includes a high-precision motor and a screw transmission mechanism, which can accurately control the pushing speed and force.

[0152] The laser welding unit is located on one side of the circulation assembly line. The laser welding unit is used to weld the welding piece to the copper terminal of the switch unit and the copper terminal of the transformer respectively. The laser welding unit adopts a welding process to form a weld seam. The corresponding welding piece and the copper terminal of the switch unit form a π-shaped weld seam; the corresponding welding piece and the copper terminal of the transformer form a π-shaped weld seam. The welding process adopts a welding piece composite laser welding process, combining pulse and continuous laser, and adopts a multi-axis linkage welding process. The welding angle sequence is controlled by three-dimensional space coordinated motion, and the parameters are adjusted in real time through real-time monitoring and feedback.

[0153] The vibration and airflow monitoring feedback subsystem automatically adjusts operating parameters or activates vibration reduction devices by installing high-precision vibration sensors and airflow sensors at key locations on the equipment.

[0154] Specifically, the system realizes intelligent automatic high-precision lap assembly, welding connection and post-welding performance testing between the terminal box unit 15, the switch unit 16, the mutual inductor 17 and the welding piece through the coordination of multiple machines, vision and force, vibration sensors, three-dimensional positioning of laser interferometers, motion trajectory and algorithm, and flexible adaptive manipulators, automatic loading and grasping of welding pieces, and welding fixtures.

[0155] The welding fixtures include welding fixture A, welding fixture B, and welding fixture C. Welding fixture A, welding fixture B, and welding fixture C respectively form independent and integrated welding fixtures for cyclic welding fixation between the terminal box unit 15, the switch unit 16, and the mutual inductor 17.

[0156] Flexible manufacturing, high-precision welding systems and fully automatic processing equipment for smart meters work together to complete welding connections and performance testing, realizing the fully automatic welding, assembly, inspection and integrated molding of hard-connected sampling components for smart single-phase, two-phase or three-phase fee-controlled meters.

[0157] The adaptive fixture subsystem with flexible structure monitors the clamping status in real time through sensors and intelligently adjusts the clamping position and force; the three-dimensional positioning subsystem based on laser interferometer combined with model predictive control algorithm can predict the deviation in the equipment movement process in advance and quickly and accurately adjust the movement trajectory of the processing equipment to ensure that when the welding switch unit 16 and the mutual inductor 17 are not in the same plane, they can achieve precise connection and improve processing accuracy; the equipment collaborative control software monitors the operating data of each module in real time, accurately matches the operating speed and beat of each module, ensures the smooth progress of the entire production process, and improves overall production efficiency; the multifunctional welding integrated equipment can be adjusted according to the different components and different The system intelligently selects welding methods and adjusts parameters based on welding requirements. The low heat input welding and thermal deformation compensation subsystem uses high-precision temperature sensors to monitor welding temperature in real time and utilizes closed-loop control to promptly compensate for thermal deformation caused by heat input. The comprehensive intelligent detection subsystem utilizes high-resolution industrial cameras and deep learning image processing for appearance inspection and high-precision instruments to monitor electrical parameters in real time. The efficient data processing and analysis subsystem collects and stores data in real time and uses big data and artificial intelligence analysis for product quality judgment and traceability. The fault diagnosis subsystem based on the Internet of Things and artificial intelligence collects operating data from sensors at key locations, enabling the remote monitoring center to predict and locate equipment faults.

[0158] The vibration and airflow monitoring feedback subsystem installs high-precision vibration sensors and airflow sensors at key locations on the robotic arm joints and welding workbench to accurately monitor the equipment's own vibration and ambient airflow changes in real time. When an anomaly is detected, the system automatically adjusts the equipment's operating parameters, such as reducing the movement speed and adjusting the motor's output power. If the vibration is severe, the system activates the vibration reduction device to ensure the stability of the automatic positioning system and meet the requirements of welding sheet processing, which requires extremely high positioning accuracy.

[0159] After the visual sensor in the intelligent recognition adaptive grasping device captures the shape, position and posture information of various components such as the switch unit 16, transformer, and mutual inductor 17, the system automatically plans the optimal grasping path based on the multi-factor fusion grasping path automatic planning and grasping force collaborative control algorithm. The force sensor continuously monitors the grasping force during the grasping process. When the grasping force is abnormal, it immediately feeds back to the control system to adjust the grasping force of the robotic arm.

[0160] Further includes:

[0161] The circulating assembly line is fixed with an integrated welding fixture 648, which is used to install and fix the terminal box unit 15, the switch unit 16, and the mutual inductor 17. The circulating assembly line here is specifically a rectangular flow direction. Specifically, it also includes a first clamp lifting unit 650 (the lifting unit is driven by a belt driven by a motor), a second clamp lifting unit 699 (the lifting unit is driven by a belt driven by a motor), a first circulating conveyor belt 647, and a second circulating conveyor belt 670. The first circulating conveyor belt 647 and the second circulating conveyor belt 670 are arranged parallel to each other in the upper and lower parts, and the lengths of the two are equal. The entire circulating assembly line is fixed on the machine platform 649. The switch unit 16 can be a relay or a circuit breaker.

[0162] The first fixture lifting unit 650 is located at the right end of the first circulating conveyor belt 647 and the second circulating conveyor belt 670, and the second fixture lifting unit 699 is located at the left end of the first circulating conveyor belt 647 and the second circulating conveyor belt 670. The integrated welding tooling 648 starts from the right end and is then transported from the first circulating conveyor belt 647 to the left end. The second fixture lifting unit 699 lowers the integrated welding tooling 648 to the second circulating conveyor belt 670, and then transports it from left to right to the right end to cooperate with the first fixture lifting unit 650, forming a circular transmission effect.

[0163] The terminal box automatic loading unit 652 is located on one side of the circulation line and is used to load the terminal box unit 15 and place the terminal box unit 15 on the integrated welding fixture 648. The integrated welding fixture 648 is provided with a welding fixture.

[0164] Loading and automatic gripping include a smooth feeding channel for the solder sheet feeding mechanism, such as, but not limited to, a U-shaped channel, a high-precision photoelectric sensor precisely installed in the feeding U-shaped channel to prevent stacking and jamming, a vacuum adsorption and precision pushing device, an intelligent recognition and adaptive gripping device equipped on the flexible robotic arm manipulator with vision and force sensor collaboration, automatic gripping path planning, and real-time gripping detection, and a multi-head collaborative working mechanism (including multi-head solder sheet loading and gripping, a loading and positioning unit 655, a welding fixture, a terminal box, a switch unit (relay or circuit breaker), and an automatic loading unit for a transformer, etc.);

[0165] The U-shaped track is used to detect the presence of soldering sheets, and the U-shaped track is used to detect the presence of soldering sheets. Figure 5 The first vacuum suction hole B115, the second vacuum suction hole B116, the third vacuum suction hole B117, and the fourth vacuum suction hole B118 are called the second transition prefabricated groove). The second transition prefabricated groove is contoured to the shape of the welding piece (the gap is 0.03-0.1mm). In order to overcome the problem that the welding piece is too thin (0.03mm), the existing technology is to provide a vacuum suction port in the middle of the bottom of the second transition prefabricated groove. The bottom of the second transition prefabricated groove and the welding piece are prone to electrostatic adsorption, which causes the welding piece to tilt when the vacuum suction nozzle on the U-shaped track manipulator sucks up the welding piece at the bottom of the groove. The vacuum suction nozzle on the U-shaped track manipulator sucks up the welding piece at the bottom of the groove. The soldering pieces placed on the two switch unit copper terminals 151 and the two transformer copper terminals 152 on the terminal box are poorly offset and tilted (the loading and grabbing of the robot arm and the suction nozzle are difficult, and the precision and accuracy are poor); in order to address the above problems, one of the features of the present invention is that a plurality of vacuum suction holes are arranged on the diagonals and the center lines of the four sides of the four second transition prefabricated grooves, namely the first vacuum suction hole B115, the second vacuum suction hole B116, the third vacuum suction hole B117, and the fourth vacuum suction hole B118; this prevents the soldering piece from tilting when the multi-suction head vacuum suction nozzle of the soldering piece feeding mechanism on the U-shaped track robot arm sucks up the soldering piece at the bottom of the groove.

[0166] The smooth feeding channel of the solder sheet loading mechanism is a special smooth feeding channel, which includes the following features:

[0167] Smooth feeding channel: The U-shaped channel is constructed from specialized materials, including but not limited to polytetrafluoroethylene (PTFE), ultra-high molecular weight polyethylene (UHMW-PE), silicon nitride ceramics, and alumina ceramics. The U-shaped channel profile has an arithmetic mean deviation (Ra) value of 0.025μm to 0.1μm. The metal spring surfaces required for soldering resistors in smart meters, where they contact precision electronic components, undergo ultra-precision grinding and polishing to a stable Ra value of approximately 0.05μm. This ensures that even minimal contact force will not damage the electronics. This minimizes friction during the transport of 0.05mm solder pieces, reducing friction-induced damage, positional shifting, and stacking. This solves the problem of separating individual solder pieces and ensures the reliable capture of single solder pieces by the solder feeding mechanism.

[0168] High-precision photoelectric sensors prevent stacking and jamming: Precisely installed in the U-shaped feeding channel, these sensors include through-beam sensors such as the Omron EE-SX770, Autonics BEN10M-TDT, and Lanbao Sensor's PSW-TC50 series; fiber-optic sensors such as the Omron E3NX-FA, Panasonic FX-500 / 550 / 100 series, and Baumer FVDM15P5103. These sensors monitor the position and status of soldering pads in real time. To prevent stacking or jamming caused by vibration and inertia, they immediately generate a signal, suspending loading and preventing disruptions in subsequent processing steps.

[0169] Specifically, the soldering pads required for the resistor brazing of smart meters and the metal springs that contact the precision electronic components,

[0170] In smart meters, the metal shrapnel that contacts the precision electronic components is welded to the PCB board. The following parts may use metal shrapnel:

[0171] Current transformer connection parts

[0172] Specific shape: Metal springs are usually designed into an arc or U-shaped structure with a certain degree of elasticity. This shape can provide appropriate elastic pressure while ensuring good electrical connection, ensuring close contact with other components.

[0173] Size: Length is generally between 10-20 mm, width is approximately 3-5 mm, and thickness is approximately 0.2-0.5 mm. Specific dimensions will be adjusted based on the actual installation space and electrical performance requirements.

[0174] Specific Function: In connecting a current transformer to a circuit board or other electrical component, the metal spring serves a dual purpose of electrical connection and mechanical fixation. It reliably transmits the current signal sensed by the current transformer to subsequent processing circuits. Furthermore, its elastic properties compensate for poor contact caused by installation errors or environmental changes (such as thermal expansion and contraction due to temperature fluctuations), ensuring stable and accurate signal transmission.

[0175] Installation Location: Typically installed at the output of the current transformer, contacting the corresponding connection point on the circuit board. During installation, the metal dome is precisely placed in the designed position and secured with a mechanical structure (such as a slot or mounting bracket) to ensure a reliable connection between the current transformer and the circuit board.

[0176] Voltage sampling component

[0177] Specific shape: It can be a flat rectangle or strip, and the two ends may have certain bends or protrusions to better contact with other parts.

[0178] Size: Length is approximately 15-30 mm, width is 4-8 mm, and thickness is between 0.3-0.6 mm.

[0179] Specific Function: This device collects the input voltage signal from the smart meter and transmits it to the voltage sampling circuit for processing. The metal dome's excellent conductivity and elasticity ensure accurate voltage signal collection and transmission. Its flexibility also allows it to adapt to different installation environments and connection requirements, ensuring connection reliability.

[0180] Installation location: Generally installed near the voltage input terminal, connected to the relevant components of the voltage sampling circuit (such as resistors, capacitors, etc.). One end of the metal dome is connected to the voltage input line, and the other end contacts the connection point of the voltage sampling circuit, forming a stable electrical connection.

[0181] Relay contact auxiliary parts

[0182] Specific shape: It is sheet-shaped, wider in the middle and narrower at both ends, and can have some special shapes (such as serrated or wavy) to increase the contact area and friction with the contact point to prevent loosening.

[0183] Size: Length is about 8-15 mm, width is between 5-10 mm, thickness is 0.2-0.4 mm.

[0184] Specific Function: In a relay's contact system, metal domes assist in contact closure and maintain good contact. When the relay operates, the metal domes provide additional pressure, ensuring a reliable connection between the contacts, reducing contact resistance and improving relay operational stability. Furthermore, their elasticity absorbs the impact force generated during contact closing and opening, protecting the contacts from damage.

[0185] Installation Location: Installed near the relay contacts, usually in direct contact with them. One end of the metal dome is fixed to the relay housing or other fixed component, and the other end is connected to the contacts, playing a role in the relay's operation.

[0186] Communication interface connection components

[0187] Specific shape: It can be a comb-like structure with multiple tentacles, each of which can contact the pins of the communication interface.

[0188] Size: The overall length is generally 20-40 mm, the width is about 10-15 mm, the thickness is 0.3-0.5 mm, and the width of each tentacle is about 1-2 mm.

[0189] Specific Function: Used for communication between smart meters and external devices (such as communication modules and concentrators). The metal dome's multiple antennae ensure close contact with the pins of the communication interface, ensuring reliable data signal transmission. Its elasticity adapts to various plug-in and plug-out operations, reducing communication failures caused by wear and looseness during insertion and removal.

[0190] Installation location: Installed at the communication interface of the smart meter, corresponding to the pins of the communication interface. During installation, the metal shrapnel will be accurately installed in a fixed position on the communication interface to ensure good contact between its tentacles and the pins.

[0191] Specifically, the solder sheet feeding mechanism has multiple suction heads that suck up multiple vacuum suction holes, which are the first vacuum suction hole B115, the second vacuum suction hole B116, the third vacuum suction hole B117, and the fourth vacuum suction hole B118. The solder sheets sucked up by the multiple suction heads of the solder sheet feeding mechanism cooperate with the terminal box unit 15 to place the four cut solder sheets on the two switch unit copper terminals 151 and the two transformer copper terminals 152 corresponding to the terminal box unit 15.

[0192] The soldering mechanism's multiple suction heads are equipped with vacuum suction and precision pushing devices. These devices, comprised of high-precision pressure sensors and intelligent control chips, utilize vacuum suction technology to automatically adjust suction force based on the thickness and material characteristics of the soldering sheet, ensuring stable soldering. The pushing device is equipped with a high-precision motor (e.g., Panasonic MINASA6 series servo motor MSMD042G1U) and a screw drive mechanism (THKRSR16 series ball screw). These precisely control pushing speed and force, delivering the soldering sheet to the designated position along a predetermined trajectory, preparing it for subsequent welding or assembly processes.

[0193] Other innovative features of the vacuum adsorption and precision pushing device include:

[0194] 1. Adaptive suction adjustment subsystem: Built-in high-precision pressure sensor (NXP MPX2010 series and MPX5010 series, etc.) and intelligent control chip (STMicroelectronics STM32F103 series, Microchip Technology PIC18F series). The pressure sensor monitors the vacuum level in the adsorption chamber in real time. The intelligent control chip quickly and accurately adjusts the vacuum pump of the adaptive suction adjustment subsystem (Changlin VTM series VTM25-1434-A, VTM50-1434-A, Festo VP series VPPE-3-1 / 8-7-010-B, VPWP-3-1) based on a pre-recorded database of the corresponding relationships between different solder sheet thicknesses, materials, and suction forces, combined with the current high-precision pressure sensor (NXP MPX2010 series and MPX5010 series) data. / 8-7-010-B, etc., SMCZQ series ZQ220A-5DZ, ZQ230A-5DZ, etc. Miaode CONVUMVCH series VCH-01, VCH-02, etc., thus achieving automatic adjustment of suction force. For example, for ultra-thin copper solder sheets with a thickness of 0.05mm, the system can automatically stabilize the suction force at 0.02MPa, ensuring stable adsorption while preventing damage to the solder sheet due to excessive suction force. For copper wires and wire caps on slightly thicker PCBs, the suction force can be increased to 0.05-0.1MPa.

[0195] 2. Flexible Adsorption Surface Design: The adsorption surface is made of a special flexible silicone material (such as Dow Corning Sylgard 184, Shin-Etsu KE1310, etc.), whose surface is covered with tiny nano-scale pores. This design allows the adsorption surface to better conform to solder pads of varying shapes and surface conditions, increasing the adsorption area and improving adsorption stability. Furthermore, the flexible silicone material provides a good cushioning effect, preventing mechanical damage to the solder pad during the adsorption process.

[0196] Specific implementation scheme of the invention with a surface covered with tiny nano-scale pores:

[0197] 3D printing-assisted method

[0198] 3D Model Design: Use 3D modeling software to design an adsorption surface model with a nanoscale pore structure. In the model, precisely set the pore diameter, depth, and distribution density. For example, design cylindrical pores with a diameter of 100 nanometers and a depth of 500 nanometers, with a distribution density of 100-500 pores per square millimeter.

[0199] 3D printing and post-processing: Using a 3D printer capable of printing flexible materials, such as one based on photocuring technology, the liquid flexible silicone material is printed into the designed model shape. After printing, the print is post-processed, such as further curing and cleaning, to obtain a flexible adsorption surface with a stable nano-scale porous structure.

[0200] 3. Multi-head collaborative working mechanism: The device is equipped with multiple independently controllable suction heads, each with independent suction force adjustment and operating status control. When handling solder wafers of varying sizes and arrangements, intelligent algorithms control the working combination of different suction heads, achieving efficient and precise suction operations. For example, for a large array of solder wafers, multiple suction heads can be activated simultaneously for coordinated suction; for small, dispersed solder wafers, some suction heads can be selectively activated for individual suction.

[0201] Further details on the specific types and calculation processes of the intelligent algorithms for the multi-adsorption head collaborative working mechanism are as follows:

[0202] Types of Intelligent Algorithms: The intelligent algorithms used in the multi-head collaborative working mechanism can be rule-based, heuristic, or machine learning (such as reinforcement learning). Rule-based algorithms determine the working combination of adsorption heads based on pre-set conditions and rules; heuristic algorithms use empirical strategies to quickly find the best solution; and reinforcement learning algorithms allow the system to learn the optimal adsorption head working combination strategy through continuous trial and error.

[0203] Rule-based algorithm calculation process:

[0204] Rule Setting: A series of rules are pre-set based on factors such as the size, shape, and distribution of the solder pads, as well as the characteristics of the adsorption device. For example, when the area of a solder pad is larger than a certain threshold, it is determined to be a large-area solder pad array, and multiple adsorption heads are activated simultaneously for coordinated adsorption. When the size of the solder pads is smaller than a certain value and the distance between them is greater than a certain range, it is determined to be small and scattered solder pads, and some adsorption heads are selectively activated for individual adsorption.

[0205] Data Collection: Sensors (such as position sensors and size sensors) are used to obtain relevant information about the solder pieces, including their size, position, and quantity. At the same time, high-precision pressure sensors monitor the vacuum level in the adsorption chamber in real time, providing data support for suction force adjustment.

[0206] Rule matching: The collected solder pad information is matched against pre-set rules. If the rule conditions for a large-area solder pad array are met, the corresponding control instructions are triggered, multiple suction heads are activated simultaneously, and the suction force of each suction head is adjusted according to the algorithm of the adaptive suction force adjustment subsystem. If the rule conditions for small and dispersed solder pads are met, some suction heads are selectively activated based on the specific location and number of solder pads, and the suction force of each suction head is adjusted individually.

[0207] Real-time Adjustment: During the adsorption process, the status of the soldering pad and the working condition of the adsorption head are continuously monitored. If the position of the soldering pad changes or the adsorption effect is not ideal, the data is re-collected and matched with the rules to promptly adjust the working combination and suction strength of the adsorption head.

[0208] Reinforcement learning algorithm calculation process:

[0209] State Definition: The state of the adsorption device (such as the operating status of the adsorption head, the vacuum level in the adsorption chamber, the position and state of the solder pad, etc.) is defined as a state space. Each state is represented by a series of eigenvectors that contain various information related to the adsorption process.

[0210] Action definition: Define the various possible working combinations and suction force adjustment operations of the suction head as an action space. For example, turning a suction head on or off, increasing or decreasing the suction force of a suction head, etc. can all be considered an action.

[0211] Reward Settings: Set a reward mechanism based on the adsorption effect. If the solder pad is successfully adsorbed and the adsorption process is stable, a positive reward will be given; if adsorption fails, the solder pad falls, or the adsorption is unstable, a negative reward will be given. The amount of the reward can be adjusted according to the specific situation to reflect the quality of the adsorption effect.

[0212] Learning Process: In its initial state, the system randomly selects an action and executes it. Based on the new state and reward obtained after executing the action, the system updates its estimate of the action's value. By repeating this process, the system gradually learns the optimal action strategy—the combination of suction head operations and suction force adjustment strategy that maximizes long-term cumulative rewards. During the learning process, the system can employ algorithms such as Q-learning to update the action-value function, thereby continuously optimizing the suction strategy.

[0213] Intelligent recognition and adaptive grabbing device:

[0214] Vision and force sensor collaboration (installed on the flexible robotic arm): Choose from the Omron FZ4 series, with various options, including 7mm and 2mm. Keyence IV series vision sensors, with resolutions exceeding 5 megapixels, offer high resolution and sensitivity, enabling rapid and accurate acquisition of the shape, position, and posture of various components, including terminal blocks, solder lugs, relays, transformers, and circuit breakers. The Huijinghe JH-WF401 four-axis force sensor and the Yuli M38XX series six-axis force sensor provide real-time standby, precisely monitoring gripping force during the grasping process.

[0215] Automatic planning of grasping path and real-time monitoring of grasping force: According to the information obtained by the visual sensor, the system uses the automatic planning of grasping path and collaborative control of grasping force based on multi-factor fusion. The algorithm automatically plans the optimal grasping path and directs the robotic arm to drive the solder piece feeding mechanism with multiple adsorption heads and terminal box automatic feeding unit 652. It is suitable for smart meters to complete the welding and assembly inspection of relays (circuit breakers), transformers and terminal boxes. It is also suitable for the use of other components. The multi-component adaptive flexible robotic arm is used to drive the robotic arm to automatically plan the grasping path and monitor the grasping force in real time, so as to realize the intelligent recognition, adaptive grasping and automatic intelligent assembly and feeding of other components before welding on the PCB board. It is suitable for other components including Transformers, current transformers, voltage transformers, crystal oscillator sockets, screws and nuts, meter cooling fans, jumper caps, varistors, SIM card or other storage card sockets, antennas, heat sinks, jumpers, communication module interfaces, fuse holders, battery holders, LED displays, potentiometers, buzzers, fuses, electrolytic capacitors, crystal oscillators, terminal blocks, batteries, farad capacitors, etc., are equipped with laser interferometer positioning detectors and force sensors on adaptive flexible manipulators and multiple grippers. By emitting laser beams and accurately measuring the changes in the interference fringes of the reflected light, ultra-high positioning accuracy at the sub-micron level is achieved. This enables the equipment to extremely accurately determine the three-dimensional spatial position of parts during the processing process and accurately move to the target position for grasping. During the grasping process, the force sensor continuously monitors the grasping force. Once it finds that the grasping force is too large or too small, it immediately feeds back to the control system, automatically adjusting the grasping force of the manipulator to avoid damage to parts due to improper grasping force. Integrating a model predictive control algorithm, the system adjusts the motion trajectory and, based on component position information acquired by the positioning system, predicts potential deviations during equipment movement and allows for rapid and accurate adjustment of the processing equipment's trajectory. This ensures precise connection when welding components such as switch units (relays or circuit breakers) and transformers that are not on the same plane, improving processing accuracy and product quality. Sensors are installed at key locations to establish a vibration and airflow monitoring feedback subsystem: High-precision vibration and airflow sensors are installed at key locations on the equipment, such as the robot arm joints (the middle end of the adaptive flexible manipulator and multiple grippers serves as the robot arm joint) and the welding table. These sensors accurately monitor the equipment's vibration and ambient airflow in real time. The vibration and airflow monitoring feedback subsystem automatically adjusts operating parameters or activates vibration damping devices. When sensors detect abnormal equipment vibration or ambient airflow, the feedback control system immediately activates.On the one hand, the operating parameters of the equipment are automatically adjusted, such as reducing the equipment movement speed and adjusting the motor output power, to reduce the impact of vibration. On the other hand, if the vibration is severe, the vibration reduction device is automatically activated, such as using active vibration reduction technology or passive vibration reduction materials to quickly suppress the vibration and ensure the stability of the automatic positioning system to meet the requirements of solder piece processing, PCB processing, and smart meter component welding processes (replacing the terminal box on the welding fixture with a circuit board PCB fixture). Figure 2 In the process, after the welding and inspection of the transformer, relay, and terminal box are completed, a process with extremely high positioning accuracy requirements is set in the flow transfer unit 698 and other places (not shown in the figure) to meet the needs of PCB board processing.

[0216] Specifically, the vacuum pump is set at:

[0217] The vacuum pump is typically located near the vacuum suction and precision pushing mechanism, taking into account factors such as ease of maintenance, ventilation and heat dissipation, and piping connections. A common setup is to install the vacuum pump in a dedicated area on the bottom or side of the equipment, connected to the suction chamber via piping. This arrangement keeps the piping relatively short, reducing pressure loss during vacuum transmission and improving vacuum suction efficiency. Furthermore, to minimize the impact of vibration and noise generated by the vacuum pump on the suction mechanism and other equipment components, the vacuum pump can be installed in a base or enclosure with vibration-damping and sound-isolating features. Also, ensure adequate space around the vacuum pump to facilitate routine inspection, maintenance, and component replacement.

[0218] The laser welding unit 656 is located on one side of the circulation assembly line. The laser welding unit 656 includes a welding sheet that is punched and cut into a specified specification shape after the welding sheet is rolled. It is stepped into multiple first prefabricated grooves with photoelectric detection through a vibrating U-shaped track. Then, the U-shaped track driven by the motor and the vacuum nozzle on the robot arm suck up the welding sheet in the first prefabricated groove and move it to the four second transition prefabricated grooves; the welding sheet feeding mechanism multi-adsorption head on the U-shaped track robot arm uses vacuum adsorption and precise pushing device to use laser interference positioning detector and force sensor to adaptively and automatically adjust the position and suction force, combine the model predictive control algorithm to adjust the motion trajectory, install sensors at key positions to build a vibration and airflow monitoring feedback subsystem, and automatically adjust the operating parameters or start the vibration reduction device in coordination with the vibration and airflow monitoring feedback subsystem and the centering adjustment of the position of the welding sheet feeding mechanism multi-adsorption head itself to achieve the precise centering and locking of the switch unit copper terminal 151 and the mutual inductor copper terminal 152 of the welding sheet terminal box unit 15.

[0219] The laser welding unit, coordinated with visual inspection and laser interferometric positioning detectors and adjusted according to a model predictive control algorithm, outputs laser pulse energy to produce a spot welding trajectory, creating a "π"-shaped trajectory weld between the welding piece and the switch unit copper terminal 151 of the terminal box unit 15, and the transformer copper terminal 152. This creates a fixed weld between each welding piece and each switch unit copper terminal 151, and between each welding piece and each transformer copper terminal 152. This pulsed "π"-shaped trajectory weld addresses the problem of existing welding pieces breaking and failing to form a continuous weld, as well as the tendency of welding pieces to fall off due to vibration and airflow during transportation.

[0220] Specifically, the thickness of the soldering lug is 0.02-0.1mm, and the laser welding unit 656 uses pulsed spot welding to form the weld. A π-shaped weld is formed between the corresponding soldering lug and the switch unit copper terminal 151; and a π-shaped weld is formed between the corresponding soldering lug and the transformer copper terminal 152. Because the soldering lug is so thin, conventional welding methods would cause the lug to vaporize, affecting subsequent processing. Pulsed spot welding, however, creates an intermittent cooling effect, preventing the lug from overheating during the welding process. The π-shaped weld increases the overall weld length, optimizes the welding route, and improves weld quality.

[0221] The welding, assembly, and inspection integrated unit has a second conductive member 161 fixed to the switch unit 16, and a third conductive member 171 fixed to the transformer 17. The welding, assembly, and inspection integrated unit welds the second conductive member 161 to the switch unit copper terminal 151 (the soldering lug melts the brazing seam); the welding, assembly, and inspection integrated unit welds the third conductive member 171 to the transformer copper terminal 152 (the soldering lug melts the brazing seam), thus securing the terminal box unit 15, switch unit 16, and transformer 17. In this embodiment, the switch unit 16 can be a relay, circuit breaker, or other switching device.

[0222] The closing detection unit closes the switch unit 16 for detection, mainly performing performance detection to determine whether the contact structure inside the switch unit 16, the communication of the mutual inductor 17, and other functions are normal.

[0223] Comprehensive detection unit 694 inspects the terminal box unit 15, to which the switch unit 16 and transformer 17 are welded. The integrated detection unit 694 detects the connection and coordination accuracy between the switch unit 16, transformer 17, the terminal box unit 15, and the switch unit 16's metering and billing, active power, reactive power, 485, and other communication units. This unit features more stable positioning accuracy, wide applicability, good stability, high automation compatibility, and protection of sampling components, preventing assembly deviations and cold welds, and improving welding quality. Smart meter sampling component welding fixture A is easy to operate and well-suited for automated production, achieving high-precision active power, reactive power, communication metering, and accurate metering and billing signals. Through the coordination of multiple machines, the welded connection between the terminal box unit 15, switch unit 16, and transformer 17 is formed, and performance testing is performed after welding. Compared to manual processing in the prior art, this processing method can greatly improve processing efficiency and reduce production costs.

[0224] Specifically, as attached Figure 6 As shown, for the automatic loading and grasping positioning of the small ultrasonic soldering wafers of the present invention, the soldering wafer loading mechanism on the laser welding unit 656 is equipped with four U-shaped suction nozzles, namely a first suction nozzle 723, a second suction nozzle 722, a third suction nozzle 721, and a fourth suction nozzle 716. The left and right air clamps of the U-shaped frame of each U-shaped suction nozzle are respectively provided with four air holes, namely a first air hole 712, a second air hole 713, a third air hole 714, and a fourth air hole 715. The adsorption surfaces of the bottom edges of the left and right air clamps are made of a special flexible silicone material, and the surface is also covered with tiny nano-scale air holes (cylindrical air holes with a designed diameter of 100 nanometers and a depth of 500 nanometers, distributed at a density of 100-500 air holes per square millimeter), which firmly adsorb the solder wafers.

[0225] The first air hole 712 and the second air hole 713 on the left air clamp are the same as the third air channel 711 and the second air channel 701 and are connected by the first vacuum generator 706 (the first vacuum generator 706 belongs to a new type of vacuum adsorption and is equipped with a precise pushing device: a high-precision pressure sensor and an intelligent control chip, etc., which constitute the adsorption device and use the vacuum adsorption technology characteristics) to control the adsorption gas volume and the suction force to form a one-way control. The third air hole 714 and the fourth air hole 715 on the right air clamp are connected to the fourth air channel 710 and the first air channel 708 and the second vacuum generator. The air generator 703 (the second vacuum generator 703 belongs to a new type of vacuum adsorption and is equipped with a precise pushing device: the adsorption device consists of a high-precision pressure sensor and an intelligent control chip, etc., and uses the characteristics of vacuum adsorption technology) is connected and the second vacuum generator 703 controls the adsorption gas volume and suction force by another control; the rear of the left and right air clamps are connected to the V-shaped air rotating clamp 709 by a quick joint 700 and fixed on the second L-shaped plate 707. The quick joint 700 is connected to the pipe joint 720 and is also fixed on the second L-shaped plate 707. The left and right air clamps cooperate with the quick joint 700 to drive the V-shaped air rotating clamp 709. A pair of first air holes 712 and second air holes 713, third air holes 714 and fourth air holes 715 on the left and right air clamps first press the welding piece 719. Due to the vibration of the equipment and the flow of the air flow when the equipment moves, the position of the welding piece 719 is offset. The AI vision set above the laser welding unit 656 draws the center line of the copper terminal 151 of the switch unit and the copper terminal 152 of the mutual inductor. According to the model predictive control algorithm adjusted according to the visual detection and laser interference positioning detector of the laser welding unit, the left and right air clamps are clamped and moved separately or in cooperation with each other to compensate and correct the existing technical left and right position errors of the center lines of the copper terminal 151 of the switch unit and the copper terminal 152 of the mutual inductor, thereby eliminating the poor offset of the welding piece on the left and right sides of the existing welding piece. The above multi-adsorption head collaborative working mechanism and the vision and force sensors jointly constitute an intelligent recognition and adaptive grasping device.

[0226] Specifically, the laser welding unit 656 also includes a first air duct 708, a second air duct 701, a first L-shaped plate 702, a second L-shaped plate 707, and a pipe joint 720. One side of the second L-shaped plate 707 is connected to a V-shaped air clamp 709, and the other side of the second L-shaped plate 707 is connected to the pipe joint 720. The quick joint 700 is connected to the pipe joint 720 to form an air supply control. The first L-shaped plate 702 is used for pressurization. The first air duct 708 is connected to the first air hole 712 to form an air supply for the first air hole 712. Here, the first air duct 708 is also provided with an adjustment structure for adjusting the air supply.

[0227] Specifically, the π-shaped weld includes a first main weld 718 , a second main weld 717 and an auxiliary weld 716 . The first main weld 718 cooperates with the second main weld 717 and the auxiliary weld 716 to form a π-shaped weld.

[0228] Specifically, the multi-axis position structure and welding implementation method

[0229] Multi-axis positioning structure: Multi-axis generally refers to the mechanical motion mechanism within the welding equipment, consisting of three linear axes (generally referred to as the X, Y, and Z axes) and at least two rotational axes (such as A, which rotates around the X axis, and B, which rotates around the Y axis). Together, these axes form a three-dimensional motion system, enabling the welding head to flexibly move and adjust its position in space to accommodate the welding requirements of different components. The linear axes are used to precisely control the position of the welding head in three dimensions, determining the weld starting point and weld path. The rotational axes are used to adjust the welding angle, ensuring that the electrode or laser beam strikes the weld at the appropriate angle.

[0230] Welding implementation method: During the welding process, multiple axes work together in a coordinated manner. First, the welding head is moved to the starting position of the part to be welded by the linear motion axis, and then the linear motion axis and the rotary motion axis move simultaneously according to the pre-set welding path and angle requirements. For example, when welding components such as switch units and transformers that are not in the same plane, the linear motion axis accurately moves the welding head along the path in three-dimensional space, and the rotary motion axis adjusts the angle of the welding head in real time so that the welding electrode or laser beam is always vertical or maintains the optimal angle pointing to the welding part. During the multi-axis linkage process, a real-time monitoring feedback mechanism will be combined to adjust the motion parameters of each axis in real time based on the information collected by the sensors, such as the actual position of the parts, welding status, etc., to ensure the accuracy and quality of the welding.

[0231] Pulse and laser coordination

[0232] In the multifunctional welding integrated equipment, the welding piece composite laser welding process is adopted, which combines pulse laser and continuous laser. The specific combination is as follows:

[0233] Solder Joint Formation: When welding ultra-thin sheets, each weld is first performed using a pulsed laser. Pulsed lasers, with their high energy density and short pulse width, instantly heat the sheet material to a molten state, forming the weld. This high-energy pulse action provides sufficient heat in a short period of time to quickly connect the sheet and the weld area, while also minimizing the heat-affected zone and reducing thermal damage to surrounding materials.

[0234] Connecting points: After completing pulsed laser welding of one weld point, the next weld point is immediately welded using a low-heat-input continuous laser. The continuous laser output, at a low power level, ensures that the solder material between adjacent weld points is melted and connected while avoiding excessive heat input, thereby reducing thermal deformation. The low-heat-input continuous laser also allows for appropriate heating and trimming of the area surrounding the weld point, resulting in a smoother and more secure connection between weld points.

[0235] Cyclic Process: Following the aforementioned method, pulsed and continuous lasers alternate, forming a "pulse-continuous-pulse-continuous..." cycle, achieving continuous welding of ultra-thin sheets. During this process, the thermal deformation compensation subsystem adjusts pulsed and continuous laser parameters, such as pulse energy, pulse frequency, and continuous laser power, in real time based on temperature information monitored by the temperature sensor and component position change information fed back by the positioning subsystem to further optimize the welding process and ensure weld quality. For example, if significant thermal deformation is detected, the pulse energy can be appropriately reduced or the continuous laser power increased to minimize thermal deformation while maintaining weld strength.

[0236] Integration with the comprehensive intelligent inspection subsystem: The comprehensive intelligent inspection subsystem utilizes high-resolution industrial cameras and deep learning image processing for appearance inspection and high-precision instruments for real-time monitoring of electrical parameters. A laser interferometer-based 3D positioning subsystem provides the inspection system with precise component position information. During appearance inspection, the inspection equipment can use the position data provided by the positioning subsystem to focus on specific parts of the component, improving inspection efficiency and accuracy. During electrical parameter monitoring, precise positioning helps accurately connect the electrical interfaces between the inspection instrument and the component, ensuring the reliability of the inspection data.

[0237] Among them, high-precision instruments for real-time monitoring of electrical parameters include power monitors, multi-function digital ammeters, AOB19 intelligent programmable digital display meters, three-phase power quality analyzers, and lightning arrester comprehensive testers;

[0238] Power monitor: Designed for the power monitoring needs of power systems, industrial and mining enterprises, it can measure grid parameters in real time, such as voltage, current, active power, reactive power, and more than 52 other electrical quantity and power quality parameters. It has the characteristics of high precision and low power consumption. It also has digital input and output, relay output, infrared communication and other functions, and can be used for power quality analysis, alarm execution, remote monitoring and control, etc.

[0239] Multi-function digital ammeter: It can measure the AC and DC current values in electrical circuits in real time and display them digitally. It has high accuracy, good stability and strong functional scalability. It has functions such as data processing, parameter setting and over-limit alarm. It can help electrical engineers understand current changes and promptly detect electrical system faults and problems.

[0240] AOB19 intelligent programmable digital display meter: It can measure and indicate AC or DC voltage and current in real time. Users can freely set the measurement display range. The measurement range can be expanded through external transformers. It also has analog transmission output, alarm output and other functions. It is equipped with an RS485 communication interface to realize remote data transmission and centralized control. It has high accuracy and is suitable for a variety of non-corrosive occasions.

[0241] Three-phase power quality analyzers, such as the Fluke 1770 series, can perform power quality testing, troubleshoot, log data, and create detailed reports. They can collect detailed data to help identify power quality and energy efficiency issues. Analysis software provides a complete overview of power quality. They are suitable for industrial plants, manufacturing plants, and utilities.

[0242] Comprehensive lightning arrester tester: For example, Zohang BLQ6111 uses a high-performance processor, equipped with high-precision sampling filter circuit and digital filtering technology, which can filter out interference signals and perform high-precision analysis of fundamental wave, harmonic voltage and current signals. It can simultaneously measure the electrical parameters of three-phase zinc oxide lightning arresters and automatically compensate for phase-to-phase interference. It can also perform single-phase measurement and has multiple functions and a good human-machine interface.

[0243] Collaboration with the High-Efficiency Data Processing and Analysis Subsystem: The high-efficiency data processing and analysis subsystem collects and stores data in real time, leveraging big data and artificial intelligence analysis for product quality assessment and traceability. The laser interferometer-based three-dimensional positioning subsystem generates a large amount of positioning data during operation, which is transmitted to the high-efficiency data processing and analysis subsystem. This subsystem comprehensively analyzes positioning data and data generated by other subsystems to assess equipment operating status, predict potential failures, and determine product quality. For example, by analyzing the changing trends in positioning data, it is possible to determine whether the equipment has positioning deviations caused by mechanical wear, allowing for proactive maintenance and ensuring stable system operation.

[0244] Cooperation with the fault diagnosis subsystem based on the Internet of Things and artificial intelligence: The fault diagnosis subsystem based on the Internet of Things and artificial intelligence collects operating data through sensors in key locations, enabling the remote monitoring center to predict and locate equipment faults. The three-dimensional positioning subsystem based on the laser interferometer is a key component of equipment operation, and its sensor data is also collected for fault diagnosis. When an abnormality occurs in the positioning subsystem, such as a decrease in positioning accuracy or abnormal fluctuations in positioning data, the fault diagnosis subsystem can quickly locate the fault point by analyzing this data and combining it with data from other subsystems transmitted by the Internet of Things. For example, it can determine whether the fault lies with the laser interferometer itself or with the related signal transmission lines, data processing modules, etc., to achieve accurate fault prediction and location, and improve equipment maintenance efficiency.

[0245] In summary, the three-dimensional positioning subsystem based on the laser interferometer is interconnected and works in coordination with other subsystems. Through data interaction and functional complementarity, they jointly ensure the efficient, stable and precise operation of the flexible manufacturing and high-precision welding systems of the fully automatic processing equipment of smart meters, and realize the hard-connected, fully automatic welding, inspection and integrated molding of sampling components of various types of smart meter products, thereby improving processing efficiency, welding accuracy and reliability, and reducing production costs.

[0246] Specifically, in the flexible manufacturing and high-precision welding systems of fully automated smart meter processing equipment, the model predictive control algorithm in the laser interferometer-based three-dimensional positioning subsystem is key to ensuring positioning accuracy and stable equipment operation. The following details the algorithm's prediction and calculation process:

[0247] Prediction Process

[0248] S1. Data collection and preprocessing

[0249] The laser interferometer continuously collects the device's position information in three-dimensional space. At the same time, other subsystems such as the vibration and airflow monitoring feedback subsystem, low heat input welding and thermal deformation compensation subsystem also provide relevant environmental and equipment status data, such as vibration amplitude, temperature changes, etc.

[0250] The collected data are preprocessed, including noise removal and normalization, to ensure the accuracy and consistency of the data and provide a reliable data basis for subsequent predictions.

[0251] S2. Build a prediction model

[0252] Use machine learning or statistical methods to build predictive models, such as linear regression, neural networks, and Kalman filters. These models can predict the future motion and position of a device based on historical data and current input data.

[0253] When using a neural network, the network is trained using a large amount of historical data to learn the patterns and laws of machine movement. During the training process, the network's weights and biases are continuously adjusted to minimize the error between the predicted and actual values.

[0254] S3. Predicting device motion deviation

[0255] The preprocessed data is input into the trained prediction model, which will predict the possible motion deviations of the device in the future based on the current state.

[0256] For example, considering the impact of thermal deformation on the position of equipment during welding, the model can predict the positional offset that may occur to the component in the next welding step based on the current temperature changes and heat conduction laws.

[0257] S4. Considering uncertainty

[0258] In actual operation, there are many uncertain factors, such as mechanical wear of equipment, sudden changes in the environment, etc. In order to improve the accuracy of prediction, the model will introduce probability distribution to describe these uncertain factors.

[0259] For example, using the Monte Carlo simulation method, multiple random samplings are used to simulate the combination of different uncertainty factors, thereby obtaining the probability distribution of equipment motion deviations and providing more comprehensive information for subsequent control decisions.

[0260] Calculation process

[0261] S1. Objective function setting

[0262] An objective function is set to measure the difference between the predicted motion deviation and the desired motion trajectory. The objective function usually includes multiple factors such as position error and velocity error, which are taken into account through a weighted summation.

[0263] For example, the objective function is expressed as: , where J is the value of the objective function, is the weight of each error factor, is the value of the i-th error factor, and e is one or both of the position error and the velocity error.

[0264] S2. Determination of Constraints

[0265] Considering the physical limitations and process requirements of the equipment, a series of constraints are determined, including the equipment's maximum speed, acceleration, and positioning accuracy requirements.

[0266] For example, the movement speed of the equipment cannot exceed its maximum design speed, and the deviation of the welding position must be controlled within the sub-micron range.

[0267] S3. Optimization solution

[0268] Under the premise of satisfying the constraints, the optimization algorithm is used to solve the minimum value of the objective function, thereby obtaining the optimal control parameters. Commonly used optimization algorithms include gradient descent, genetic algorithm, particle swarm optimization, etc.

[0269] When using the gradient descent method, the objective function's value is gradually reduced by continuously iteratively updating the control parameters until convergence is reached. In each iteration, the control parameters are adjusted according to the direction of the objective function's gradient, aiming to approach the optimal solution as quickly as possible.

[0270] S4. Control parameter update

[0271] Based on the optimal control parameters obtained through optimization, the device's motion trajectory and positioning data are adjusted in real time. For example, if a device position deviation is predicted, the motor drive signal is adjusted to ensure the device moves along the corrected trajectory, thereby compensating for position deviations caused by various factors.

[0272] The basic process of model predictive control algorithm

[0273] The process of the model predictive control algorithm is as follows:

[0274] S1. Data Collection: This simulates the laser interferometer collecting position data by calling the collect_position_data function. This function generates an array of three random numbers representing the position information in three-dimensional space. In the main program, this function is called 10 times in a loop to obtain 10 sets of position data and store them in the position_data list.

[0275] S2. Model initialization: Create an instance of the LinearRegressionModel class, model, which implements a simple linear regression model. In the class's __init__ constructor, initialize the model's weights, which is an array of three random numbers.

[0276] S3. Train the prediction model: Extract training data from the collected location data, using the first nine sets of data as input features X and the last nine sets of data as target values y. Then call the model's train method to fit a linear regression model by performing matrix operations to obtain the optimal weight parameters.

[0277] S4. Predict the next position: Take the last set of position data collected as the current position current_position, call the model's predict method, and predict the next position based on the trained model and the current position data to obtain predicted_position.

[0278] S5. Calculate the objective function value: Define the objective function objective_function, which is used to measure the sum of squared errors between the predicted position predicted_position and the desired position desired_position. In the main program, call this function to calculate the objective function value cost between the predicted position and the desired position [0.5, 0.5, 0.5].

[0279] S6. Optimization: Call the gradient_descent function to optimize the model. This function uses a simple gradient descent method to continuously calculate the error between the predicted value and the target value within a specified number of iterations (the default is 100), then calculate the gradient, and update the model weights based on the learning rate (the default is 0.01). Finally, it returns the optimized model optimized_model.

[0280] S7. Update control parameters and output results: Use the optimized model optimized_model to predict the current position current_position again to obtain new_predicted_position. Finally, output the original predicted position predicted_position and the optimized predicted position new_predicted_position for comparison and observation of the optimization effect.

[0281] The model predictive control algorithm in the laser interferometer-based 3D positioning subsystem has the following advantages:

[0282] 1. Complex System Processing: This system can handle complex systems with multivariable, strongly coupled, nonlinear, and time-varying characteristics. For example, in fully automated processing equipment for smart meters, it can comprehensively consider the interactions between the laser interferometer's three-dimensional positioning subsystem and multiple other subsystems to effectively control the complex operating status of the equipment.

[0283] 2. Considering Constraints: This system can naturally handle various constraints within the system, such as control input amplitude limits, actuator physical limitations, and system state boundary constraints. In smart meter manufacturing, this ensures that the equipment can achieve high-precision positioning and welding operations within the physical parameter limits and process requirements of each subsystem.

[0284] 3. Model-based prediction: By building a mathematical model of the system, the system's future behavior can be predicted. In the 3D positioning subsystem of the laser interferometer, model prediction can be used to estimate component position changes in advance. Even in complex situations such as equipment vibration and thermal deformation, positioning data can be adjusted in a timely manner to maintain positioning accuracy.

[0285] 4. Rolling Optimization: This strategy uses a rolling optimization strategy, continuously optimizing the control strategy online based on new measurement information and the current system status. For example, during the smart meter manufacturing process, the motion trajectory and control parameters are dynamically adjusted based on real-time collected position data and other subsystem status information to adapt to changing operating conditions.

[0286] 5. Robustness: The system is robust to changes in system parameters and external interference. When the smart meter processing equipment is affected by environmental factors (such as airflow changes) or internal factors (such as equipment wear), the model predictive control algorithm can make real-time adjustments to maintain stable system operation and control performance.

[0287] Multivariable control: Applicable to multivariable control problems, it can simultaneously optimize multiple control objectives. In fully automated smart meter processing equipment, this technology can simultaneously address multiple objectives, such as positioning accuracy, welding quality, and equipment operational stability, enabling the coordinated operation of various subsystems to improve overall processing efficiency and product quality.

[0288] Specifically, the closing detection unit includes communication detection of the mutual inductor 17 , current detection of the mutual inductor 17 , opening and closing detection of the switch unit 16 , and current detection of the switch unit 16 .

[0289] Specifically, as attached Figure 2 As shown, the automatic loading unit 652 for terminal button boxes includes a loading robot 653 and a circulating hopper 654. The circulating hopper 654 is used for conveying, lifting, and positioning. Specifically, the hopper is 600x400 (21 per layer), with a total of 20 layers. The number of layers can be adjusted according to actual needs. It also includes a shift stop 651 to create a blocking effect.

[0290] In addition to the terminal box automatic loading unit 652, the loading robot 653 has the functions of loading and automatic grasping. Laser interference positioning detectors, force sensors and intelligent recognition adaptive grasping devices with visual collaboration, automatic grasping path planning and real-time grasping detection are arranged on the flexible robotic arm manipulator and multiple grippers. The motion trajectory is adjusted in combination with the model predictive control algorithm, and sensors are installed at key locations to build a vibration and airflow monitoring feedback subsystem: vibration and airflow monitoring feedback are installed on key parts of the equipment such as the robotic arm joints, welding workbench, and integrated welding tooling 648. The subsystem automatically adjusts the operating parameters or starts the vibration reduction device. At the same time, a special flexible silicone material is used on the gripping surface of the manipulator and multiple grippers, and cylindrical pores with a diameter of 100 nanometers and a depth of 500 nanometers are set on the gripping surface of the flexible silicone material. In addition to the density of 100-500 pores per square millimeter, its automatic loading and gripping of smart meters such as switch units (relays or circuit breakers), mutual inductors, and transformers, its technical features are the same as those of the terminal box automatic loading unit 652 and the loading robot 653.

[0291] Specifically, the integrated welding fixture 648 includes a welding fixture, which has three types of structures, namely welding fixture A, welding fixture B and welding fixture C. Welding fixture A, welding fixture B and welding fixture C can all perform single process cycles or independent operations. Figure 8For example: when welding fixture B and integrated welding fixture 648 are used in conjunction with a single process cycle around the cycle line welding inspection (such as Figure 8 and Figure 2 As shown); the welding fixture B includes: a base plate 11. When the base plate 11 is used to cooperate with the integrated welding tool 648, the welding fixture B does not have the first drive mechanism 14, the sixth cylinder drive and the opening and closing drive mechanism. The first drive mechanism 14, the opening and closing drive mechanism and the sixth cylinder drive are respectively installed on the welding fixture B on the integrated welding tool 648. The flow passes through and faces the first point welding unit 683 of the switch unit; the second point welding unit 684 of the mutual inductor; the second point welding unit 688 of the switch unit; and the first point welding unit 689 of the mutual inductor; respectively realize the delivery of the welding fixture B to the welding position, the opening of the relay before welding, the closing of the relay after welding, the positioning and locking of the terminal box and the switch unit (relay or circuit breaker) and the mutual inductor during welding, so as to ensure the consistency of welding size and strength. Welding fixtures A, B, and C, combined with integrated welding fixture 648, form the flexible manufacturing and high-precision welding equipment BD24 for fully automated smart meter processing. The mobile welding fixture A and integrated welding fixture 648 on the multi-process welding, assembly, and inspection cycle line are integrated and circulated to each workstation, enabling high-precision welding, assembly, and inspection. In addition to the aforementioned technical features, this system automatically handles the loading and unloading of terminal boxes, switch units (relays or circuit breakers), transformers, and soldering lugs, enabling welding, testing, and opening and closing. The following technical features also apply to independent operations:

[0292] Welding fixture A and welding fixture B can both work independently. Figure 8 As shown, welding fixture A is used for welding fee-controlled smart meters, while welding fixture B replaces the mounting portion of welding fixture A and shares the same drive mechanism for welding IoT smart meters. The clamping unit, consisting of a rotating jaw and a fixed jaw, differs from welding fixture B in that the rotating jaw is equipped with a first deflection plate B700, and the fixed jaw is equipped with a second deflection plate B701. Welding fixture C is used for welding metering, which consists of circuit breakers and transformers for ultra-high current capacity smart meters, and for welding smart metering IoT-connected meters. The remaining structural features are identical.

[0293] The flexible robotic arm and gripper are equipped with vision and force sensors and laser interferometer positioning detectors, which work together to adjust the motion trajectory in conjunction with a model predictive control algorithm. Automatic planning of the grasping path and real-time grasp detection are intelligently recognized and adaptively grasp terminal boxes of different specifications and complex shapes, switch units (relays or circuit breakers), transformers, etc. Multiple processes are integrated and assembled on a single tooling platform, namely, welding fixture A, welding fixture B, and welding fixture C. High-precision vibration sensors and airflow sensors are installed on welding fixtures A, B, and C, and vibration and airflow monitoring feedback subsystems automatically adjust operating parameters or activate vibration reduction devices. Through the carefully designed and flexible tooling structure, welding operations on multiple parts can be completed in a single clamping operation, greatly improving production efficiency and reducing positioning errors caused by multiple clamping operations. This overcomes the difficulties in compatible processing of complex parts, improves welding accuracy and efficiency, and optimizes equipment collaboration. Flexible, high-precision, and fully automated welding, assembly, and inspection are integrated into a single clamping and processing process on a single device.

[0294] As attached Figure 7 As shown, welding fixture A has the following technical features: Here, base plate 11 can be movably connected to integrated welding fixture 648, or it can be fixedly connected to integrated welding fixture 648. Those skilled in the art can adjust this according to actual needs. Base plate 11 has a first concave cavity 113 and a first fixed cavity 114. First fixed cavity 114 is used to secure terminal box unit 15. Here, first fixed cavity 114 is open upward, and terminal box unit 15 is placed into first fixed cavity 114 from above.

[0295] The first protrusion 115 is fixed to the upper right end of the bottom plate 11, the fourth sliding pair 33 is installed on both sides of the first concave cavity 113 on the bottom plate 11, the T-plate B114 is installed on the fourth sliding pair 33 (the T-plate B114 realizes linear sliding), the rear end of the groove in the middle of the T-plate B114 is installed with a rotating shaft, a bearing is provided on the rotating shaft, the tenth connecting plate 124 is fixed by the screw of the spring sleeve on the front end threaded hole B131 of the T-plate B114 (the sixth connecting plate 111 floats along the screw and the spring, the sixth connecting plate 11 1 slides forward, backward, left, and right along the bearing on the rotating shaft). The sixth connecting plate 111 is fixed to the front threaded hole B131, forming a floating lower composite lower slide A. The tenth connecting plate 124, with the sixth connecting plate 111 compressed and expanded relative to the spring on the front threaded hole B131, slides linearly along the first concave cavity 113, lowering and pressing downward or raising its head. That is, the tenth connecting plate 124 slides within the first concave cavity 113, specifically sliding and lowering and pressing downward or raising its head toward the first fixed cavity 114. The sixth connecting plate 111 is provided with a second fixed cavity 131, which is used to secure the switch unit 16. The switch unit 16 is fixed to the second fixed cavity 131. The switch unit 16 can be a relay, load switch, circuit breaker, or other switch for closing and closing the switch.

[0296] The clamping unit is a positioning frame A119 installed in the first open groove A255 and the second open groove A118 on the sixth connecting plate 111, one end of the return spring 120 is fixed on the second positioning pin A105 on the positioning frame A119, and the other end is fixed on the second positioning pin A105 on the base plate 11, and the first clamping claw B33 is fixed in the third open groove A126 on the sixth connecting plate 111; the third conductive member 171 on the fixed mutual inductor 17 is first clamped in the first step opening groove A120 and the second step opening groove A124 on the positioning frame A119. This setting allows the fixed mutual inductor 17 to be pre-positioned first. This pre-positioning setting first ensures the welding assembly position of the third conductive member 171 Centering and centering of the current sampling pin (eliminating the error in sampling current and accuracy caused by the offset of the current sampling pin in the prior art), a tension spring is set in the middle of the rear end of the rotating claw of the fixed transformer 17 and the fixed claw of the fixed transformer 17, which are clamped by the fixed transformer 17 in the first clamping claw B33; this upper and lower double-profiling design and the floating tension spring lock the fixed transformer and are flexible and compatible with transformers of different specifications and complex shapes, eliminating the operational errors after the transformer is assembled, the errors in the complex shape of the product and the poor tilt of the pin caused by the rotation of the fixed transformer in the prior art.

[0297] The tensioning spring causes the fixed claw to rotate relative to the rotating claw, and the contour locking fixes the transformer 17 to be centered and locked in the vertical position after the silver needle is positioned. The sixth connecting plate 111 on the clamping unit is first slidably connected with the first clamping claw B33 along the positioning frame A119, and the first protrusion 256 on the sixth connecting plate 111 is synchronized to slide the second time along the first horizontal groove 1121 on the slide 112 on the first protrusion 115. Under the action of the locking position of the first clamping claw B33, the fixed transformer 17 slides along the first horizontal groove 1121 and the first inclined groove 1122 on the slide 112 and is accurately pressed down on the welding piece of the transformer copper terminal 152, ensuring the precise welding positioning and assembly accuracy of the three welding parts of the fixed transformer 17, the transformer copper terminal 152 and the welding piece, and solving the problem that the misalignment and tilt of the existing transformer 17 cannot be eliminated and the positioning cannot be achieved during the grabbing and feeding process. The switch unit 16 is positioned in the second fixed cavity 131 on the sixth connecting plate 111, and the welding surface of the second conductive member 161 on the switch unit 16 is driven by the sixth connecting plate 111 to achieve precise positioning, pressing, tightening and locking assembly with the welding piece on the copper terminal 151 of the switch unit; this precise positioning, pressing, tightening and locking assembly setting eliminates the risk of the second conductive member 161 being positioned and pushing off the welding piece during the assembly process, resulting in a cold weld.

[0298] The L-shaped upper plate cover is above the first clamping claw B33 of the positioning frame A119. Specifically, the L-shaped upper plate is fixed on the sixth connecting plate 111. The clamping unit is arranged between the sixth connecting plate 111 and the L-shaped upper plate cover. The clamping unit slides A along the lower sliding pair 33 of the T-shaped plate B114. The clamping unit is driven by the cylinder rod at the back of the sixth connecting plate 111 to slide B relative to the upper side of the positioning frame A119.

[0299] The clamping unit includes a first clamping claw B33, a T-shaped plate B114 sliding along the lower sliding A of the fourth sliding pair 33, the sixth connecting plate 111 driven by the cylinder rod at the back to slide B (side sliding bearing) relative to the positioning frame A119, and a floating pressure plate at the rear end of the second fixed cavity 131 (pressing the switch unit, the square outer shell of the switch unit (relay or circuit breaker)), the rotating claw and the ninth U-shaped groove A257 on the positioning frame A119 form the third sliding width, and the L-shaped upper plate cover and the sixth connecting plate 111 on the positioning frame A119 form the fourth sliding width (upper and lower sliding).

[0300] The sixth connecting plate 111 slides relative to the third sliding amplitude, the fourth sliding amplitude, the lower sliding A, and the upper sliding B. The first protrusion 256 on the sixth connecting plate 111 slides along the first horizontal groove 1121 on the slide groove 112 on the first protrusion 115 for the second sliding amplitude, and the sixth connecting plate 111 is floatingly fixed on the tenth connecting plate 124 along the bearing sliding on the rotating shaft installed at the rear end of the first concave cavity 113 on the bottom plate 11 to form a composite sliding amplitude. This design solves the interference and position error of the switch unit (relay or circuit breaker) with large adaptive complex shape error, the mutual inductor, the welding piece, the boss with the conductive part, the copper terminal 151 of the switch unit, and the copper terminal 152 of the mutual inductor. After the interference, it is adaptively corrected to the center welding position front, back, left and right, forming a flexible adaptive automatic centering adjustment multi-station integrated fixture.

[0301] Here, the clamping unit passes through the middle groove A132 and slides in the direction of the first fixed cavity 114. The second conductive part 161 is welded to the copper terminal 151 of the switch unit; the third conductive part 171 is welded to the copper terminal 152 of the transformer. The welding fixture A is used to form a welding fixation between the terminal box unit 15, the switch unit 16, and the transformer 17, making the processing more convenient. When the entire fixture is fixed in place, the upper electrode and the lower electrode cooperate to form a welding connection effect, and the welding method here is specifically resistance brazing. With this structural setting, first, the switch unit 16 and the transformer 17 move relative to the terminal box unit 15, so that the cooperation between the switch unit 16, the transformer 17 and the terminal box unit 15 is more stable, and the combined fixing method of the three components forms an automated processing welding, which can avoid failures and defects caused by manual operation.

[0302] Specifically, it also includes a first protrusion 115, which is connected and fixed to the base plate 11. Here, the first protrusion 115 partially extends into the first concave cavity 113 and is positioned adjacent to the middle groove A132, while the remaining portion of the first protrusion 115 extends upward. Specifically, the first protrusion 115 partially extends beyond the top surface of the base plate 11. A chute 112 is provided on the side of the portion of the first protrusion 115 that extends beyond the top surface of the base plate 11. The chute 112 includes a first horizontal groove 1121 and a first inclined groove 1122. The first horizontal groove 1121 communicates with the first inclined groove 1122. The first inclined groove 1122 is closer to the first fixed cavity 114 than the first horizontal groove 1121, and the first inclined groove 1122 is inclined downward toward the first fixed cavity 114. Alternatively, the chute 112 can be directly provided on the side of the base plate 11. In this case, the base plate 11 is an L-shaped structure, and the chute 112 is provided on the side of the base plate 11. The sixth connecting plate 111 is provided with a first protrusion 256. The first protrusion 256 is located on the side of the sixth connecting plate 111 and slides within the slide groove 112. When the sixth connecting plate 111 slides relative to the base plate 11, the first protrusion 256 slides along the slide groove 112. It should be noted that there is only one first protrusion 256, which only serves as a single-sided guide to facilitate the downward sliding A and upward sliding B of the sixth connecting plate 111 and the clamping unit. Because the contact surfaces of the switch unit 16 and the terminal box unit 15 are not at the same level as the contact surfaces of the mutual inductor 17 and the terminal box unit 15, the first drive mechanism 14 drives the sixth connecting plate 111 to move. When the first protrusion 256 engages with the first inclined groove 1122, a downwardly pressing action is formed, which ensures stable and reliable welding between the switch unit 16 and the terminal box unit 15, the mutual inductor 17 and the terminal box unit 15, and the welding piece. In addition, the downward pressing and fixing method here can also be vertical downward pressing, that is, there are two fixing blocks above the second fixing cavity 131 and the third fixing cavity I 132, realizing a vertical downward pressing and fixing structure. However, the problem with this structure is that the space in the vertical direction is mainly used to place the switch unit 16 and the mutual inductor 17. During the entire automation process, the upper space utilization rate is insufficient, interference is easy to occur, and a good layout cannot be formed. The combination of the slide groove 112 and the first protrusion 256 on one side cleverly forms a downward pressing effect. The elasticity of the second conductive part 161 and the third conductive part 171 solves the problem of height difference, so that there is more space vertically above, which can facilitate the operation of the robot or other devices. The design of the first inclined groove 1122 is simple in structure, exquisite and practical.

[0303] The device further includes a positioning frame A119 and a return spring 120. The positioning frame A119 is provided with a ninth U-shaped slot A257 and a first fixing post. The forearm of the ninth U-shaped slot A257 is symmetrically provided with a double-sided L-shaped first step opening slot A120 and a second step opening slot A124. The first step opening slot A120 and the second step opening slot A124 are used to position and support the third conductive member 171. When the mutual inductor 17 is locked and fixed to the first clamping claw B33, there are two third conductive members 171, which respectively cooperate with the first step opening slot A120 and the second step opening slot A124. The bottom surface of the positioning frame A119 is provided with a seven-shaped step surface A123, which is used by the return spring 120 to tighten the positioning frame A119 to achieve a limiting effect. The sixth connecting plate 111 is provided with a first opening groove A255 and a second opening groove A118, and a positioning frame A119 cooperates with the first opening groove A255 and the second opening groove A118. A linear ball guide is installed between one side of the positioning frame A119 and the first opening groove A255, and a linear ball guide is installed between the other side of the positioning frame A119 and the second opening groove A118. The linear ball guide forms a relative sliding effect, and the positioning frame A119 is provided with a mounting groove for mounting the linear ball guide. The positioning frame A119 slides relative to the sixth connecting plate 111. The clamping unit is fixed in the third opening groove A126 on the sixth connecting plate 111 and slides along the ninth U-shaped groove A257 on the positioning frame A119, thereby achieving the effect of the clamping unit fixed on the sixth connecting plate 111 sliding relative to the ninth U-shaped groove A257 on the positioning frame A119. The base plate 11 is provided with a second fixing post 105. One end of the return spring 120 is hung on the first fixing post A105 on the positioning frame A119. The other end of the return spring 120 is hung on the second fixing post 105 to achieve the spring-flexible locking of the positioning frame A119. This solves the problem of the first protrusion 256 sliding along the slide groove 112. After the synchronous integration of the sixth connecting plate 111 and the lower sliding A and upper sliding B of the clamping unit, it eliminates the jamming caused by various poor clearances and prevents poor welding caused by assembly misalignment. A fifth connecting plate is fixed to the base plate 11. The fifth connecting plate cooperates with the fourth drive mechanism. When the base plate 11 slides, the force of the return spring 120 forms a soft connection between the positioning frame A119 and the base plate 11, thereby achieving the drive of the positioning frame A119. This design of a return spring 120 tensioning force plus a movable pair addresses the existing difficulties in assembling the third conductive member 171 of the transformer 17, such as the inability to separate positioning, clamping, and welding during assembly. Furthermore, the positioning bracket A119 is prone to poor welding with the transformer copper terminal 152 and the third conductive member 171. By moving the positioning bracket A119, relative movement can be achieved. The sixth connecting plate 111 is also provided with a third opening slot A126.

[0304] Specifically, the third drive mechanism 40 and the fifth drive mechanism 41 are further included. The third drive mechanism 40 drives the base plate 11 to move along the second direction, and the fifth drive mechanism 41 drives the base plate 11 to move along the third direction. The first, second, and third directions are arranged perpendicularly to each other. Here, the first direction is the Z-axis direction, the second direction is the X-axis direction, and the third direction is the Y-axis direction. The second drive mechanism 29, the third drive mechanism 40, and the fifth drive mechanism 41 form a driving effect in different directions, namely, a sliding effect in the X-axis, Y-axis, and Z-axis directions.

[0305] Specifically, it also includes a first connecting plate A20, a second connecting plate A22, a third connecting plate A23, a fourth connecting plate A25, and a seventh connecting plate A33. The third driving mechanism 40 drives the first connecting plate A20 to move, and the third driving mechanism 40 drives the first connecting plate A20 to achieve sliding of the base plate 11 in the X-axis direction. The fifth driving mechanism 41 is arranged above the first connecting plate A20. The fifth driving mechanism 41 drives the second connecting plate A22 to connect. The third connecting plate A23 is perpendicularly connected to the second connecting plate A22. The fourth connecting plate A25 is arranged parallel to the second connecting plate A22. The fourth connecting plate A25 is perpendicularly connected to the third connecting plate A23. The seventh connecting plate A33 is perpendicularly connected to the base plate 11. The seventh connecting plate A33 is respectively connected to the third connecting plate A23 and the second connecting plate A22. Through the cooperation between the multiple connecting plates, a certain connection strength is formed to meet the requirements of movement in different directions. It should also be noted that the second driving mechanism 29 is arranged on the fourth connecting plate A25.

[0306] Specifically, welding fixture A, welding fixture B (attached Figure 7 As shown in the figure, the number of the ninth U-shaped grooves A257 on the positioning frame A119 is one, two or three (the ninth U-shaped groove A257 is the first, the tenth U-shaped groove B257 is the second, and the eleventh U-shaped groove C257 is the third), and each ninth U-shaped groove A257 is fixed with a clamping unit (the first clamping claw B33 is positioned in the ninth U-shaped groove A257; the second clamping claw C33 is positioned in the tenth U-shaped groove B257 and clamps a mutual inductor 17; the third clamping claw D33 is positioned in the eleventh U-shaped groove C257 and clamps a mutual inductor 17). The ninth U-shaped groove A257 is fixed with one clamping unit, and one clamping unit corresponds to one mutual inductor 17. As shown in the attached figure, Figure 13 As shown, when the electric meter is single-phase, the number of the ninth U-shaped slot A257 is one, and the first opening slot A255 and the second opening slot on the sixth connecting plate 111 are one, respectively, forming a corresponding effect. Figure 13As shown, when the electric meter is two-phase, the positioning frame A119 is provided with a ninth U-shaped groove A257 and a tenth U-shaped groove B257, which correspond to the first clamping claw B33 and the second clamping claw C33. Here, the number of grooves of the sixth connecting plate 111 is three, forming a corresponding effect. Figure 13 As shown, when the electric meter is three-phase, the positioning frame A119 is provided with a ninth U-shaped groove A257, a tenth U-shaped groove B257 and an eleventh U-shaped groove C257, corresponding to the first clamping claw B33, the second clamping claw C33 and the third clamping claw D33; here the number of grooves of the sixth connecting plate 111 is four, forming a corresponding effect.

[0307] As attached Figure 13 、 Figure 9As shown, there are three clamping claws in the clamping unit, namely the first clamping claw B33, the second clamping claw C33, and the third clamping claw D33. The three clamping claws have the same structure. The clamping claws include a rotating claw Ⅰ25 (one form of the rotating claw) and a fixed claw Ⅰ26 (one form of the fixed claw) rotating around the rotating axis Ⅰ260. A tension spring is installed at one end of the rotating claw Ⅰ25 and the fixed claw Ⅰ26 to rotate the fixed claw Ⅰ26 relative to the rotating claw Ⅰ25. The other end of the fixed claw Ⅰ26 cooperates with the rotating claw Ⅰ25 to form a third clamping claw. Three fixed cavities Ⅰ132; the rotating claw Ⅰ25 is provided with an inner arc Ⅰ258 (pressing the upper arc surface of the transformer), the fixed claw Ⅰ26 is provided with a first L-shaped step groove Ⅰ261 (a double L-shaped limit groove platform for the transformer lead pin), the first arc Ⅰ128 and the second arc Ⅰ129 are used to position the double arc protrusion of the transformer, and the third arc IA127 (used for supporting and limiting the lower arc of the transformer), the first L-shaped step groove Ⅰ261, the first arc Ⅰ128, the second arc Ⅰ129, and the third arc IA127 are connected in sequence. The clamping unit clamps and fixes the transformer 17 (eliminating the existing problem of the transformer 17 being unable to be accurately positioned, which easily leads to rotational misalignment, pin tilting, and misalignment). Since the main body of the transformer 17 is annular, it is clamped and fixed by the clamping mechanism. Secondly, after welding is completed, the terminal box unit 15, the switch unit 16, and the transformer 17 form an integrated structure. By rotating the fixing claw I 26, the entire structure can be removed for the next step of inspection, which is highly convenient to operate. In addition, this structural setting forms a fixing effect for different transformers 17. This clamping unit can be applied to both the Southern Power Grid and the State Grid transformers. The rotating claw I 25 is provided with a drive unit I 262. The fixed claw I 26 and the rotating claw I 25 rotate via the rotating shaft I 260. The drive unit elastically presses against the rotating shaft I 260. The drive unit is provided with a hole for mounting the rotating shaft I 260. The front end of the rotating claw I25 features an inner arc I258, which compresses and locks the outer edge of the transformer 17 (not shown in the figure). This arc aligns with the outer shape of the transformer 17, and an outer arc I125 is positioned outside the inner arc I258. The fixed claw I26 features a first L-shaped stepped groove I261, which provides clearance for the communication line of the transformer 17. Connected to this first L-shaped stepped groove I261 is a first arc I128, with a counterclockwise slope of greater than 1.5 degrees. Adjacent to the first arc I128 is a second arc I129, with a counterclockwise slope of greater than 1.5 degrees. This second arc I129 is used to lock the State Grid transformer in place. The width of the second arc I129 is greater than the first and second protruding arcs of the State Grid transformer. The second protruding arc is adjacent to the first arc I128, which is adjacent to the third arc IA127. The second protruding arc is taller than the first protruding arc.Adjacent to the second arc Ⅰ129, there is an outer arc Ⅰ125 of the inclined surface of the State Grid transformer for tightening the third arc IA127 at the limit position, which fits tightly with the first arc Ⅰ128; this limitation can not only ensure the limitation and non-swaying of the State Grid transformer, but also limit the upper conductive pin of the transformer 17 to ensure that the vertical front, back, left and right positions are not offset; the difference between the clamping unit of the Southern Grid transformer and the clamping unit of the State Grid transformer is that the fixing claw Ⅰ26 lacks the second protruding end arc. This limitation can not only ensure the limitation and non-swaying of the State Grid transformer, but also limit the upper conductive pin of the transformer 17 to ensure that the vertical front, back, left and right positions are not offset.

[0308] As attached Figure 12 、 Figure 11 、 Figure 8As shown, the clamping claw in the welding fixture C (used for the intelligent fee control meter of the ultra-large current circuit breaker) includes a rotating claw ⅡB25 (another form of the rotating claw) and a fixed claw ⅡB26 (another form of the fixed claw) rotating around the rotating shaft B260. A tension spring is installed at the rear end of the rotating claw ⅡB25 and the fixed claw ⅡB26 to rotate the fixed claw ⅡB26 relative to the rotating claw ⅡB25. The rear end of the rotating claw ⅡB25 is connected to the first turning plate B700 and superimposed on the second turning plate B701 of the fixed claw ⅡB26. The second turning plate B701 cooperates with the front end of the fixed claw ⅡB26 and the outer arc ⅡB125 of the front end of the rotating claw ⅡB25 to form a third fixed cavity ⅡB132; the third fixed cavity ⅡB132 is used to clamp and position the mutual inductor 17. The rear end, middle end and front end of the rotating claw ⅡB25 and the fixed claw ⅡB26 on the clamping claw are arranged in a "Z" shape. This arrangement makes the clamping claw arranged in The front end of the sixth connecting plate 111 simultaneously realizes the overlap formation of the third conductive part 171 on the transformer 17 and the middle transformer copper terminal 152 and the welding piece in the terminal box unit 15; the second conductive part 161 on the switch unit 16 (specifically the circuit breaker) and the switch unit copper terminals 151 (corresponding to the circuit breaker) and the welding pieces on both sides of the front end of the terminal box unit 15 are overlapped and formed; the rotating B25 is provided with an inner arc B258 (pressing the upper arc surface of the transformer), the fixed claw ⅡB26 is provided with a first L-shaped step groove ⅡB261 (a double L-shaped limit groove platform for the transformer pin), the first arc ⅡB128 and the second arc ⅡB129 are used to clamp the double arc protrusion of the transformer, and the third arc B127 (for the support and limit of the lower arc of the transformer), the first L-shaped step groove ⅡB261, the first arc ⅡB128, the second arc ⅡB129, and the third arc ⅡB127 are connected in sequence. The clamping unit secures the transformer 17 (eliminating existing issues such as inaccurate positioning of the transformer 17, which can easily lead to rotational misalignment, pin tilting, and misalignment). Because the main body of the transformer 17 is annular, the clamping mechanism provides secure clamping. Furthermore, after welding is complete, the terminal box unit 15, switch unit 16 (specifically, the circuit breaker), and transformer 17 form a single unit. By rotating the fixing claw ⅡB26, the entire unit can be removed for further inspection, providing enhanced convenience. Furthermore, this structural arrangement allows for the securement of different transformers 17. Another version of this clamping unit is suitable for both Southern Power Grid and State Grid transformers. The rotating claw ⅡB25 is equipped with a drive unit ⅡB262. The fixing claw ⅡB26 rotates with the rotating claw ⅡB25 via a rotating shaft ⅡB260. The drive unit elastically presses against the rotating shaft ⅡB260, which is provided with a hole for mounting the rotating shaft ⅡB260. The front end of the rotating claw Ⅱ B25 is provided with an inner arc B258 for pressing the outer edge of the mutual inductor 17 (not shown in the figure) and conforming to the outer shape of the mutual inductor 17. The outer part of the inner arc B258 is provided with an outer arc Ⅱ B125.The retaining claw IIB26 features a first L-shaped stepped groove IIB261, which provides clearance for the communication line of the transformer 17. Connected to this first L-shaped stepped groove IIB261 is a first arc IIB128, with a counterclockwise slope greater than 1°. Adjacent to this first arc IIB128 is a second arc IIB129, with a counterclockwise slope greater than 1°. This second arc IIB129 is used to secure the State Grid transformer. Its width is greater than the first and second protruding arcs of the State Grid transformer. The second protruding arc is adjacent to the first arc IIB128, which is adjacent to the third arc IIB127. The second protruding arc is taller than the first protruding arc. Adjacent to the second arc ⅡB129, there is an outer arc ⅡB125 of the inclined surface of the State Grid transformer for tightening the third arc ⅡB127 at the limit position, which fits tightly with the first arc ⅡB128; this limitation can not only ensure the limitation and non-swaying of the State Grid transformer, but also limit the upper conductive pin of the transformer 17 to ensure that the vertical front, back, left and right positions are not offset; the difference between the clamping unit of the Southern Grid transformer and the clamping unit of the State Grid transformer is that the fixing claw ⅡB26 lacks the second protruding end arc. This limitation can not only ensure the limitation and non-swaying of the State Grid transformer, but also limit the upper conductive pin of the transformer 17 to ensure that the vertical front, back, left and right positions are not offset. Figure 11 It can also be used for smart meter terminal box units, high-current relays and transformer assemblies.

[0309] As attached Figure 8 As shown, specifically, the first pressing mechanism 12 includes a first pressing member 121, and the first pressing member 121 rotates horizontally and moves vertically up and down relative to the lower base D110. The first pressing member 121 can rotate in the horizontal direction, and the first pressing member 121 can also move vertically up and down. The vertical up and down movement in this embodiment specifically refers to vertical up and down movement along the Z-axis direction. The first pressing member 121 is used to fix the terminal button box unit 15 to prevent the terminal button box unit 15 from shaking during the welding process and the welding and bonding button box unit 15 and other components from being pulled out and unable to be welded. In the initial state, the first pressing member 121 rotates to the outside of the first fixed cavity D114, so that the terminal button box unit 15 can be placed in the first fixed cavity D114. After the terminal button box unit 15, the switch unit 16, and the mutual inductor 17 are placed, the first pressing member 121 will rotate to the top of the terminal button box unit 15 and move toward the terminal button box unit 15 until it contacts the terminal button box unit 15, forming a fixed effect. Here, how the first pressing mechanism 12 realizes rotation and lifting is specifically realized by a rotating motor and a lifting motor. This is the existing technology, so it will not be described in detail in this embodiment.

[0310] As attached Figure 8As shown, two L-shaped front grooves 560 are provided on the inner side of the second concave cavity D135 on the base D110, a second square groove 134 and a rear groove 136 are provided at the rear end of the lower base D110, U-shaped plates 530 are provided on both sides of the front end of the lower base D110 close to the second square groove 134, and a 7-type adjustment plate 529 is installed in the middle, the four side feet of the lower base D110 are provided with a first side plate 32 and a second side plate 526, a buffer mechanism 30 is fixed on the first side plate 32 and the second side plate 526, a pressing unit D121 of a rotating cylinder is provided in the middle of the first side plate 32 and the second side plate 526, the rear groove 136 is used to install the lower electrode, the second square groove 134 is used to clamp the terminal button box unit 15, and the 7-type adjustment plate 529 is used to adjust the gap and position of the terminal button box unit 15. The pressing unit D121 is used to press the terminal box unit 15; the upper right end of the slide 610 is provided with a mounting spring hole 614 and a second groove 612 in the middle, and one side of the first sliding pair 607 and the second sliding pair 606 are respectively installed on the steps of the L-shaped front groove 560 on both sides of the second concave cavity D135 on the lower base D110, and the other side of the first sliding pair 607 and the second sliding pair 606 are respectively installed in the L-shaped groove 616 and the inverted L-shaped groove 613 on the other side of the slide 610 (the slide 610 is realized in the second concave cavity D135 on the lower base D110). A pad 608 is placed on the lower right end of the slide 610, close to the side of the pad 608, and the first screw at the rear end of the single-phase L-shaped first U-shaped groove plate 583 The threaded hole 574 and the second through hole 570 on the first U-shaped groove 118 are respectively locked in the second threaded hole 620 on the U-shaped rotating plate 609 by screws, and the U-shaped rotating plate 609 is installed at the rear end of the second groove 612 in the middle of the slide 610. The first hole 617 and the second hole 618 on the rotating plate 609 are provided with an axis passing through the third hole 611 and the sixth hole 615 on the slide 610 to realize even rotation. The first U-shaped groove 118 at the front end of the first U-shaped groove plate 583 is provided with a slide rod hole 571, and the slide rod floats and presses the first U-shaped groove plate 583 on the spring in the spring hole 614 of the slide 610 through the slide rod hole 571; the positioning frame 119 is embedded in the first U-shaped groove 118 and forms a third sliding pair; a pair of pin holes 582 at the rear end of the positioning frame 119 are provided on A pin is provided (one end of a pair of springs D24 is fixed on it), and the other end of the pair of springs D24 is fixed to the second fixing column 105 on the lower base D110. The second fixing column 105 is provided on the second mounting plate 531. The fourth threaded hole D105 at the rear end of the lower base D110 is fixed to the second mounting plate 531 by screws; the positioning frame 119 is flexibly floatingly connected to the first U-shaped groove 118; the clamping claw B563 is fixed by screws in the third threaded hole 569 in the first U-shaped groove 118 on the positioning frame 119, and the slot plate D111 is fixed to the first threaded hole 574 on the first U-shaped slot plate 583 and the threaded hole on the pad 608 by screws in the fourth hole 527 and the fifth hole 524 respectively; the T-plate 237 is fixed to the slot plate D111 by screws.The spring installed on the T-plate 237 and the cross-shaped slide 627 are installed in the card slot 251 and the first square slot 252 to form a floating top pressure unit; the floating top pressure unit is used to press the switch unit (relay or circuit breaker) installed in the second square slot D112 of the slot plate D111; the opening and closing unit is installed in the T-shaped opening slot 250 on the T-plate 237; the front end of the slot plate D111 is provided with a T-shaped opening slot 250 (the second U-shaped slot 244, the third U-shaped slot 246, and the second clearance slot 247 are used for position adjustment and limiting of the third conductive member 171 and the second conductive member 161); the lower left end of the slide 610 is provided with a cylinder D14 fixed on the L-shaped plate, and the cylinder rod of the cylinder D14 is arranged opposite the T-plate 237; a limit screw F (not shown in the figure) is provided in the middle of the fourth fixed cavity D132, and the upper cover 598 is installed on the first U-shaped slot plate 583. The clamping claw B563 on the first U-shaped groove plate 583 slides with the groove plate D111 along the positioning frame 119; the limit screw F is driven by the cylinder D14 to limit the end position of movement; the sliding column 619 on the first U-shaped groove plate 583 slides along the straight groove 621 and the curved groove 622 on the second protrusion D620 (defined as a sliding trajectory pair); the sliding trajectory of the sliding column 619 ensures that the second conductive part 161 of the switch unit and the third conductive part 171 on the mutual inductor 17 are grasped and assembled, moved downward, and pressed on the welding piece on the copper terminal 151 of the switch unit and the copper terminal 152 of the mutual inductor on the terminal box unit 15 to realize fully automatic assembly; when welding is completed, the clamping unit D121 is reset and released to release the lock, the welded parts of the terminal box unit 15 are taken out, and the cylinder D14 is reset to reset the groove plate D111 and the clamping claw B563 to their original positions. In addition to the technical advantages of welding fixture B and welding fixture A, welding fixture C is suitable for the copper terminal 151 of the switch unit and the copper terminal 152 of the transformer without a limit step. The slot plate D111 and the clamping claw B563 are driven to rotate by the U-shaped rotating plate 609, and the spring in the spring hole 614 of the slide 610 presses down and resets the slot plate D111 and the clamping claw B563 as a flexible rotation; the movement and pressing of the slot plate D111 and the clamping claw B563 are achieved by the superposition and fusion of the three sliding pairs of the linear sliding pair, the third sliding pair, and the sliding track pair with the running track; this setting solves the offset error and position overshoot error of the movement and downward pressing assembly in the existing technology, and has a simple structure and precise assembly accuracy.

[0311] A fourth opening slot 576 and a fifth opening slot 577 are provided at the front end of the positioning frame 119 for positioning the third conductive member 171. A twelfth U-shaped slot 578 is provided at the rear end of the fourth opening slot 576 and the fifth opening slot 577. The twelfth U-shaped slot 578 is used to automatically correct the offset of the transformer during the manufacturing process of the existing transformer 17. A ninth U-shaped slot A257 is provided at the rear end of the twelfth U-shaped slot 578. The ninth U-shaped slot A257 serves as a sliding slot for the clamping claw B563. The difference between the clamping claw B563 and the first clamping claw B33 is that a rotating floating pressure head 565 is added.

[0312] The two-phase L-shaped second U-shaped slot plate 585 is additionally provided with a thirteenth U-shaped slot 586 and a fourteenth U-shaped slot 588 , and the three-phase L-shaped third U-shaped slot plate 590 is additionally provided with a fifteenth U-shaped slot 592 , a sixteenth U-shaped slot 596 and a seventeenth U-shaped slot 594 .

[0313] Specifically, as attached Figure 7 、 Figure 8 、 Figure 10 、 Figure 14 As shown, the floating pressure gate opening support unit 235 includes a T-plate 237, an L-shaped plate 312 is provided at the lower right end of the T-plate 237, a yield L-shaped port D249 is provided at the upper end of the L-shaped plate 312, a limit plate 310 is provided at the front end of the L-shaped plate 312, and a limit adjustment screw block is configured on the limit plate 310 to prevent the foolproof stop position of the positioning frame A119 and the first clamping claw B33; connected to the L-shaped plate 312 is a support plate 316, which is provided with a T-shaped sliding groove for mounting the U-shaped slide 238, and a spring is mounted at the large end of the T-shaped sliding groove to connect with the U-shaped slide 238. 8 is floatingly connected and can slide along the T-shaped sliding groove. A mounting plate groove is provided on the side of the support plate 316 for limiting the position of the "X"-shaped slide plate 627. A trapezoidal slide rail 315 is provided in the center of the support plate 316. Screw counterbores and through holes 133 are provided on both sides of the trapezoidal slide rail 315 (the support plate 316 is mounted on the T-shaped plate B114 or the slot plate D111). A mounting hole 314 is provided on the side of the first mounting plate 313 for tightening the screw to position the base 291. The mounting hole 314 communicates with the T-shaped open slot 250 provided on the right end of the first mounting plate 313. The first mounting plate 313 is fixedly connected to the support plate 316 by screws.

[0314] T-plate 237 is provided with a T-shaped slot 250 and a clearance L-shaped opening D249. The clearance L-shaped opening D249 is used to make way for the positioning frame A119 and is located at the lower right corner of the T-plate 237. The T-shaped slot 250 is used to secure the opening and closing mechanism A316. Here, the T-shaped slot 250 is located at the upper right corner of the T-plate 237. However, it should be noted that the T-shaped slot 250 and the clearance L-shaped opening D249 are not connected. In this embodiment, the T-shaped slot 250 is arranged in an inverted T-shape, i.e., larger at the bottom and smaller at the top, creating a one-way sliding effect.

[0315] The opening and closing mechanism A316 is housed in the T-shaped slot 250. Here, the opening and closing mechanism A316 can move forward and backward relative to the T-plate 237. This forward and backward movement is used to adjust the position of the opening and closing mechanism A316. Once the adjustment is complete, the opening and closing mechanism A316 is fixed by the fixing structure. The opening and closing mechanism A316 has a chamber with front and back openings. In this embodiment, the end of the chamber closest to the switch unit 16 is the front end of the chamber, and the end away from the switch unit 16 is the rear end of the chamber.

[0316] There are two sliding tongue plates 265, each housed in a corresponding chamber. The two sliding tongue plates 265 are symmetrically arranged, with their front ends extending outside the front end of the chamber. They mate with the first pins 162 of the switch unit 16. Here, there are two first pins 162, each serving as the communication pins of the switch unit 16. Controlling these communication pins connects or disconnects the moving and static contacts within the switch unit 16. The switch unit 16 can be a switch unit 16, a load switch, or other closing and closing control switch. The front ends of the two sliding tongue plates 265 each form an electrical connection with the corresponding first pins 162, creating a control effect. The rear ends of the sliding tongue plates 265 extend outside the rear end of the chamber, and the other ends of the sliding tongue plates 265 mate with a drive source and power cord. The drive source drives the sliding tongue plates 265 along the Y-axis, establishing an electrical connection between the front ends of the sliding tongue plates 265 and the first pins 162. The power cord forms an electrical connection with the tongue plate 265, which then forms an electrical connection with the first pin 162, thereby controlling the on / off state of the switch. The tongue plate 265 is specifically made of a conductive material. In this embodiment, the end of the tongue plate 265 closest to the switch unit 16 is the front end of the tongue plate 265, and the end of the tongue plate 265 away from the switch unit 16 is the rear end of the tongue plate 265.

[0317] The slide rod 267 extends between the two sliding tongue plates 265 to form a sliding pair. The slide rod 267 forms a separation effect between the two sliding tongue plates 265, and the sliding tongue plates 265 slide relative to the slide rod 267.

[0318] An elastic reset member, one end of the elastic reset member is against one of the sliding tongue plates 265, and the other end of the elastic reset member is against the other sliding tongue plate 265. The elastic reset member is located at the front end of the chamber, and the elastic reset member forms an opening or tightening effect at the front end of the sliding tongue plate 265.

[0319] In the first state, the sliding tongue plate 265 moves toward the switch unit 16, and the front end of the sliding tongue plate 265 cooperates with the first pin 162 to disconnect the switch unit 16. Here, the first state controls the switch unit 16 to disconnect, creating an opening effect. Specifically, the control end sends a trip signal to the power line, controlling the disconnection of the moving and static contacts inside the switch unit 16. When the switch unit 16 is open, an electrical connection is established between the switch unit 16 and the terminal box unit 15 through resistance brazing. When welding is completed, that is, the second state, the sliding tongue plate 265 and the first pin 162 are still in an electrical connection. The front end of the sliding tongue plate 265 cooperates with the first pin 162 to connect the switch unit 16. Specifically, the control end sends a closing signal to the power line, controlling the connection of the moving and static contacts inside the switch unit 16. When the switch unit 16 is in the closed state, the sliding tongue plate 265 moves away from the switch unit 16.

[0320] The opening and closing mechanism A316 is designed to prevent the moving and static contacts inside the switch unit 16 from being in a connected state. During the welding process, if the moving and static contacts inside the switch unit 16 are in a connected state, welding will be performed at this time. The large welding current will cause the moving and static contacts of the switch unit 16 to stick and melt, resulting in the mechanism being stuck, the mutual inductor 17 being de-energized, etc., and the remote opening and closing and electricity fee control functions of the low-voltage user cannot be realized; and a shunt will be formed during the welding process, resulting in a cold weld, which affects the welding quality; with the above structure, the first state (the switch unit 16 is disconnected) eliminates the risk of welding shunt cold welds and the risk of melting the moving and static contacts of the switch unit 16; in the second state (the switch unit 16 is connected), the closing of the switch unit 16 after welding realizes the requirements of the smart meter welding power detection resistance and meter performance; the opening and closing mechanism A316 ensures that the moving and static contacts inside the switch unit 16 are in a disconnected state, thereby improving the stability and welding quality of subsequent welding.

[0321] Specifically, as attached Figure 1 、 Figure 10 、 Figure 14As shown, the first positioning pin 268 is also included. The tongue plate 265 is provided with a first positioning hole 272. The first positioning pin 268 passes through the first positioning hole 272 and is linked to the tongue plate 265. Here, the first positioning pin 268 extends through the tongue plate 265 along the Z-axis, forming a linkage effect between the tongue plate 265 and the tongue plate 265. The first positioning hole 272 is located at the rear end of the chamber. The first positioning pin 268 secures the tongue plate 265. When the front end of the tongue plate 265 engages with the first pin 162, the elastic reset member compresses and tightens. At this time, the rear end of the tongue plate 265 rotates around the first positioning pin 268. At the same time, the tension of the elastic reset member drives the front end of the tongue plate 265 outward, allowing the tongue plate 265 to better engage with the first pin 162. Alternatively, multiple elastic reset members can be provided between the two tongue plates 265. However, this arrangement suffers from inconvenient installation and insufficient stability. Through the structural setting of the first positioning pin 268, one end is positioned after movement, and the other end forms a tightening or loosening effect. The structure is ingenious and better realizes the electrical connection between the sliding tongue plate 265 and the first pin 162.

[0322] Specifically, as attached Figure 10 As shown, the opening and closing mechanism A316 includes a base 291 and an eighteenth U-shaped groove plate 264. The base 291 and the eighteenth U-shaped groove plate 264 cooperate to form a chamber. The base 291 is provided with a partition portion 300, which is provided with a first waist-shaped hole 292. The elastic return member passes through the first waist-shaped hole 292 and slides in the first waist-shaped hole 292. That is, one end of the elastic return member abuts against one of the sliding tongue plates 265, and the other end of the elastic return member passes through the first waist-shaped hole 292 and abuts against the other sliding tongue plate 265. The two sliding tongue plates 265 are provided on either side of the partition portion 300. The left and right separation setting prevents the two sliding tongue plates 265 from creeping, and the setting of the first waist-shaped hole 292 better realizes the sliding effect of the elastic reset member. It should be noted here that the elastic reset member will not electrically connect the two sliding tongue plates 265, that is, no short circuit will occur between the two sliding tongue plates 265. Here, when the elastic reset member is a compression spring, an insulating pad or an insulating sleeve can be installed at the matching position of the elastic reset member and the sliding tongue plate 265 to form an insulating effect; in addition, an insulating separation can also be formed by an elastic reset member whose outer surface is an insulating material, such as a rainbow ring structure.

[0323] Specifically, as attached Figure 10As shown, the base 291 is provided with a first I-shaped groove 282 and a second I-shaped groove 283. There are two of each, two in a group. The first I-shaped groove 282 and the second I-shaped groove 283 are connected to form a group, and the two groups are located on either side of the partition portion 300. The sliding tongue plate 265 passes through the first and second I-shaped grooves 282, 283 and extends to the outside of the front end of the chamber. The bottom surface of the first I-shaped groove 282 is provided with a first groove 281. The lower end of the first positioning pin 268 is provided with a semicircular protrusion. The sliding tongue plate 265 is provided with a second lower step 274, which has a step portion 301. In the initial position, the protrusion engages with the first groove 281, the sliding tongue plate 265 slides, and the step portion 301 abuts against the first I-shaped groove. In the initial position, the protrusion abuts against the first groove 281, creating a limiting effect. When the step portion 301 abuts against the first I-shaped groove, the sliding tongue plate 265 cannot continue to move toward the front end, thereby achieving a limiting and fixing effect and preventing excessive movement of the sliding tongue plate 265. Furthermore, the base 291 is provided with a second positioning hole 285. In the initial position, the first positioning pin 268 passes through the first positioning hole 272, and the second positioning hole 285 is engaged with the first groove 281. Here, the second positioning hole 285 is a semicircular hole with a notch in its side wall, allowing the first positioning pin 268 to move outside the second positioning hole 285.

[0324] Specifically, as attached Figure 10 As shown, the front end of the tongue plate 265 is provided with a fourth arc 278 and an I-shaped step 279. The fourth arc 278 is connected to one end of the I-shaped step 279, and the other end of the I-shaped step 279 extends obliquely toward the front end of the tongue plate 265. The fourth arc 278 and the I-shaped step 279 cooperate to form an abutment area with the first pin 162, thereby achieving better electrical connectivity. The elastic reset member also makes the electrical connection more stable.

[0325] Specifically, as attached Figure 10As shown, the tongue plate 265 is sequentially provided with a first lower step 271, a second lower step 274, and a third lower step 276, with the second lower step 274 connecting the first and third lower steps 271 and 276. The first lower step 271 is located at the rear end of the tongue plate 265 and is provided with a motor connection hole 269 for the drive source and a power cord connection hole 270 for the power cord. The connection between the second lower step 274 and the first lower step 271 is provided with a first positioning hole 272 for the first positioning pin 268 and a step portion 301. A fourth U-shaped groove 273 is provided on the side of the second lower step 274, with the step portion 301 located on the side wall of the fourth U-shaped groove 273. An L-groove 27 is provided at one end of the second lower step 274 near the third lower step 276, and a fourth arc 278 is provided in the L-groove 27. The fourth arc 278 is connected to the I-shaped step 279. The I-shaped step is used for buffering the extension, and the arc protrusion of the fourth arc 278 makes the conduction more reliable and stable.

[0326] Specifically, as attached Figure 10 As shown, the eighteenth U-shaped slot plate 264 is provided with two countersunk holes 293, and the base 291 is provided with two corresponding first through holes 284. The screws pass through the countersunk holes 293 and the first through holes 284 and connect with the T-shaped opening slot 250 to form a connection and fixing effect.

[0327] Specifically, as attached Figure 10 As shown, the bottom surface of the first I-shaped groove 282 is provided with a step surface 302, and the first groove 281 is provided on the step surface 302. Here, the step surface 302 is lower than the bottom surface of the second I-shaped groove 283, forming a step structure, which also realizes the limitation of the sliding tongue plate 265.

[0328] Specifically, as attached Figure 10 As shown, the eighteenth U-shaped groove plate 264 is provided with a fifth U-shaped groove 295 and a sixth U-shaped groove 294. The fifth U-shaped groove 295 is located above the sixth U-shaped groove 294, and the fifth U-shaped groove 295 and the sixth U-shaped groove 294 are vertically connected. The base 291 is provided with a first square groove 287, specifically, a first square groove 287 is provided on the isolation portion. The first square groove 287 is connected to the fifth U-shaped groove 295 and the sixth U-shaped groove 294, and the first square groove 287 is also connected to the first waist-shaped hole 292. Sliding rod 267 has a thick cylindrical shape at one end and a thin cylindrical shape at the other. The thin cylindrical lower end of sliding rod 267 is fixed to the middle bottom plate of first square slot 287 of base 291. The thick cylindrical upper end of sliding rod 267 is installed in the middle hole of first square slot 287, the fifth U-shaped slot 295, and the sixth U-shaped slot 294, and extends outward. The thick cylindrical portion of sliding rod 267 forms a sliding pair with the fourth U-shaped slot 273 of the two sliding tongue plates 265. Alternatively, sliding rod 267 can be thick in the middle and thin at both ends.

[0329] Specifically, as attached Figure 10As shown, the front end of the eighteenth U-shaped groove plate 264 is provided with a seventh U-shaped groove 296 and an L-shaped clearance groove 297 that cooperate with the partition part 300, and the seventh U-shaped groove 296 is connected to the L-shaped clearance groove 297.

[0330] Specifically, as attached Figure 10 、 Figure 14 As shown, two slots 251 are set at the lower left end of the T-plate 237, and the two slots 251 are used to cooperate with the U-shaped slide 238. An eighth U-shaped slot 253 is set in the middle of the U-shaped slide 238, and a second waist-shaped hole 254 is set on the eighth U-shaped slot 253. The second waist-shaped hole 254 is equipped with a tension spring to enable the U-shaped slide 238 to slide in the slot 251. The upper steps at both ends of the eighth U-shaped slot 253 serve as sliding stroke limits, and the upper steps at both ends of the eighth U-shaped slot 253 are welded or assembled.

[0331] Specifically, as attached Figure 2 As shown, welding fixture A, welding fixture B, and welding fixture C are overlapped on the floating carrier, and a single process is cyclically welded and inspected along the circulation line, and also includes a first welding unit 682 and a second welding unit 687. The first welding unit 682 includes a switch unit first spot welding unit 683 and a mutual inductor second spot welding unit 684. The switch unit first spot welding unit 683 is used to achieve welding of one of the second conductive members 161. The mutual inductor second spot welding unit 684 is used to achieve welding of one of the third conductive members 171. The second welding unit 687 includes a switch unit second spot welding unit 688 and a mutual inductor first spot welding unit 689. The switch unit second spot welding unit 688 is used to achieve welding of another second conductive member 161. The mutual inductor first spot welding unit 689 is used to achieve welding of another third conductive member 171.

[0332] Specifically, it also includes binocular vision inspection 666, which performs welding inspection and can illuminate both sides of the equipment.

[0333] Specifically, a reserved laser welding position 667 is also included to block the laser machine.

[0334] Specifically, it also includes transformer loading and transformer discharging 668. Here, transformer discharging 668 specifically refers to the processing of unqualified products when the transformer 17 is unqualified.

[0335] Specifically, it also includes a welding energy temperature detection unit 690 for detecting the energy during welding.

[0336] Specifically, it also includes a temperature control unit 692, an intelligent control system 693, a comprehensive testing instrument unit 695 (automatically detecting the contact resistance, on-resistance, welding resistance and electrical performance of the switch unit (relay or circuit breaker), the transformer, etc.), a material unloading unit 696, a finished product defective storage unit 697, and a pipeline transfer unit 698.

[0337] Specifically, each subsystem of the fully automatic processing equipment for smart meters generates a variety of data during operation. These data are collected in real time by the efficient data processing and analysis subsystem, as follows:

[0338] Visual sensor data: The visual sensor in the intelligent recognition adaptive gripping device captures component information, including visual image data such as the shape, size, and position of the component, which is used to plan the gripping path.

[0339] Laser interferometer data: The laser interferometer-based 3D positioning subsystem provides precise spatial position information for each mechanism. It collects precise position data of components and related mechanisms in 3D space to ensure the accuracy of operations such as grasping and welding.

[0340] Photoelectric sensor data: The high-precision photoelectric sensor in the solder piece feeding mechanism collects relevant data during the solder piece feeding process, such as the position and quantity of the solder piece, to achieve accurate solder piece feeding.

[0341] Temperature sensor data: The high-precision temperature sensor in the low heat input welding and thermal deformation compensation subsystem monitors the welding temperature in real time and collects temperature data during the welding process to provide a basis for thermal deformation compensation.

[0342] Vibration and airflow sensor data: The vibration and airflow monitoring feedback subsystem collects real-time data on the equipment's own vibration and changes in the surrounding airflow through sensors installed at key locations such as the robotic arm joints and welding workbench. This data is used to promptly adjust equipment operating parameters and ensure positioning accuracy.

[0343] Other data: The welding parameters involved in the welding process of the multifunctional welding integrated equipment, such as welding method, welding current, voltage, pulse frequency, etc., as well as the appearance image data of components collected by the high-resolution industrial camera in the comprehensive intelligent detection subsystem and the electrical parameter data collected by the high-precision instruments used for electrical parameter monitoring, are also collected in real time by the efficient data processing and analysis subsystem.

[0344] Specifically, further technical features of multifunctional welding integrated equipment refer to the multiple composite welding processes involved in welding, the arrangement of water, electricity, gas, heat, vibration, and displacement sensors around the welding head, the collection of multi-modal water, electricity, heat, displacement, and sound multi-parameter fusion, the composite welding process control to achieve qualified specifications and strength of welding, vision and temperature sensors to collect images, videos, and sound multi-modal multi-parameters as artificial intelligence and deep learning monitoring to achieve reliable and high-precision welding quality of multi-functional equipment.

[0345] Detailed welding piece and terminal box unit switch unit copper terminal, mutual inductor copper terminal; laser welding unit adopts welding process to form weld, corresponding welding piece and switch unit copper terminal form π-shaped weld; corresponding welding piece and mutual inductor copper terminal form π-shaped weld; welding process adopts welding piece composite laser welding process, combines pulse and continuous laser, welding piece automatic loading and robot and adopts multi-axis linkage welding process, controls welding angle sequence through three-dimensional space collaborative motion, and monitors feedback adjustment parameters in real time; multi-axis linkage welding process except welding piece automatic loading and robot gripping and positioning welding piece adopts composite laser (welding point adopts pulse and next point adopts pulse In addition to the continuous welding of low-heat-input laser welding technology and the pulse cycle welding process of the thermal deformation compensation subsystem at the next welding point, the welding process also includes a flexible adaptive manipulator (mechanical air gripper) and welding fixture A and welding fixture B. The welding fixtures cooperate to realize the automatic loading and assembly of relays (circuit breakers), mutual inductors, terminal box unit multi-devices, and the setting of convex hulls between intermediate relays (circuit breakers) and mutual inductors. Melt spot welding is first achieved and then resistance brazing is achieved around the convex hull and the ultra-thin welding sheets on the copper terminals of the switch unit and the copper terminals of the mutual inductor (referred to as double-strength convex hull resistance brazing composite welding).

[0346] Coordination with the low-heat-input welding and thermal deformation compensation subsystem: The low-heat-input welding and thermal deformation compensation subsystem monitors the welding temperature in real time through high-precision temperature sensors and utilizes closed-loop control to promptly compensate for thermal deformation caused by heat input. The laser interferometer-based three-dimensional positioning subsystem can monitor component position changes in real time when thermal deformation occurs. For example, when thermal deformation during welding causes the position of a component to shift, the positioning subsystem feeds this information back to the thermal deformation compensation subsystem, which adjusts its compensation strategy accordingly. Simultaneously, the positioning subsystem, combined with a model predictive control algorithm, adjusts its own positioning data to ensure that the high-precision positioning required for welding is maintained even in the presence of thermal deformation, thereby ensuring weld quality.

[0347] Furthermore, the technical features of the closed-loop control of the above technical invention are:

[0348] Real-time temperature monitoring: Real-time monitoring of welding temperature through high-precision temperature sensors provides a data basis for subsequent thermal deformation compensation.

[0349] Thermal deformation compensation: The low heat input welding and thermal deformation compensation subsystem uses closed-loop control to compensate for thermal deformation caused by heat input in a timely manner based on the welding temperature information monitored by the temperature sensor.

[0350] Real-time Position Monitoring and Feedback: The laser interferometer-based 3D positioning subsystem monitors component position changes in real time when thermal deformation occurs and feeds this information back to the thermal deformation compensation subsystem. The thermal deformation compensation subsystem adjusts its compensation strategy based on this feedback. Simultaneously, the positioning subsystem, incorporating a model predictive control algorithm, adjusts its own positioning data to ensure high-precision welding despite thermal deformation, ensuring weld quality.

[0351] Multi-process collaborative control: The welding process involves the coordinated operation of multiple welding processes and equipment, such as automatic welding sheet loading, robotic gripping and positioning, hybrid laser welding, multi-axis linkage welding, and hybrid welding with double-strength convex hull resistance brazing. Closed-loop control achieves automated and precise control of the entire welding process through coordinated control of these processes and equipment. For example, the robotic arm and multi-axis linkage welding process control the welding angle sequence through coordinated three-dimensional motion, and real-time monitoring and feedback are used to adjust parameters to ensure weld quality. Simultaneously, a flexible, adaptive robotic arm (mechanical air gripper) works in conjunction with welding fixtures A and B to enable automated loading and assembly of relays (circuit breakers), instrument transformers, and terminal box units. Furthermore, the convex hulls of the intermediate relays (circuit breakers) and instrument transformers are first melted and spot welded, followed by resistance brazing of the hulls around the hulls to the ultra-thin solder tabs on the switch unit and instrument transformer copper terminals.

[0352] Specifically, the intelligent recognition adaptive grasping device and the efficient data processing and analysis subsystem output big data and artificial intelligence analysis for quality judgment realize the automatic planning of grasping path and real-time monitoring of grasping force through the collaboration of vision and force sensors.

[0353] The laser interferometer-based 3D positioning subsystem works closely with other subsystems to form the flexible manufacturing and high-precision welding system for fully automatic processing equipment for smart meters. The connection relationship and coordination method are as follows:

[0354] Integration with the multi-component automatic loading and gripping mechanism: The intelligent recognition and adaptive gripping device in the multi-component automatic loading and gripping mechanism uses visual sensors to capture component information and then plan the gripping path. A laser interferometer-based 3D positioning subsystem provides the gripping device with precise spatial position information, ensuring accurate grasping. For example, when grasping components such as switch units, transformers, and mutual inductors, the positioning subsystem can accurately determine their position in space, enabling the gripping device to grasp quickly and accurately, improving gripping efficiency and accuracy and avoiding grasping failures or inaccurate assembly due to positional deviations.

[0355] Integration with the solder feeding mechanism: The solder feeding mechanism utilizes a smooth feeding channel, high-precision photoelectric sensors, vacuum suction, and a precise pushing mechanism to facilitate solder feeding. A three-dimensional positioning subsystem based on a laser interferometer precisely monitors and adjusts the solder feeding position. Once the soldering pad is positioned, the positioning subsystem ensures it is in the precise starting position for subsequent high-precision welding. For example, submicron positioning accuracy minimizes pre-weld positioning deviation, ensuring weld quality.

[0356] Cooperation with the vibration and airflow monitoring feedback subsystem: The vibration and airflow monitoring feedback subsystem monitors the equipment's own vibration and changes in the surrounding airflow in real time by installing sensors at key locations such as the robotic arm joints and welding workbench. When an anomaly is detected that could affect positioning accuracy, the equipment's operating parameters are automatically adjusted. The three-dimensional positioning subsystem based on a laser interferometer can receive this adjustment information in real time and optimize the positioning data accordingly. For example, when vibration causes a slight shift in the equipment's position, the positioning subsystem, combined with the model predictive control algorithm, adjusts the motion trajectory in a timely manner to compensate for the position deviation caused by vibration, maintain positioning accuracy, and meet the requirements of processes such as welding sheet processing that require extremely high positioning accuracy.

[0357] Integration with Multifunctional Welding Integrated Equipment: The multifunctional welding integrated equipment intelligently selects welding methods and adjusts parameters based on the different components and welding requirements of the smart meter. A three-dimensional positioning subsystem based on a laser interferometer provides the welding equipment with precise welding position information. When welding components that are not on the same plane, such as switch units and transformers, the positioning subsystem achieves submicron positioning accuracy, helping the welding equipment accurately determine the welding starting point and welding path. This ensures that the electrode or laser beam accurately targets the welding area during the welding process, improving welding precision and reliability and avoiding welding defects caused by inaccurate positioning.

[0358] Specifically, the following supplementary instructions are provided regarding the vibration damping device:

[0359] Types and working principles of vibration damping devices

[0360] Passive vibration damping devices: Common examples include spring dampers and rubber vibration pads. Spring dampers absorb vibration energy through the elastic deformation of the spring and dissipate the energy through a damping medium (such as oil or air), thereby reducing the vibration amplitude. Rubber vibration pads utilize the elastic properties of rubber to transfer vibrations generated by the equipment to the pad, where the deformation of the rubber absorbs and buffers the vibration energy.

[0361] Active vibration damping devices: These devices typically consist of sensors, controllers, and actuators. The sensors monitor the equipment's vibration in real time and transmit the data to the controller, which analyzes and processes the data based on preset algorithms and thresholds before issuing instructions to the actuators. The actuators (such as electromagnetic actuators and piezoelectric actuators) respond to the instructions by generating a force opposite to the vibration direction, thereby offsetting or reducing the equipment's vibration.

[0362] Installation position of vibration damping device

[0363] Robotic arm joints: Because robotic arms generate significant vibration during motion, especially when moving quickly or grasping heavy objects, installing vibration-damping devices, such as small spring dampers or piezoelectric actuators, at the joints can effectively reduce vibrations caused by joint motion and improve the arm's motion accuracy and stability. For example, installing vibration-damping devices at the joints of an intelligent recognition and adaptive gripping device can prevent vibration-induced grasping position deviations, ensuring accurate grasping of parts.

[0364] Welding table: The welding table is a critical foundational component for equipment operation, and its stability directly impacts welding quality. Installing rubber damping pads or active vibration damping devices on the bottom or supporting structure of the welding table can reduce the shaking caused by vibrations generated by equipment operation. For example, when a laser welding unit is performing welding on the table, the damping device prevents table vibrations from affecting the stability of the welding electrode or laser beam, ensuring welding accuracy.

[0365] Key areas of multi-axis linkages: Multi-axis linkages generate a certain amount of vibration during coordinated three-dimensional motion. Installing vibration damping devices at key locations, such as the drive motor and transmission components, such as rubber pads on the motor base or dampers in the transmission chain, can reduce vibration transmission during motion and improve the precision and reliability of the multi-axis linkage. For example, during multi-axis welding of welding pads, vibration damping devices can ensure accurate control of the welding angle sequence and avoid welding deviations caused by vibration.

[0366] The specific process of vibration reduction by the vibration reduction device

[0367] The vibration reduction process of a passive vibration damping device: For example, when equipment vibrates, the vibration energy is transferred to the rubber pad through the equipment's support structure. The rubber pad elastically deforms under vibration, converting the vibration energy into elastic potential energy and heat within the rubber. As the rubber deforms and dissipates energy, the vibration amplitude gradually decreases, achieving the desired vibration reduction effect. A spring damper operates in a similar manner, reducing vibration intensity through the expansion and contraction of the spring and the energy dissipation of the damping medium.

[0368] The vibration reduction process of an active vibration reduction device: When a high-precision vibration sensor detects the equipment's vibration signal, it transmits the signal to a controller. The controller analyzes and processes the vibration signal, calculating parameters such as frequency, amplitude, and phase, and compares them with preset standard values. Based on the comparison results, the controller issues corresponding instructions to the actuator. For example, when the detected vibration amplitude exceeds a threshold, the controller instructs the electromagnetic actuator to generate a force opposite to the vibration direction to offset some of the vibration energy. Through continuous monitoring, analysis, and control, the active vibration reduction device can adjust the equipment's vibration status in real time to ensure stable operation.

[0369] By installing appropriate vibration reduction devices at key locations on the equipment and selecting appropriate vibration reduction methods based on the equipment's vibration characteristics, the vibration during equipment operation can be effectively reduced, improving the stability and reliability of the flexible manufacturing and high-precision welding systems of fully automatic processing equipment for smart meters.

[0370] Specifically, the module in the equipment collaborative control software includes real-time monitoring of module operation data and beat matching.

[0371] Intelligent recognition and adaptive grasping device module: It involves visual sensors to capture component information, which is used to plan the grasping path and cooperate with the three-dimensional positioning subsystem based on the laser interferometer to obtain precise spatial position information. Its operating data, including the visual image data of the components, grasping path planning data, spatial position data, etc., need to be monitored in real time to match the rhythm with other modules to ensure the accuracy and efficiency of the grasping action.

[0372] Laser interferometer-based three-dimensional positioning subsystem module: provides accurate spatial position information for each mechanism. The precise position data of components and related mechanisms in three-dimensional space collected by it needs to be monitored in real time and matched with the action rhythm of modules such as multi-component automatic loading and grasping mechanism, welding sheet loading mechanism, and multi-functional welding integrated equipment to ensure the positioning accuracy and action coordination of each link.

[0373] Multi-component automatic loading and gripping mechanism module: In addition to intelligent recognition and adaptive gripping devices, the operating data of the entire mechanism, such as the speed of component loading, the movement speed and position of the gripping device, also need to be monitored in real time and matched with other modules to achieve efficient loading and gripping operations.

[0374] Solder feeding mechanism module: High-precision photoelectric sensors collect relevant data during the solder feeding process, such as the position and quantity of the solder pieces, which need to be monitored in real time. At the same time, the feeding speed of the mechanism and the action of the pushing device must match the rhythm of other modules to ensure that the solder pieces can reach the welding position accurately and in a timely manner.

[0375] Multifunctional welding integrated equipment module: The welding parameters involved in the welding process, such as welding method, welding current, voltage, pulse frequency and other data need to be monitored in real time, and the welding action of the equipment and its coordination with other mechanisms must match the overall beat to achieve high-quality welding.

[0376] Low heat input welding and thermal deformation compensation subsystem module: High-precision temperature sensors monitor welding temperature data in real time, and related data of thermal deformation compensation need to be monitored in real time. At the same time, the coordinated action of this subsystem and the three-dimensional positioning subsystem based on laser interferometers must match the overall beat to ensure that the high-precision positioning required for welding can be maintained under thermal deformation conditions.

[0377] Vibration and airflow monitoring feedback subsystem module: Sensors installed at key locations such as the robotic arm joints and welding workbench collect data on the equipment's own vibration and changes in the surrounding airflow in real time, which requires real-time monitoring. The feedback adjustment action must match the operating rhythm of other modules to ensure positioning accuracy and stable operation of the equipment.

[0378] Comprehensive intelligent detection subsystem module: Component appearance image data collected by high-resolution industrial cameras and electrical parameter data collected by high-precision instruments for electrical parameter monitoring need to be monitored in real time. The timing and frequency of detection actions must match the rhythm of other modules to achieve timely detection and judgment of product quality.

[0379] Distributed control subsystem architecture ensures collaboration in communication collaboration

[0380] Collaboration between the multi-component automatic loading and gripping mechanism and the three-dimensional positioning subsystem based on laser interferometer: The positioning subsystem provides precise position information for the gripping device, and the two collaborate through communication to ensure accurate gripping positions.

[0381] Collaboration between the soldering sheet feeding mechanism and the three-dimensional positioning subsystem based on the laser interferometer: The positioning subsystem accurately monitors and adjusts the soldering sheet feeding position to ensure that the soldering sheet is in the precise welding starting position. The two work together through communication.

[0382] Collaboration between the vibration and airflow monitoring feedback subsystem and the laser interferometer-based three-dimensional positioning subsystem: When the monitoring feedback subsystem detects an abnormality that affects the positioning accuracy, it transmits the information to the positioning subsystem. The positioning subsystem optimizes the positioning data accordingly and achieves collaboration through communication to maintain positioning accuracy.

[0383] Collaboration between multifunctional welding integrated equipment and a three-dimensional positioning subsystem based on a laser interferometer: The positioning subsystem provides precise welding position information for the welding equipment, and the two communicate and collaborate to ensure that the electrode or laser beam can accurately act on the welding position during the welding process.

[0384] Collaboration between low heat input welding and thermal deformation compensation subsystem and laser interferometer-based three-dimensional positioning subsystem: The positioning subsystem monitors the position changes of components during thermal deformation and feeds back to the compensation subsystem, while adjusting its own positioning data to ensure high-precision welding positioning through communication collaboration.

[0385] Collaboration between the comprehensive intelligent detection subsystem and the laser interferometer-based three-dimensional positioning subsystem: The positioning subsystem provides the detection system with precise component position information, enabling the detection equipment to focus on specific parts. The two achieve collaboration through communication to improve detection efficiency and accuracy.

[0386] Key parts of the fault diagnosis subsystem based on the Internet of Things and artificial intelligence to collect operating data from key sensors

[0387] Robotic arm joints: Sensors are installed to collect vibration, angle, torque and other data during the movement of the robotic arm. These data can reflect the operating status of the robotic arm and help determine whether there are any faults in the robotic arm, such as joint wear and motor failure.

[0388] Welding workbench: Collect vibration, temperature and other data of the workbench. Vibration data can reflect the overall stability of the equipment. Temperature data is important for judging whether the welding process is normal and whether there are potential faults such as overheating.

[0389] Sensors are installed at key moving parts of the multi-component automatic loading and gripping mechanism, such as the drive motor and transmission components of the gripping device, to collect data such as the motor's current and speed, and the displacement and vibration of the transmission components. This data can be used to determine whether the gripping mechanism is working properly and whether there are any problems such as component damage or jamming.

[0390] Key components of the solder feeding mechanism: such as the drive device of the feeding channel, the installation position of the photoelectric sensor, the vacuum adsorption device, etc. Collecting data from these parts can help us understand whether the solder feeding process is smooth, and whether there are any faults such as inaccurate feeding and loose adsorption.

[0391] Welding head and related components of multifunctional welding integrated equipment: Sensors are installed on the welding head to collect data such as welding current, voltage, and temperature. Sensors are also installed on related components such as the welding power supply and cooling system to collect corresponding operating data. This is used to determine whether the welding process is stable and whether the equipment has welding defects, overheating, electrical failures, and other problems.

[0392] The key parts of the low heat input welding and thermal deformation compensation subsystem are mainly the installation locations of high-precision temperature sensors and the relevant parts of the thermal deformation compensation mechanism. Temperature data and the operating data of the compensation mechanism are collected to monitor whether the thermal deformation compensation is effective, whether the welding temperature is within a reasonable range, and whether there are faults such as excessive thermal deformation.

[0393] The sensor installation locations of the vibration and airflow monitoring feedback subsystem are: key locations such as the robotic arm joints and welding workbench. The vibration and airflow data collected by the sensors at these locations play a key role in determining whether the equipment operating environment is stable and whether there is external interference affecting the equipment accuracy.

[0394] Furthermore, there is a close composition and cooperation relationship between the multi-component automatic feeding and grasping mechanism and the intelligent recognition and adaptive grasping device, which is specifically manifested as follows:

[0395] Composition relationship: The intelligent recognition and adaptive grasping device is an important component of the multi-component automatic loading and grasping mechanism. The multi-component automatic loading and grasping mechanism includes the terminal box automatic loading unit, the switch unit automatic loading unit, the mutual inductor automatic loading unit, etc., and the intelligent recognition and adaptive grasping device is a key component used to perform the grasping operation and is installed on the manipulator or mechanical air gripper of the mechanism. The multi-component automatic loading and grasping mechanism adopts a joint modular design, which can realize the rapid replacement of various end effectors (electromagnetic adsorption, mechanical snaps). As a form of end effector, the intelligent recognition and adaptive grasping device is integrated into the multi-component automatic loading and grasping mechanism through this modular design, becoming an important part of realizing the loading and grasping functions.

[0396] Collaborative relationship: The multi-component automatic loading and grasping mechanism is responsible for the planning and coordination of the overall loading and grasping process, and the intelligent recognition and adaptive grasping device plays a specific grasping execution role. The intelligent recognition and adaptive grasping device uses vision and force sensors to work together. The vision sensor plans the grasping path after acquiring component information, and the force sensor monitors the grasping force in real time to achieve precise grasping operations. When grasping components such as switch units, transformers, and mutual inductors, the multi-component automatic loading and grasping mechanism transports the components to the appropriate position. The intelligent recognition and adaptive grasping device quickly and accurately plans the grasping path and grasps based on the information obtained by the vision sensor and the precise spatial position information provided by the three-dimensional positioning subsystem based on the laser interferometer. At the same time, the force sensor monitors the grasping force in real time to ensure that the grasping process is stable and does not cause damage to the components. The intelligent recognition and adaptive grasping device cooperates with other parts of the multi-component automatic loading and grasping mechanism (such as each automatic loading unit) to jointly achieve efficient loading and grasping operations. Its operating data (such as grasping path planning data, grasping force data, etc.) also needs to be monitored and matched in real time with the overall operating data of the multi-component automatic loading and grasping mechanism (such as parts loading speed, etc.) to ensure the coordinated operation of the entire mechanism.

[0397] Adaptive clamp subsystem: The adaptive clamp subsystem intelligently adjusts the clamping position and force. The adaptive clamp subsystem adopts a flexible material surface damage-resistant design and monitors the clamping status in real time through sensors.

[0398] Sensors in the Adaptive Gripper Subsystem

[0399] force sensor

[0400] Type: Strain gauge force sensors are commonly used. This type of sensor utilizes the strain effect of metal or semiconductor materials. When an external force acts on the sensor's elastic element, the elastic element deforms, causing the resistance of the strain gauge attached to its surface to change. The force is detected by measuring this change in resistance.

[0401] Placement: Installed where the clamp contacts the part, such as on the inside of the clamp's jaws. This allows for direct measurement of the clamping force applied by the jaws. During design, the force sensor is cleverly integrated into the jaw structure, ensuring accurate sensing of clamping force without interfering with the jaw's normal opening and closing motion.

[0402] Monitoring Implementation: When the gripper grips a component, it experiences a reaction force from the component. This force is transmitted to the force sensor, causing the resistance of the internal strain gauge to change. This resistance change is converted into a voltage signal via a Wheatstone bridge circuit. The signal conditioning circuit amplifies and filters the output voltage signal before transmitting it to the control system. The control system determines whether the current clamping force is appropriate based on the preset clamping force range. If the clamping force is too high, the control system issues a command to reduce the gripping force of the gripper; if the clamping force is too low, the control system increases the gripping force, thereby enabling intelligent adjustment and real-time monitoring of the clamping force.

[0403] Position Sensor

[0404] Type: A linear variable differential transformer (LVDT) position sensor can be used. It operates based on the principle of electromagnetic induction and consists of a primary coil and two secondary coils. When the iron core moves within the coils, the mutual inductance between the primary and secondary coils changes, resulting in an output voltage signal proportional to the iron core's position.

[0405] Placement: Installed at the gripper's movable joint to monitor the jaw's opening and closing position. For example, near the gripper's rotating axis, connect the LVDT position sensor's core to the gripper's rotating component, while securing the housing to the gripper's base. This way, when the gripper opens and closes, the core moves with the rotating component, and the LVDT detects the position change.

[0406] Monitoring Implementation: As the gripper jaws open and close, the position of the core within the LVDT changes, causing the secondary coil's output voltage to vary. The signal processing circuit demodulates and amplifies this voltage signal, generating a digital signal corresponding to the gripper jaw's position. This signal is then transmitted to the control system. Based on the gripper's target position and the currently monitored actual position, the control system adjusts the gripper jaw's movement in real time, ensuring it accurately reaches the intended gripping position, enabling precise monitoring and control of the gripping position.

[0407] Pressure distribution sensor (optional)

[0408] Type: For example, a pressure sensitive array sensor based on the piezoresistive effect. This sensor consists of an array of multiple tiny piezoresistive pressure sensitive units, each of which changes resistance when subjected to pressure.

[0409] Placement: Attached to the flexible material surface where the gripper contacts the component. A special process integrates the pressure distribution sensor with the flexible material, enabling it to accurately sense the pressure distribution on the contact surface between the gripper and the component.

[0410] Monitoring Implementation: When the gripper grips a component, pressure at different locations on the contact surface causes the resistance of the corresponding pressure-sensitive elements to change. By measuring and analyzing the resistance values of each element in the entire array, a pressure distribution image is generated. The signal processing circuit converts these resistance changes into digital signals and transmits them to the control system. Based on the pressure distribution, the control system determines whether the gripper is in uniform contact with the component. If local pressure is excessive or insufficient, the control system adjusts the gripper's gripping posture or force to ensure stable and reliable grip while avoiding damage to the component surface.

[0411] The sensors in the intelligent recognition and adaptive gripping device include:

[0412] Vision Sensors

[0413] Type: Industrial-grade CMOS cameras are typically used as visual sensors. CMOS cameras offer high resolution, high frame rate, and low power consumption, enabling them to quickly and accurately capture image information of components.

[0414] Placement: The camera is mounted on the front of the robot or gripper, ensuring that its field of view covers the area of the part to be grasped. Typically, a specific bracket is used to secure the camera to the mechanical structure, ensuring that the camera's position remains stable during robot movement and that it can clearly capture the target part. The camera's mounting angle is also carefully adjusted to achieve the optimal viewing angle for image capture.

[0415] Monitoring Implementation: The visual sensor collects image data of parts at a set frequency. The captured images are transmitted to the image processing unit via an image acquisition card. The image processing unit uses a deep learning algorithm to analyze the images and identify information such as the shape, size, position, and posture of the parts. For example, by training on a large number of known part images, the deep learning model can accurately segment the target parts from the real-time captured images and calculate their position coordinates in three-dimensional space. This information is transmitted to the control system for planning the grasping path. During the grasping process, the visual sensor continuously monitors the position changes of the parts. If the part moves, the new position information is promptly fed back to the control system to adjust the grasping path to ensure accurate grasping of the parts.

[0416] force sensor

[0417] Type: Similar to the adaptive gripper subsystem, strain gauge force sensors are commonly used. These sensors accurately measure the forces acting during the gripping process and are compact, making them easy to install within the gripping area of the robot or gripper.

[0418] Placement: Installed where the robot arm or gripper comes into direct contact with the object being grasped, such as on the gripper's fingers. The force sensor is cleverly embedded within the gripper structure, enabling real-time sensing of the gripping force without affecting the gripper's normal gripping action.

[0419] Monitoring implementation: When the mechanical air gripper grasps a component, the gripper fingers are subjected to a reaction force from the component, and the force sensor converts this force into an electrical signal. The electrical signal is amplified, filtered, and processed by the signal conditioning circuit before being transmitted to the control system. The control system determines whether the current gripping force is appropriate based on the preset gripping force range. During the gripping process, if the gripping force is too weak, the component may not be firmly grasped and may fall; if the gripping force is too strong, the component may be damaged. Based on the feedback from the force sensor, the control system adjusts the gripping force of the mechanical air gripper in real time to ensure a stable and safe gripping process, achieving real-time monitoring and precise control of the gripping force.

[0420] The intelligent recognition and adaptive grasping device mainly realizes intelligent recognition through the coordinated work of visual sensors, force sensors, and corresponding algorithms and control systems. The specific process is as follows:

[0421] Visual Information Acquisition: Intelligent recognition and adaptive grasping devices utilize visual sensors, such as industrial-grade CMOS cameras, mounted on the front end of a robotic arm or gripper to cover the area of the component being grasped. The visual sensors collect component image data at a set frequency, capturing information such as its shape, size, color, and texture. For example, when grasping components such as the switch unit and transformer of a smart meter, the visual sensors can clearly capture their appearance.

[0422] Image processing and feature extraction: The captured images are transmitted via the image acquisition card to the image processing unit, where they are analyzed and processed using deep learning algorithms. Deep learning models, trained on a large number of known component images, can segment target components from real-time images and extract key features such as edges, corners, and contours. For example, a convolutional neural network (CNN) extracts features layer by layer from images to identify the unique shape and structural characteristics of components.

[0423] Position and Posture Calculation: Based on the extracted component features, the image processing unit further calculates the component's position coordinates and posture information in three-dimensional space. By analyzing and matching multiple feature points of the component in the image, combining the camera's intrinsic and extrinsic parameters, and utilizing computer vision algorithms (such as perspective transformation and stereo vision), the component's precise position and posture are determined. For example, parameters such as the component's center coordinates and rotation angle are calculated, providing an accurate basis for subsequent grasping path planning.

[0424] Fusion with other sensor information: Force sensors monitor the forces acting during the grasping process in real time, and this information is integrated with the image information captured by the vision sensor. For example, during the grasping process, the force sensor can provide feedback on the magnitude and direction of the grasping force. Combined with the component position and posture determined by the vision sensor, this information can more accurately determine whether the grasp was successful and whether the component is stable. Furthermore, this information can be integrated with the precise spatial position information provided by the laser interferometer-based 3D positioning subsystem to further improve the accuracy of the perception of component position and posture.

[0425] Intelligent Decision-Making and Path Planning: The control system comprehensively processes information from visual sensors, force sensors, and other sensors, making intelligent decisions based on pre-set rules and algorithms. For example, based on information such as the component's position, posture, and gripping force, it determines whether the grasping conditions are met and, if so, plans the optimal grasping path. When planning the grasping path, it considers factors such as the range, speed, and acceleration of the manipulator or gripper, as well as avoiding collisions with surrounding objects, to ensure efficient, accurate, and safe grasping.

[0426] Real-time Adjustment and Feedback: During the grasping process, the intelligent recognition and adaptive grasping device continuously monitors the component's status and changes in grasping force. If it detects component movement or abnormal grasping force, the visual and force sensors promptly feed this new information back to the control system. Based on this feedback, the control system adjusts the grasping strategy in real time, such as replanning the grasping path and adjusting the grasping force, to adapt to the changing situation and ensure successful grasping of the component.

[0427] Through the collaborative work of the above links, the intelligent recognition and adaptive grasping device can realize intelligent recognition of parts and adaptively adjust the grasping action according to the recognition results, thereby improving the accuracy and reliability of grasping.

[0428] The system of this invention has achieved many remarkable effects and results in practical applications:

[0429] Production efficiency has been greatly improved

[0430] Integrated welding fixtures shorten production time by integrating multiple welding processes, such as welding switch units to terminal strips and transformers to terminal strips. This allows multiple operations to be completed in a single clamping setup. For example, in the production of smart meters, welding previously required multiple clamping steps, but can now be completed in a single clamping setup. This significantly reduces clamping time and shortens the overall production cycle.

[0431] Equipment Collaboration Optimization Process: Equipment collaborative control software monitors operating data from each module in real time, precisely matching operating speeds and beats. In smart meter processing equipment, multi-component automatic loading and gripping mechanisms, welding units, and other modules work closely together, aligning material supply with processing time. This reduces waiting times, streamlines the production process, and significantly improves overall production efficiency.

[0432] Significantly improved welding accuracy

[0433] High-precision positioning ensures connections: A laser interferometer-based 3D positioning subsystem achieves submicron positioning accuracy. Combined with a model predictive control algorithm, this system precisely determines the position and adjusts the motion trajectory when welding components with different planes, such as switch units (relays or circuit breakers) and transformers, ensuring precise connections. In the welding of smart meter components, this positioning system minimizes weld position deviations, improving processing accuracy.

[0434] Low heat input reduces deformation: The low heat input welding and thermal deformation compensation subsystem utilizes a low heat input laser welding process, coupled with high-precision temperature sensors and closed-loop control, to precisely control the welding temperature and compensate for thermal deformation. This effectively reduces the heat-affected zone (HAZ) during soldering, minimizing deformation and ensuring high standards for dimensional accuracy and electrical performance of smart meters.

[0435] Enhanced equipment adaptability and flexibility

[0436] Flexible structure adapts to diverse needs: The flexible mechanical structure utilizes a modular joint design, enabling rapid interchange of various end effectors. The adaptive gripper subsystem intelligently adjusts gripping position and force. In smart meter production, automated loading and gripping (suction) robots (pneumatic grippers) and flexible quick-change grippers are key features that enable rapid adjustment to meet diverse production needs, including terminal boxes and switch units (relays or circuit breakers) of varying specifications.

[0437] Multifunctional welding to meet diverse requirements: The multifunctional welding integrated equipment integrates multiple welding methods, intelligently selecting welding methods and adjusting parameters based on component material and shape. Flexible switching between different components of smart meters ensures high-quality welding.

[0438] Improved equipment reliability and stability

[0439] Vibration and airflow monitoring ensures stability: The vibration and airflow monitoring feedback subsystem features sensors installed in key locations on the equipment to monitor vibration and airflow changes in real time. When an anomaly is detected, it automatically adjusts operating parameters or activates vibration damping devices to ensure the stability of the automatic positioning system. This ensures stable operation in processes requiring high positioning accuracy, such as soldering, improving processing precision and product quality.

[0440] Intelligent inspection and fault diagnosis improve efficiency: A comprehensive intelligent inspection subsystem utilizes high-resolution industrial cameras and deep learning image processing for appearance inspection. High-precision instruments monitor electrical parameters. An efficient data processing and analysis subsystem collects and stores data in real time and analyzes it using big data and AI. The IoT and AI-based fault diagnosis subsystem uses sensors to collect operational data, enabling remote monitoring and fault prediction and location. These features improve equipment maintenance efficiency, reduce downtime, and enhance equipment reliability and stability.

[0441] Reduce production costs

[0442] Reduce labor costs: Through the cooperation of multiple machines with vision, force, laser interferometer and other sensors and flexible adaptive manipulators, intelligent automatic high-precision lap assembly, welding connection and post-welding performance testing are formed between terminal box units, switch units, mutual inductors, etc. Compared with manual processing in existing technologies, it greatly reduces the manual operation links and reduces labor costs.

[0443] Improve material utilization: High-precision positioning and welding technology, as well as precise processing of welding pieces, reduce material waste caused by poor welding, component damage, etc., improve material utilization and reduce material costs.

[0444] Meeting market demand

[0445] Improving product competitiveness: With the development of the power industry, the performance and quality requirements for smart meters are becoming increasingly stringent. Flexible manufacturing and high-precision welding technologies can produce smart meters with higher accuracy and more stable performance, meeting market demand for high-quality smart meters and improving the company's market competitiveness.

[0446] Quickly respond to market changes: The flexibility and adaptability of flexible manufacturing systems enable companies to quickly adjust production plans and product models, respond to market changes and customers' personalized needs in a timely manner, and win more market opportunities for companies.

[0447] Obviously, the above embodiments are merely examples for clarity of explanation and are not intended to limit the implementation methods. Those skilled in the art will readily appreciate that other variations or modifications based on the above descriptions are possible. It is not necessary and impossible to enumerate all implementation methods here. Obvious variations or modifications arising therefrom remain within the scope of protection of the present invention.

Claims

1. A flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters, characterized by: include: The integrated welding tooling is arranged in sequence around the circulation line from right to left and then from left to the starting right through the lifting cycle. The integrated welding tooling goes from right to left through the terminal box automatic loading unit, the welding piece loading and positioning unit, the laser welding unit, the opening detection unit, the welding inspection integration unit, the closing detection unit, and the comprehensive detection unit; the laser welding unit includes a welding piece loading mechanism; Multi-component automatic loading and grabbing mechanism; Vibration and airflow monitoring feedback subsystem; The intelligent recognition and adaptive gripping device uses an efficient data processing and analysis subsystem to output big data and artificial intelligence analysis for quality judgment. Through the collaboration of vision and force sensors, it realizes automatic grasping path planning and real-time monitoring of grasping force. Laser interferometer-based 3D positioning subsystem: achieves submicron positioning accuracy and adjusts motion trajectory in conjunction with model predictive control algorithms. This laser interferometer-based 3D positioning subsystem works closely with the multi-component automatic feeding and gripping mechanism, the soldering sheet feeding mechanism, the vibration and airflow monitoring and feedback subsystem, and the functional welding integrated equipment to form a flexible manufacturing and high-precision welding system for fully automatic processing equipment for smart meters. Multifunctional welding integrated equipment, integrating multiple welding methods, intelligently selecting welding methods and adjusting parameters; The low heat input welding and thermal deformation compensation subsystem uses a low heat input laser welding process and uses high-precision temperature sensors and closed-loop control to achieve protection and reduce welding interference; A comprehensive intelligent inspection subsystem uses high-resolution industrial cameras and deep learning image processing for appearance inspection, while also utilizing high-precision instruments to monitor electrical parameters in real time. An efficient data processing and analysis subsystem enables real-time data collection and storage, and uses big data and artificial intelligence analysis for quality judgment and traceability; Equipment collaborative control software, which monitors and matches module operation data in real time, includes intelligent recognition and adaptive gripping device module, laser interferometer-based 3D positioning subsystem module, multi-component automatic loading and gripping mechanism module, solder sheet loading mechanism module, multi-functional welding integrated equipment module, low heat input welding and thermal deformation compensation subsystem module, vibration and airflow monitoring and feedback subsystem module, and comprehensive intelligent detection subsystem module. Distributed control subsystem architecture ensures communication coordination; The distributed control subsystem architecture ensures the coordination of communication collaboration, including: multi-component automatic loading and gripping mechanism, welding sheet loading mechanism, vibration and airflow monitoring feedback subsystem, multi-functional welding integrated equipment, low heat input welding and thermal deformation compensation subsystem, comprehensive intelligent detection subsystem and laser interferometer-based three-dimensional positioning subsystem. The fault diagnosis subsystem based on the Internet of Things and artificial intelligence collects operating data through sensors in key locations, enabling remote monitoring and fault prediction and location. The circulation line is fixed with an integrated welding tool; the integrated welding tool is used to install and fix the terminal box unit, switch unit, and mutual inductor; The terminal box automatic loading unit is located on one side of the circulation line; The solder piece loading and positioning unit is located on one side of the circulation assembly line. The solder piece loading and positioning unit adopts a smooth feeding channel. A high-precision photoelectric sensor is set on the channel to prevent stacking and jamming of materials, as well as a vacuum adsorption and precise pushing device to form the loading of the solder piece. The solder piece cooperates with the terminal box unit; the vacuum adsorption and precise pushing device includes a high-precision pressure sensor and an intelligent control chip, which automatically adjusts the suction force according to the thickness and material characteristics of the solder piece. The vacuum adsorption and precise pushing device includes a high-precision motor and a screw transmission mechanism, which can accurately control the pushing speed and force.

2. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 1 is characterized in that: The laser welding unit is located on one side of the circulation line. It is used to weld the welding piece to the copper terminals of the switch unit and the copper terminals of the transformer. The laser welding unit uses a welding process to form welds, forming a π-shaped weld between the corresponding welding piece and the copper terminal of the switch unit; and a π-shaped weld between the corresponding welding piece and the copper terminal of the transformer. The welding process adopts a welding piece composite laser welding process, combining pulse and continuous laser, and adopting a multi-axis linkage welding process. The welding angle sequence is controlled through coordinated motion in three-dimensional space, and the parameters are adjusted in real time through real-time monitoring and feedback. The vibration and airflow monitoring feedback subsystem automatically adjusts operating parameters or activates vibration reduction devices by installing high-precision vibration sensors and airflow sensors at key locations on the equipment.

3. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 1 is characterized in that: Also includes: The switch unit is fixed with a second conductive member, and the mutual inductor is fixed with a third conductive member; the welding and inspection integrated unit welds the second conductive member to the copper terminal of the switch unit; the welding and inspection integrated unit welds the third conductive member to the copper terminal of the mutual inductor; The closing detection unit closes the switch unit for detection, including transformer communication detection, transformer current detection, switch unit opening and closing detection, and switch unit current detection; Comprehensive detection unit, which detects the terminal box unit where the switch unit and transformer are welded and fixed; The multi-component automatic loading and gripping mechanism includes a terminal box automatic loading unit, a switch unit automatic loading unit, and a transformer automatic loading unit. The multi-component automatic loading and gripping mechanism adopts a joint modular design to achieve rapid replacement of various end effectors. Adaptive clamp subsystem: The adaptive clamp subsystem intelligently adjusts the clamping position and force. The adaptive clamp subsystem adopts a flexible material surface damage-resistant design and monitors the clamping status in real time through sensors. Intelligent recognition and adaptive gripping device, used for solder sheet feeding mechanism, multi-component automatic loading and gripping mechanism's manipulator or mechanical air gripper, realizes automatic grasping path planning and real-time monitoring of grasping force through the collaboration of vision and force sensors.

4. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 1 is characterized in that: The vacuum adsorption and precise pushing device also includes an adaptive suction adjustment subsystem and a flexible adsorption surface: Adaptive suction adjustment subsystem: Equipped with a high-precision pressure sensor and intelligent control chip, the pressure sensor monitors the vacuum level in the adsorption chamber in real time. The intelligent control chip uses a pre-recorded database of the corresponding relationships between different solder sheet thicknesses, materials, and suction forces, combined with high-precision pressure sensor data, to quickly and accurately adjust the power of the vacuum pump located at the bottom or side of the vacuum adsorption and precision pushing device, or in a shock-absorbing base or box, thereby achieving automatic adjustment of the suction force. The flexible adsorption surface of the adsorption head and the gripper or finger surface is made of flexible silicone material. The surface of the adsorption surface is covered with tiny nano-scale pores. It is manufactured by 3D printing assisted method. The diameter, depth and distribution density of the pores are precisely set in the 3D model design. Multi-head collaborative working mechanism: The device is equipped with multiple independently controllable adsorption heads, each of which can independently adjust the suction force and control the working state. The working combination of different adsorption heads is controlled by rule-based algorithms, heuristic algorithms, or machine learning algorithms. When facing a large-area solder wafer array, the multi-adsorption head collaborative working mechanism simultaneously activates multiple adsorption heads for collaborative adsorption; for small-sized and scattered solder wafers, some adsorption heads are selectively enabled for separate adsorption, and the working combination of different adsorption heads is controlled by intelligent algorithms.

5. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 1 is characterized in that: The integrated welding tooling is fixed with welding fixtures. Welding fixture includes: The bottom plate is provided with a first concave cavity and a first fixing cavity, the first fixing cavity is used to fix the terminal button box unit; the bottom plate is provided with a slide groove, the slide groove is provided with a first horizontal groove and a first inclined groove, and the first horizontal groove is connected to the first inclined groove; or, the bottom plate further includes a protrusion, the protrusion is connected to the bottom plate, the protrusion is provided with a slide groove, the slide groove is provided with a first horizontal groove and a first inclined groove, and the first horizontal groove is connected to the first inclined groove; The sixth connecting plate is accommodated in the first concave cavity, and the sixth connecting plate slides relative to the first concave cavity; the sixth connecting plate is provided with a second fixed cavity, and the second fixed cavity is used to fix the switch unit; the sixth connecting plate is provided with a first protrusion, and the first protrusion is located in the sliding groove and slides; the sixth connecting plate is provided with a first opening groove and a second opening groove.

6. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 5 is characterized in that: When the first protrusion slides in the slide groove, it cooperates with the first inclined groove to form an inclined downward pressing action, so that better welding cooperation is achieved between the switch unit and the terminal box unit, and between the mutual inductor and the terminal box unit.

7. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 5 is characterized in that: The welding fixture also includes a clamping unit, a positioning frame and a return spring. The clamping unit is slidably connected to the sixth connecting plate, and the clamping unit is provided with a third fixing cavity, which is used to fix the mutual inductor; the clamping unit includes a fixed claw and a rotating claw, one end of the rotating claw rotates relative to the fixed claw, and the other end of the rotating claw cooperates with the fixed claw to form a third fixing cavity; a pressing spring is provided between the fixed claw and the rotating claw, the fixed claw is provided with an inner arc, and the rotating claw is provided with a first L-shaped step groove, a first arc, a second arc, and a third arc, and the first L-shaped step groove, the first arc, the second arc, and the third arc are connected in sequence; The positioning frame is provided with a first U-shaped groove and a first fixed column. A double-sided L-shaped first step opening groove and a second step opening groove are symmetrically provided on both sides of the forearm of the first U-shaped groove. The first step opening groove and the second step opening groove are used for positioning and supporting the third conductive member. A 7-shaped step surface is provided on the bottom surface of the positioning frame; a linear ball guide is installed between one side surface of the positioning frame and the first opening groove, and a linear ball guide is installed between the other side surface of the positioning frame and the first opening groove; the positioning frame slides relative to the sixth connecting plate, and the clamping unit is fixed to the positioning frame; the bottom plate is provided with a second fixed column, one end of the return spring cooperates with the first fixed column, and the other end of the return spring cooperates with the second fixed column; The second conductive member is connected to the copper terminal of the switch unit by welding; the third conductive member is connected to the copper terminal of the mutual inductor by welding.

8. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 7 is characterized in that: The fixed claw and rotating claw of the clamping unit cooperate with each other, and the clamping unit clamps and fixes the transformer. After welding is completed, the rotating claw can be rotated to easily remove the terminal box unit, switch unit, and transformer integrated structure for the next step of detection operation.

9. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 5, characterized in that: The floating pressure gate opening support unit is also included. The floating pressure gate opening support unit includes a T-plate, and the T-plate is provided with a T-shaped opening groove and a giving L-shaped opening; The opening and closing mechanism is accommodated in the T-shaped opening slot, and is provided with a chamber, which is open at the front and rear. The opening and closing mechanism includes a base and an eighteenth U-shaped slot plate, and the base and the eighteenth U-shaped slot plate cooperate to form a chamber, and the base is provided with a partition portion, and the partition portion is provided with a first waist-shaped hole; the base is provided with a first I-shaped slot and a second I-shaped slot, the first I-shaped slot is connected to the second I-shaped slot, and the bottom surface of the first I-shaped slot is provided with a first groove; There are two sliding tongue plates, which are accommodated in the cavity. The two sliding tongue plates are symmetrically arranged, and the front end of the sliding tongue plate extends to the outside of the front end of the cavity, and is used to cooperate with the first pin of the switch unit; the rear end of the sliding tongue plate extends to the outside of the rear end of the cavity, and the rear end of the sliding tongue plate cooperates with the driving source and the power cord; the sliding tongue plate is provided with a first positioning hole and a second lower step, and the second lower step is provided with a step portion; A sliding rod extending between the two sliding tongue plates to form a sliding pair; An elastic reset member, one end of which abuts against one of the sliding tongue plates, and the other end of which abuts against the other sliding tongue plate. The elastic reset member is located at the front end of the chamber and passes through the first waist-shaped hole. The two sliding tongue plates are respectively arranged on both sides of the partition portion. A first positioning pin, the first positioning pin passes through the first positioning hole and is linked to the sliding tongue plate, the first positioning hole is located at the rear end of the chamber, and a convex point is provided at the lower end of the first positioning pin; In the first state, the sliding tongue plate moves toward the switch unit, and the front end of the sliding tongue plate cooperates with the first pin to disconnect the switch unit; In the second state, the front end of the sliding tongue plate cooperates with the first pin to form a connection effect of the switch unit; the sliding tongue plate moves away from the switch unit; in the initial position, the protrusion cooperates with the first groove, the sliding tongue plate slides, and the step portion abuts against the first I-shaped groove.

10. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 9, characterized in that: The first positioning pin passes through the first positioning hole of the sliding tongue plate. When the front end of the sliding tongue plate cooperates with the first pin, the elastic reset member is compressed and tightened, and the rear end of the sliding tongue plate rotates around the first positioning pin. At the same time, the tension of the elastic reset member drives the front end of the sliding tongue plate to move outward, so that the sliding tongue plate and the first pin can better cooperate.

11. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 5, characterized in that: The welding fixtures include welding fixture A, welding fixture B, and welding fixture C. Welding fixture A, welding fixture B, and welding fixture C respectively form independent and integrated welding fixtures for cyclic welding fixation between the terminal box unit, the switch unit, and the transformer unit.

12. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 1, characterized in that: The system achieves intelligent, automatic, high-precision lap assembly, welding connection, and post-weld performance testing between terminal box units, switch units, mutual inductors, and welding pieces through the coordination of multiple machines, vision sensors, force sensors, vibration sensors, three-dimensional positioning, motion trajectory and algorithms of laser interferometers, as well as flexible adaptive manipulators, automatic loading and grabbing of welding pieces, and welding fixtures.

13. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 1, characterized in that: Flexible manufacturing, high-precision welding systems and fully automatic processing equipment for smart meters work together to complete welding connections and performance testing, realizing the fully automatic welding, assembly, inspection and integrated molding of hard-connected sampling components for smart single-phase, two-phase or three-phase fee-controlled meters.

14. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 3, characterized in that: The flexible, adaptive fixture subsystem uses sensors to monitor the clamping status in real time and intelligently adjust the clamping position and force. The laser interferometer-based three-dimensional positioning subsystem, combined with a model predictive control algorithm, can predict deviations in equipment movement and quickly and accurately adjust the motion trajectory of the processing equipment, ensuring precise connection and improving processing accuracy when the welding switch unit and the mutual inductor are not in the same plane. The equipment collaborative control software monitors the operating data of each module in real time and accurately matches the operating speed and beat of each module to ensure the smooth progress of the entire production process and improve overall production efficiency. The multifunctional integrated welding equipment can intelligently select welding methods and adjust parameters according to the different components and welding requirements of smart meters. The low heat input welding and thermal deformation compensation subsystem uses high-precision temperature sensors to monitor welding temperature in real time and uses closed-loop control to promptly compensate for thermal deformation caused by heat input. The comprehensive intelligent inspection subsystem utilizes high-resolution industrial cameras and deep learning image processing for appearance inspection and high-precision instruments for real-time monitoring of electrical parameters. The efficient data processing and analysis subsystem collects and stores data in real time, and uses big data and artificial intelligence analysis to determine and trace product quality. The IoT and artificial intelligence-based fault diagnosis subsystem collects operating data from sensors in key locations, enabling the remote monitoring center to predict and locate equipment faults. The vibration and airflow monitoring feedback subsystem installs high-precision vibration sensors and airflow sensors at key locations on the robotic arm joints and welding workbench to accurately monitor the equipment's own vibration and ambient airflow changes in real time. When an anomaly is detected, the system automatically adjusts the equipment's operating parameters, such as reducing the movement speed and adjusting the motor's output power. If the vibration is severe, the system activates the vibration reduction device to ensure the stability of the automatic positioning system and meet the requirements of welding sheet processing, which requires extremely high positioning accuracy. After the visual sensor in the intelligent recognition adaptive grasping device captures the shape, position and posture information of various components such as switch units, transformers and mutual inductors, the system automatically plans the optimal grasping path based on the multi-factor fusion grasping path automatic planning and grasping force collaborative control algorithm. The force sensor continuously monitors the grasping force during the grasping process. When the grasping force is abnormal, it immediately feeds back to the control system to adjust the grasping force of the robotic arm.

15. The flexible manufacturing and high-precision welding system for fully automatic processing equipment of smart meters according to claim 14, characterized in that: The high-precision welding system includes the model predictive control algorithm in the three-dimensional positioning subsystem. The prediction and calculation process of the model predictive control algorithm is as follows: Prediction Process S1. Data collection and preprocessing The laser interferometer continuously collects information about the equipment's position in three-dimensional space. Meanwhile, the vibration and airflow monitoring feedback subsystem and the low-heat-input welding and thermal deformation compensation subsystem provide relevant environmental and equipment status data, including vibration amplitude and temperature changes. The model removes noise and normalizes the data. S2. Build a prediction model Apply machine learning or statistical methods to build predictive models, using linear regression or neural network or Kalman filter algorithms; When using a neural network, the network is trained using a large amount of historical data to learn the patterns and laws of equipment movement. During the training process, the network's weights and biases are continuously adjusted to minimize the error between the predicted value and the actual value. S3. Predicting device motion deviation The pre-processed data is fed into a trained prediction model, which predicts the device's motion deviations over the next period of time based on the current state. S4. Considering uncertainty Using the Monte Carlo simulation method, multiple random samplings are used to simulate the combination of different uncertainty factors, thereby obtaining the probability distribution of equipment motion deviations, providing more comprehensive information for subsequent control decisions; Calculation process S1. Objective function setting Set an objective function to measure the difference between the predicted motion deviation and the desired motion trajectory; the objective function usually includes multiple factors such as position error and velocity error; The objective function is expressed as: , where J is the value of the objective function, is the weight of each error factor, is the value of the i-th error factor, e is one or both of the position error and velocity error; S2. Determination of Constraints Constraints include the device's maximum speed, acceleration, and positioning accuracy requirements; S3. Optimization solution Under the premise of satisfying the constraints, the optimization algorithm is used to solve the minimum value of the objective function to obtain the optimal control parameters; commonly used optimization algorithms include gradient descent method, genetic algorithm, and particle swarm algorithm; When using the gradient descent method, the control parameters are updated iteratively, so that the value of the objective function gradually decreases until the convergence condition is reached. In each iteration, the control parameters are adjusted according to the gradient direction of the objective function to approach the optimal solution as quickly as possible. S4. Control parameter update Based on the optimal control parameters obtained through optimization, the device's motion trajectory and positioning data are adjusted in real time. When position deviation is predicted, the motor drive signal is adjusted to make the device move along the corrected trajectory, thereby compensating for position deviations caused by various factors. The process of the model predictive control algorithm is as follows: S1. Data collection: The laser interferometer is simulated by calling the collect_position_data function to collect position data. This function generates an array of 3 random numbers, representing the position information in 3D space. In the main program, this function is called 10 times in a loop to obtain 10 sets of position data and store them in the position_data list. S2. Model initialization: Create an instance model of the LinearRegressionModel class, which is used to implement a simple linear regression model; in the class constructor __init__, initialize the model weights, which is an array containing 3 random numbers; S3. Train the prediction model: Extract training data from the collected location data, use the first 9 sets of data as input features X, and the last 9 sets of data as target values y; then call the model's train method to fit the linear regression model by calculating matrix operations to obtain the optimal weight parameters; S4. Predict the next position: Take the last set of position data collected as the current position current_position, call the model's predict method, and predict the next position based on the trained model and the current position data to obtain predicted_position; S5. Calculate the objective function value: define the objective function objective_function, which is used to measure the sum of squares of the error between the predicted position predicted_position and the desired position desired_position; in the main program, the objective function value cost between the predicted position and the desired position [0.5, 0.5, 0.5] is calculated by calling this function; S6. Optimization solution: Call the gradient_descent function to optimize the model; this function uses a simple gradient descent method to continuously calculate the error between the predicted value and the target value within a specified number of iterations, and then calculate the gradient, and update the model weights according to the learning rate, and finally return the optimized model optimized_model; S7. Update control parameters and output results: Use the optimized model optimized_model to predict the current position current_position again to obtain new_predicted_position; finally, output the original predicted position predicted_position and the optimized predicted position new_predicted_position to compare and observe the optimization effect.

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