An injection molding device for manufacturing solenoid valve coils

Abstract

The present invention provides an injection molding device for manufacturing solenoid valve coils, which relates to the technical field of electromagnetic coil injection molding, and includes: a material table, a conveyor line, a rotary distribution disk, a six-axis robot, and two injection molding machines. A conveyor line is installed above the material table, and a material tray is provided on the conveyor line. An upper material robot and a lower material robot are installed above the material table by screws. A reducer is provided above the conveyor line. The automated loading and unloading function can effectively reduce the manual labor intensity and improve the loading and unloading efficiency, reduce the waiting time of the injection molding machine, and improve the injection molding efficiency. It solves the problems in the traditional coil injection molding process that workers need to manually install the coils into the injection molds and manually disassemble the finished coils after injection molding, resulting in high manual labor intensity and low efficiency. At the same time, before coil injection molding, pins need to be assembled on the coil blanks, and the injection-molded coils need to undergo conduction tests. Separately performing multiple steps will increase the transportation cost of workpieces and reduce the coil injection molding efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of electromagnetic coil injection molding, and particularly to an injection molding device for manufacturing solenoid valve coils. Background Art

[0002] The coil injection molding of a solenoid valve is a manufacturing technique that coats a thermosetting or thermoplastic material around the outside of the coil through an injection molding process to enhance its protection, insulation, and mechanical strength. This process usually uses materials such as epoxy resin, nylon (PA), polyphenylene sulfide (PPS), or BMC unsaturated polyester. The molten plastic is injected into the mold to wrap the coil body, forming a sealing layer outside the coil, which can effectively improve protection and sealing performance, effectively prevent water and dust, and adapt to harsh environments such as high temperature and corrosion.

[0003] During the traditional coil injection molding process, it is necessary to manually install the coil into the injection mold and manually disassemble the finished coil after injection molding. The manual labor intensity is high and the efficiency is low. At the same time, before coil injection molding, it is necessary to assemble pins on the coil blank, and the injected coil needs to undergo a conduction test. Separately performing multiple steps will increase the transportation cost of workpieces and reduce the coil injection molding efficiency. Summary of the Invention

[0004] The present invention provides an injection molding device for manufacturing solenoid valve coils to solve the problems in the traditional coil injection molding process, where it is necessary to manually install the coil into the injection mold and manually disassemble the finished coil after injection molding, with high manual labor intensity and low efficiency. At the same time, before coil injection molding, it is necessary to assemble pins on the coil blank, and the injected coil needs to undergo a conduction test. Separately performing multiple steps will increase the transportation cost of workpieces and reduce the coil injection molding efficiency.

[0005] The present invention provides an injection molding device for manufacturing solenoid valve coils, specifically including: a material table, a conveyor line, a rotary distribution disk, a six-axis robot, and two injection molding machines. A conveyor line is installed above the material table, and a material tray is provided on the conveyor line. An upper loading robot and a lower loading robot are installed above the material table by screws. A speed reducer is provided above the conveyor line. The input shaft of the speed reducer is connected to the rotating shaft of the servo motor through a coupling, and the upper end of the output shaft of the speed reducer is connected to and drives the rotary distribution disk. The axis of the rotary distribution disk is perpendicular to the upper surface of the material table. Four turntable carriers are provided at the upper edge of the rotary distribution disk. An insertion and extraction mechanism and a conduction test mechanism are installed above the conveyor line through brackets. The insertion and extraction mechanism and the conduction test mechanism are respectively located above the rear quadrant point and the right quadrant point of the rotary distribution disk. The two injection molding machines are both located behind the material table, and the six-axis robot is located between the two injection molding machines.

[0006] Further, the conveyor line is a belt conveyor. The right end of the conveyor line is the blank feeding end, and the left end of the conveyor line is the finished product discharging end. A conveyor driving motor is provided at the bottom of the right end of the conveyor line, and the conveyor driving motor drives the rotating shaft at the right end of the conveyor line to rotate counterclockwise.

[0007] Further, a protective cover is provided above the material table. There are two openings at the left end and the right end of the material table protective cover respectively, and the conveyor line horizontally passes through the two openings of the protective cover.

[0008] Further, the loading robot is a four-axis robot. The loading robot is located at the rear right side of the conveyor line. A coil blank gripper is installed at the end of the loading robot, and a loading camera is installed at the end of the loading robot.

[0009] Further, the unloading robot is a four-axis robot. The unloading robot is located at the rear left side of the conveyor line. A coil finished product gripper is installed at the end of the unloading robot.

[0010] Further, the rotary distribution disk is driven by a servo motor through a reducer to rotate clockwise. There are a loading position and an unloading position on the turntable carrier.

[0011] Further, a robot gripper is installed at the end of the six-axis robot through bolts. Coil grippers, injection molded product grippers and sprue grippers are respectively arranged on the three surfaces of the robot gripper.

[0012] Further, a crusher is provided between the two injection molding machines. A sprue conveyor line is provided above the feed inlet of the crusher, and the sprue conveyor line is an inclined roller type conveyor belt.

[0013] Further, a micro push cylinder is respectively installed on the left side and the right side of the bracket of the conduction testing mechanism. The push rod of the micro push cylinder faces the center of the rotary distribution disk, and a conduction probe is provided at the end of the push rod of the micro push cylinder.

[0014] Further, a limit push cylinder is fixedly connected above the bracket of the conduction testing mechanism. The lower end of the push rod of the limit push cylinder is fixedly connected with a guide cylinder testing limit block, and a circular clamping groove is provided on the lower surface of the guide cylinder testing limit block.

[0015] The present invention provides an injection molding device for manufacturing solenoid valves, which has the following beneficial effects:

[0016] The feeding and discharging methods of the electromagnetic coil injection molding device in the present invention are convenient. Through the cooperation of the conveyor line, the tray, and two groups of four-axis robots, the tray with the blank coils is placed through the blank feeding end. As the conveyor line transports the blank coils into the interior of the material table, then the blank coils in the tray are automatically transported by the feeding robot to the feeding position for automatic feeding. At the same time, the finished coils after injection molding are taken by the discharging robot from the discharging position and placed on the tray that is conveyed to the position of the finished product discharging end for automatic discharging. The automated feeding and discharging function can effectively reduce the manual labor intensity and improve the feeding and discharging efficiency, reduce the waiting time of the injection molding machine, and improve the injection molding efficiency.

[0017] In addition, as an important part of the coil conveying link, with the clockwise rotation of the rotary distribution disk, the blank coils after feeding are transported clockwise by the turntable carrier to the position of the plugging and unplugging mechanism. The assembly of the pins in the coil blanks is completed through the plugging and unplugging mechanism. Subsequently, the turntable carrier is exchanged in position with the blank coils and the finished coils in the injection molding machine by the six-axis robot. The blank coils at the feeding position are transferred to the injection molding machine for injection molding. At the same time, the finished coils after injection molding are inserted into the discharging position. With the clockwise rotation of the rotary distribution disk, the finished coils are transported to the position below the conduction testing mechanism for conduction testing, and finally transported to the vicinity of the discharging robot for discharging. Through the setting of the rotary distribution disk, the rotary distribution disk serves as the positioning frame for the feeding, discharging, pin assembly, and conduction testing of the coils. At the same time, it can complete the precise transfer of the coils in multiple processing steps, facilitate the combination of multiple steps in the coil injection molding process, improve the utilization effect of space, and make the injection molding device more integrated.

[0018] In addition, the six-axis robot has the clamping function for blank coils, finished coils, and sprue gates. Through the six-axis robot, the transfer of the blank coils to the injection molding machine, the discharging and placing of the finished coils, and the disassembly of the injection molding sprue gates can be realized. For the treatment of the injection molding sprue gates, a crusher is also provided. The waste sprue gates can be disassembled by the six-axis robot and then transferred to the sprue gate conveyor line, and are transported through the sprue gate conveyor line into the crusher for crushing and recycling. Through the improvement of the six-axis robot, multiple functions can be integrated into one, reducing the input cost of the injection molding device. By reasonably planning the switching and cooperation of various grippers in the robot gripper, the transfer efficiency of the coils is further improved. Brief Description of the Drawings

[0019] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments will be briefly introduced below.

[0020] The accompanying drawings in the following description only relate to some embodiments of the present invention and do not limit the present invention.

[0021] In the accompanying drawings:

[0022] Figure 1A schematic diagram showing the overall structure of the present application;

[0023] Figure 2 A schematic top view structure diagram of the present application;

[0024] Figure 3 A schematic rear structure diagram of the present application;

[0025] Figure 4 A schematic structure diagram of the conveyor line of the present application;

[0026] Figure 5 Shows the present application Figure 4 of the top view structure diagram;

[0027] Figure 6 A schematic structure diagram of the rotary distribution disk of the present application;

[0028] Figure 7 A schematic structure diagram of the bottom of the rotary distribution disk of the present application;

[0029] Figure 8 A schematic structure diagram of the plugging and unplugging mechanism of the present application;

[0030] Figure 9 A schematic structure diagram of the conduction test mechanism of the present application;

[0031] Figure 10 A schematic structure diagram of the guide cylinder test limit block of the present application;

[0032] Figure 11 A schematic structure diagram of the robot gripper of the present application.

[0033] Reference numerals:

[0034] 1. Material table; 2. Conveyor line; 201. Blank feeding end; 202. Finished product discharging end; 203. Conveyor driving motor; 3. Material tray; 4. Loading robot; 401. Coil blank gripper; 402. Loading camera; 5. Unloading robot; 501. Coil finished product gripper; 6. Reducer; 7. Servo motor; 8. Rotary distribution disk; 801. Turntable carrier;802. Loading position; 803. Unloading position; 9. Plugging and unplugging mechanism; 10. Six-axis robot; 1001. Robot gripper; 1002. Coil gripper; 1003. Injection molded finished product gripper; 1004. Sprue gripper; 11. Injection molding machine; 12. Conduction test mechanism; 1201. Micro push cylinder; 1202. Conduction probe; 1203. Limit push cylinder; 1204. Guide cylinder test limit block; 13. Sprue conveyor line; 14. Crusher. Detailed implementation manners

[0035] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the following will clearly and completely describe the technical solutions of the embodiments of the present invention with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of them. All other embodiments obtained by those of ordinary skill in the art based on the described embodiments of the present invention without creative work fall within the scope of protection of the present invention.

[0036] Embodiment 1: Please refer to Figures 1 to 11 :

[0037] The present invention provides an injection molding device for manufacturing solenoid valve coils, including: a material table 1, a conveyor line 2, a rotary distribution disk 8, a six-axis robot 10, and two injection molding machines 11. A conveyor line 2 is installed above the material table 1, and a material tray 3 is provided on the conveyor line 2. Above the material table 1, a loading robot 4 and an unloading robot 5 are installed by screws. Above the conveyor line 2, a speed reducer 6 is provided. The input shaft of the speed reducer 6 is connected to the rotating shaft of a servo motor 7 through a coupling. The upper end of the output shaft of the speed reducer 6 is connected to and drives the rotary distribution disk 8. The axis of the rotary distribution disk 8 is perpendicular to the upper surface of the material table 1. Four turntable carriers 801 are provided at the upper edge of the rotary distribution disk 8. Above the conveyor line 2, a plugging and unplugging mechanism 9 and a conduction testing mechanism 12 are installed through brackets. The plugging and unplugging mechanism 9 and the conduction testing mechanism 12 are respectively located above the rear quadrant point and the right quadrant point of the rotary distribution disk 8. The two injection molding machines 11 are both located behind the material table 1, and the six-axis robot 10 is located between the two injection molding machines 11; with the cooperation of the conveyor line 2, the material tray 3 on the conveyor line 2, the loading robot 4, and the unloading robot 5, the blank coil in the material tray 3 transported into the material table 1 is transferred by the loading robot 4 to the loading position 802 for automatic loading. The finished coil after injection molding is taken by the unloading robot 5 from the unloading position 803 and placed in the material tray 3 transported to the position of the finished product discharge end 202, completing the automatic discharge of the finished coil, reducing the manual labor intensity and improving the loading and unloading efficiency.

[0038] In the embodiments of the present disclosure, the conveyor line 2 is a belt conveyor. The right end of the conveyor line 2 is the blank feed end 201, and the left end of the conveyor line 2 is the finished product discharge end 202. A conveyor drive motor 203 is provided at the bottom of the right end of the conveyor line 2, and the conveyor drive motor 203 drives the rotating shaft at the right end of the conveyor line 2 to rotate counterclockwise; by driving the conveyor line 2 to rotate counterclockwise through the conveyor drive motor 203, the material tray 3 is conveyed from right to left.

[0039] In the embodiments of the present disclosure, a protective cover is provided above the material table 1. Two openings are respectively provided at the left end and the right end of the protective cover of the material table 1. The conveyor line 2 horizontally passes through the two openings of the protective cover, reducing the dust entering the loading robot 4, the unloading robot 5, and the rotary distribution disk 8 and reducing the noise.

[0040] In the embodiment of the present disclosure, the loading robot 4 is a four-axis robot. The loading robot 4 is located on the rear right side of the conveyor line 2. A coil blank gripper 401 is installed at the end of the loading robot 4, and a loading camera 402 is installed at the end of the loading robot 4. The blank coil is clamped by the coil blank gripper 401, and the blank coil in the tray 3 at the blank feeding end 201 position is transferred to the loading position 802. During the process, visual detection and positioning are performed by the loading camera 402 to improve the grasping accuracy of the loading robot 4.

[0041] In the embodiment of the present disclosure, the unloading robot 5 is a four-axis robot. The unloading robot 5 is located on the rear left side of the conveyor line 2. A coil finished product gripper 501 is installed at the end of the unloading robot 5. The finished product coil at the unloading position 803 is removed by the unloading robot 5 and placed in the tray 3 at the finished product discharging end 202 position, realizing the automatic unloading of the finished product coil.

[0042] In the embodiment of the present disclosure, the rotary distribution disk 8 is driven by a reducer 6 and a servo motor 7 to rotate clockwise. The turntable carrier 801 is provided with a loading position 802 and an unloading position 803. When loading, the blank coil is clamped and installed in the loading position 802 by the loading robot 4. The loading position 802 serves as the installation position for the blank coil. After the six-axis robot 10 removes the finished product coil completed by injection molding in the injection molding machine 11, it is placed in the unloading position 803. The unloading position 803 serves as the installation position for the finished product coil.

[0043] In the embodiment of the present disclosure, a robot gripper 1001 is installed at the end of the six-axis robot 10 through bolts. Coil grippers 1002, injection molding finished product grippers 1003, and sprue grippers 1004 are respectively arranged on three surfaces of the robot gripper 1001. The six-axis robot 10 has the function of clamping the blank coil, the finished product coil, and the sprue. Through the six-axis robot 10, the transfer of the blank coil into the injection molding machine 11, the discharging and placement of the finished product coil, and the disassembly of the injection molding sprue can be realized. Through the improvement of the six-axis robot 10, multiple functions can be integrated into one, reducing the input cost of the injection molding device. By reasonably planning the switching and cooperation of various grippers in the robot gripper 1001, the transfer efficiency of the coil is improved.

[0044] In the embodiment of the present disclosure, a crusher 14 is provided between two injection molding machines 11. A sprue conveyor line 13 is provided above the inlet of the crusher 14. The sprue conveyor line 13 is an inclined roller conveyor belt. After the finished product coil completed by injection molding is taken out, the waste sprue is disassembled by the six-axis robot 10 and transferred to the sprue conveyor line 13, and is conveyed into the crusher 14 through the sprue conveyor line 13 for crushing, realizing the recycling of waste materials.

[0045] Embodiment 2. On the basis of Embodiment 1, a micro-push cylinder 1201 is installed on each of the left and right sides of the bracket of the conduction test mechanism 12. The push rod of the micro-push cylinder 1201 faces the center of the rotary distribution disc 8, and a conduction probe 1202 is provided at the end of the push rod of the micro-push cylinder 1201; a limit push cylinder 1203 is fixedly connected above the bracket of the conduction test mechanism 12, and a guide cylinder test limit block 1204 is fixedly connected to the lower end of the push rod of the limit push cylinder 1203. A circular card slot is provided on the lower surface of the guide cylinder test limit block 1204; the conduction test mechanism 12 is located at the upper right quadrant point position of the rotary distribution disc 8. When the finished coil is transported to the position of the conduction test mechanism 12 by rotation along with the clockwise rotation of the rotary distribution disc 8, the conduction probes 1202 on both sides are respectively located on both sides of the finished coil. The guide cylinder test limit block 1204 is pushed downward by the limit push cylinder 1203, so that the card slot below the guide cylinder test limit block 1204 is in close contact with the coil to reinforce the coil. Then, the two conduction probes 1202 are pushed towards the coil by the two micro-push cylinders 1201, so that the conduction probes 1202 on both sides are respectively in contact with the contact pins of the two columns of finished coils in the blanking position 803, and the conduction detection of the finished coil is carried out.

[0046] Working principle of this embodiment: First, place the blank coil on the tray 3, and place the tray 3 with the blank coil on the right end of the upper surface of the conveyor line 2. As the conveyor line 2 starts, the tray 3 is conveyed to the left into the loading station 1. The blank coil in the tray 3 is automatically transported by the loading robot 4 to the loading position 802 for automatic loading. The rotary distribution disk 8 rotates intermittently clockwise driven by the reducer 6 and the servo motor 7, and transports the blank coil to the position of the plug-in mechanism 9. The coil pins are assembled by the plug-in mechanism 9. Then, the blank coil after pin assembly is clamped and transported into the injection molding machine 11 by the six-axis robot 10. The blank coil is injection molded by the injection molding machine 11 so that the blank coil is coated with thermoplastic material on the outside. The blank coil after injection molding is clamped and transferred to the unloading position 803 at the rearmost end by the six-axis robot 10, and the injection molding nozzle is disassembled by the nozzle gripper 1004 and placed in the nozzle conveyor line 13, and is transferred to the inside of the crusher 14 by the nozzle conveyor line 13 for crushing and recycling. The rotary distribution disk 8 continues to rotate, and the subsequent blank finished products are grabbed by the six-axis robot 10 and sent into the injection molding machine 11 for injection molding. The finished coil after injection molding rotates clockwise with the rotary distribution disk 8 and moves to the lower part of the right conduction test mechanism 12. The guide cylinder test limit block 1204 is pushed downward by the limit push cylinder 1203, so that the card slot below the guide cylinder test limit block 1204 is in close contact with the coil to reinforce the coil. Then, the two conduction probes 1202 are pushed towards the coil by the two micro push cylinders 1201, so that the conduction probes 1202 on both sides are respectively in contact with the contact pins of the two columns of finished coils in the unloading position 803 to conduct a conduction test on the finished coil. After the conduction test is completed, the finished coil is transferred to the front end of the rotary distribution disk 8 with the rotation of the rotary distribution disk 8. The finished coil is grabbed by the unloading robot 5 and placed on the tray 3 above the left side of the conveyor line 2. As the conveyor line 2 rotates, the tray 3 with the finished coil is sent out, and the finished coil is collected manually.

[0047] In this article, the following points need to be noted:

[0048] 1. The attached drawings of the embodiments of the present disclosure only relate to the structures involved in the embodiments of the present disclosure, and other structures can refer to the general design.

[0049] 2. Without conflict, the embodiments of the present disclosure and the features in the embodiments can be combined with each other to obtain new embodiments.

[0050] The above is only the specific implementation manner of the present disclosure, but the protection scope of the present disclosure is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present disclosure can easily think of changes or substitutions, which should be covered by the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure should be subject to the protection scope of the claims.

Claims

1. An injection molding device for manufacturing a solenoid valve coil, comprising: Material platform (1), conveyor line (2), rotary distribution disk (8), six-axis robot (10), two injection molding machines (11), characterized in that a conveyor line (2) is installed above the material platform (1), a material tray (3) is provided on the conveyor line (2), a loading robot (4) and an unloading robot (5) are installed above the material platform (1) by screws, a speed reducer (6) is provided above the conveyor line (2), the input shaft of the speed reducer (6) is connected to the rotating shaft of the servo motor (7) through a coupling, the upper end of the output shaft of the speed reducer (6) is connected to and drives the rotary distribution disk (8), the axis of the rotary distribution disk (8) is perpendicular to the upper surface of the material platform (1), four turntable carriers (801) are provided at the upper edge of the rotary distribution disk (8), a plugging and unplugging mechanism (9) and a conduction testing mechanism (12) are installed above the conveyor line (2) through a bracket, the plugging and unplugging mechanism (9) and the conduction testing mechanism (12) are respectively located above the rear quadrant point and the right quadrant point of the rotary distribution disk (8), the two injection molding machines (11) are both located behind the material platform (1), and the six-axis robot (10) is located between the two injection molding machines (11); the conveyor line (2) is a belt conveyor, the right end of the conveyor line (2) is the blank feeding end (201), the left end of the conveyor line (2) is the finished product discharging end (202), a conveyor driving motor (203) is provided at the bottom of the right end of the conveyor line (2), and the conveyor driving motor (203) drives the rotating shaft at the right end of the conveyor line (2) to rotate counterclockwise; the loading robot (4) is a four-axis robot, the loading robot (4) is located at the rear right side of the conveyor line (2), a coil blank gripper (401) is installed at the end of the loading robot (4), and a loading camera (402) is installed at the end of the loading robot (4); the unloading robot (5) is a four-axis robot, the unloading robot (5) is located at the rear left side of the conveyor line (2), and a coil finished product gripper (501) is installed at the end of the unloading robot (5); a robot gripper (1001) is installed at the end of the six-axis robot (10) through bolts, and coil grippers (1002), injection molding finished product grippers (1003) and sprue grippers (1004) are respectively arranged on three surfaces of the robot gripper (1001); a micro push cylinder (1201) is installed on the left side and the right side of the bracket of the conduction testing mechanism (12) respectively, the push rod of the micro push cylinder (1201) faces the center of the rotary distribution disk (8), and a conduction probe (1202) is provided at the end of the push rod of the micro push cylinder (1201).

2. The injection molding device for manufacturing an electromagnetic valve coil according to claim 1, characterized in that A protective cover is provided above the material platform (1), and two openings are respectively provided at the left end and the right end of the protective cover of the material platform (1), and the conveyor line (2) horizontally passes through the two openings of the protective cover.

3. The injection molding device for manufacturing an electromagnetic valve coil according to claim 1, characterized in that The rotary distribution disk (8) is driven by a servo motor (7) through a speed reducer (6) to rotate clockwise. A loading position (802) and an unloading position (803) are provided on the turntable carrier (801).

4. An injection molding device for manufacturing solenoid valve coils according to claim 1, characterized in that A grinder (14) is provided between the two injection molding machines (11). Above the feed inlet of the grinder (14), a sprue conveyor line (13) is provided. The sprue conveyor line (13) is an inclined roller conveyor belt.

5. An injection molding device for manufacturing solenoid valve coils according to claim 1, characterized in that A limit push cylinder (1203) is fixedly connected above the bracket of the conduction test mechanism (12). The lower end of the push rod of the limit push cylinder (1203) is fixedly connected with a guide tube test limit block (1204). A circular clamping groove is provided on the lower surface of the guide tube test limit block (1204).

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