An assembly test production line for a plurality of small products

Abstract

The application belongs to the technical field of product assembly detection, and discloses an assembly test production line for various small products, which comprises a first workbench, a second workbench, a third workbench and a fourth workbench, a shuttle module assembly and a manual operation unit are arranged between adjacent workbenches, the middle part of each workbench is provided with a six-axis manipulator with an upper vision, the free end of the six-axis manipulator is provided with a combined suction tool, a lower vision, an NG belt line and a quick-change disc support frame are further arranged on each workbench, and various modules for assembly and detection are arranged around the six-axis manipulator of each workbench. The assembly test production line has the advantages of small floor space, high integration, high assembly production efficiency, low labor intensity, good applicability, the ability of assembly detection for different types of small products, and lower manufacturing cost compared with the original multiple production lines.

Description

Technical Field

[0001] This invention belongs to the field of product assembly and testing technology, specifically relating to an assembly and testing production line for various small products. Background Technology

[0002] Various small products (such as terminal stations, second-generation electronic control modules, charging boxes, battery back covers, and new and old remote controls) require separate production lines for production. Each production line occupies a considerable area, and the various processes in the manufacturing process (such as material loading, assembly, testing, and unloading) require a large amount of manpower for repetitive labor.

[0003] Currently, in the production, assembly, and testing of small products, different production lines are used for different processes. During each process, manual labor is required to load materials onto each corresponding production line, perform the corresponding tasks, and then unload them to complete the process. This reliance on manual intervention and repetitive loading and unloading processes significantly reduces the efficiency of production, assembly, and testing.

[0004] Therefore, there is an urgent need for a small-scale product assembly and testing production line that is compact, highly integrated, efficient in assembly and production, and requires minimal manual labor. The assembly and testing production line of this invention has good applicability, capable of assembling and testing different types of small products, and has lower manufacturing costs compared to existing multi-line production lines. Summary of the Invention

[0005] In view of this, the purpose of this invention is to provide an assembly and testing production line for a variety of small products. This invention aims to solve the problems of existing technologies that require multiple different production lines for producing various small products, resulting in large floor space, high manufacturing costs, and low assembly and testing efficiency.

[0006] To achieve the above objectives, the present invention provides an assembly and testing production line for various small products, including a first workbench, a second workbench, a third workbench, and a fourth workbench. A shuttle module assembly is provided between each pair of adjacent workbench, and a manual operation unit is provided below each shuttle module assembly. A six-axis robot arm with an upper vision is provided in the middle of the first, second, third, and fourth workbench. A combination suction cup is provided at the free end of the six-axis robot arm. The combination suction cup is detachably connected to the six-axis robot arm through a quick-change plate. A lower vision, an NG conveyor belt, and a quick-change plate support frame are provided on the first, second, third, and fourth workbench. The quick-change plate support frame is used to place different types of combination suction cups.

[0007] The first workbench is equipped with a first loading and unloading machine, a battery cover vibratory feeder, a marking module, a roll feeder, and a flipping module around a six-axis robot arm. The battery cover vibratory feeder is equipped with a battery cover positioning fixture at its discharge end. The roll feeder is used to provide plastic labels. The marking module is used to mark product information on the product or the plastic label.

[0008] The second workbench is equipped with a second loading and unloading machine, a material bin buffer platform, a double screwdriver bit locking module, a screw arranging machine, a hexagonal stud vibrating plate, and an insulating paper feeding module around the six-axis robot arm. The screw arranging machine is used for screw loading, and the hexagonal stud vibrating plate is used for hexagonal stud vibration loading.

[0009] The third workbench is equipped with a third loading and unloading machine, a three-head locking and attaching module, an end-station top cover screw feeder, a second-generation electronic control module top cover screw feeder, a new remote control top cover screw feeder, a new remote control PCB screw feeder, an adhesive application module, a semi-finished product loading and unloading station, and a reserved welding station, all surrounding the six-axis robot arm. The adhesive application module is used to apply adhesive to the assembly surface of the end-station top cover, and the semi-finished product loading and unloading station is used to place the glued semi-finished end-station. The third workbench is also equipped with a flipping module.

[0010] The fourth workbench is equipped with a fourth loading / unloading machine, a second-generation electronic control module testing module, a charging box testing module, an end-point station testing module, and a shielding testing module, all mounted around the six-axis robotic arm. The fourth workbench also has a semi-finished product loading / unloading station. The end-point station testing module can perform power-on and button tests on finished and semi-finished end-point stations. The shielding testing module can perform power-on and button tests on new and old remote controls, as well as the second-generation electronic control module.

[0011] Furthermore, the shuttle module assembly includes a travel beam, on which a sliding frame is slidably connected. The travel beam is equipped with a motor that drives the sliding frame to move horizontally along the travel beam, and a carrier is fixedly connected to the upper end of the sliding frame.

[0012] Furthermore, the manual operation unit includes a manual operation workbench, an information display screen, and specialized workpieces placed on the manual operation workbench.

[0013] Furthermore, the marking module includes a lifting cylinder, a protective cover, and a first guide rail mounted on a first workbench. The free end of the lifting cylinder is fixedly connected to a marking machine that extends into the protective cover. The first guide rail is located directly below the protective cover, and a first carrier plate is slidably connected to the first guide rail. Several positioning plates of different specifications are provided on the upper end of the first carrier plate. The positioning plates are used to place the parts of the corresponding products. The marking head of the marking machine is directly facing the positioning plates. The first guide rail is equipped with a first linear motor, which is used to drive the first carrier plate to move horizontally along the first guide rail.

[0014] Furthermore, the flipping module includes a support frame, one end of which is equipped with a rotary cylinder. The output end of the rotary cylinder is fixedly connected to a sliding limit plate. Both ends of the slide rail of the sliding limit plate are equipped with first sliders. The other end of the support frame is rotatably connected to a pneumatic slide table. Both ends of the slide rail of the pneumatic slide table are slidably connected to second sliders. A U-shaped clamp is fixedly connected between the opposing second sliders and the first sliders. The pneumatic slide table is equipped with a cylinder, which is used to drive the two second sliders on the pneumatic slide table to move closer or further apart.

[0015] Furthermore, the dual-head locking module includes a support beam and a second guide rail mounted on a second workbench. A vertical plate is slidably connected to the support beam, and two telescopic cylinders are mounted on the outer side of the vertical plate. An electric screwdriver is mounted on the free end of each telescopic cylinder. The support beam is equipped with a second linear motor, which drives the vertical plate to move horizontally along the support beam. The second guide rail is located directly below the support beam and is perpendicular to the support beam. A second carrier plate is slidably connected to the second guide rail, and multiple positioning plates of different specifications are also provided on the upper end of the second carrier plate. The second guide rail is equipped with a motor that drives the second carrier plate to move horizontally along the second guide rail.

[0016] Furthermore, the insulating paper feeding module includes an insulating paper feeder and a standard baffle pager set on the second workbench. The standard baffle pager is used to page the insulating paper supplied by the insulating paper feeder. A bracket is provided on one side of the standard baffle pager, and a height adjustment cylinder is provided on the upper end of the bracket. An insulating paper suction cup is fixedly connected to the free end of the height adjustment cylinder, and the insulating paper suction cup is located directly above the second guide rail.

[0017] Furthermore, the three-head locking module includes a U-shaped frame, on which a mounting base is slidably connected. The U-shaped frame is equipped with a linear motor that drives the mounting base to move horizontally along the U-shaped frame. Two electric screwdrivers are arranged on the left side of the mounting base, and one electric screwdriver is arranged on the right side of the mounting base. The electric screwdrivers on both sides of the mounting base are adjusted for height by a pneumatic slide table. A third guide rail is provided below the U-shaped frame. The third guide rail is perpendicular to the U-shaped frame. A third carrier plate is slidably connected to the third guide rail. The upper part of the third carrier plate is also provided with multiple positioning plates of different specifications. The third guide rail is equipped with a motor that drives the third carrier plate to move horizontally along the third guide rail.

[0018] Furthermore, the adhesive application module includes a stand, with a sliding seat slidably connected to the upper end of the stand. The stand is equipped with a linear motor that drives the sliding seat to move horizontally along the stand. A linear guide rail is provided on the outer side of the sliding seat. An adhesive applicator is slidably connected to the linear guide rail. The linear guide rail is equipped with a linear motor that drives the adhesive applicator to move up and down along the linear guide rail. A fourth guide rail is provided below the stand, and the fourth guide rail is perpendicular to the stand. A fourth carrier plate is slidably connected to the fourth guide rail. A positioning plate for placing the end station is provided at the upper end of the fourth carrier plate. The fourth guide rail is equipped with a motor that drives the fourth carrier plate to move horizontally along the fourth guide rail.

[0019] Furthermore, the positioning plate, the flipping module, and the NG conveyor belt are all equipped with positioning sensors.

[0020] Beneficial effects:

[0021] This invention provides an assembly and testing production line for various small products, featuring a small footprint, high integration, high assembly efficiency, and low labor intensity. The assembly and testing production line of this invention has good applicability, capable of assembling and testing different types of small products, and has lower manufacturing costs compared to traditional multiple production lines.

[0022] Other advantages, objectives, and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination, or may be learned from practice of the invention. The objectives and other advantages of the invention can be realized and obtained through the following description. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the assembly and testing production line for various small products according to the present invention;

[0024] Figure 2 This is the first view of the first workbench;

[0025] Figure 3 This is a second view of the first workbench;

[0026] Figure 4 This is a schematic diagram of the structure of the first guide rail and the first carrier plate;

[0027] Figure 5 This is a schematic diagram of the flip module structure;

[0028] Figure 6 This is the first view of the second workbench;

[0029] Figure 7 This is the second view of the second workbench;

[0030] Figure 8 A schematic diagram of the structure of the double-head locking module;

[0031] Figure 9 A schematic diagram of the insulating paper feeding module;

[0032] Figure 10 First view of the third workbench;

[0033] Figure 11 This is the second view of the third workbench;

[0034] Figure 12 A schematic diagram of the structure of the three-phase head lock module;

[0035] Figure 13 This is a schematic diagram of the adhesive application module.

[0036] Figure 14 This is the first view of the fourth workbench;

[0037] Figure 15 This is the second view of the fourth workbench;

[0038] The attached diagrams are labeled as follows: 1. First workbench; 2. Second workbench; 3. Third workbench; 4. Fourth workbench; 4. Six-axis robot; 5. NG belt conveyor; 6. First loading / unloading machine; 7. Battery cover vibratory feeder; 8. Marking module; 9. Roll feeder; 10. Tilting module; 11. Battery cover positioning fixture; 12. Second loading / unloading machine; 13. Material bin buffer; 14. Double screwdriver bit locking module; 15. Screw arranging machine; 16. Hexagonal stud vibratory feeder; 17. Insulating paper feeding module; 18. Third loading / unloading machine; 19. Three screwdriver bit locking module; 20. Glue application module; 21. Semi-finished product loading / unloading station; 22. Welding. 23. Receiving station; 24. Fourth loading / unloading machine; 25. Second-generation electronic control module test module; 26. Charging box test module; 27. End station test module; 28. Shielding test module; 29. ​​Shuttle module assembly; 30. Stroke beam; 31. Protective cover; 32. First guide rail; 33. First carrier plate; 34. Positioning plate; 35. Clamping plate; 36. Second guide rail; 37. Second carrier plate; 38. Insulating paper feeder; 39. Standard baffle pager; 40. Bracket; 41. Height adjustment cylinder; 42. Insulating paper suction cup; 43. Third guide rail; 44. Third carrier plate; 45. Stand; 46. Fourth guide rail; 47. Fourth carrier plate. Detailed Implementation

[0039] To make the technical solutions, advantages, and objectives of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the described embodiments of the present invention without creative effort are within the protection scope of this application.

[0040] like Figures 1-15 As shown, this invention provides an assembly and testing production line for various small products, including a first workbench 1, a second workbench 2, a third workbench 3, and a fourth workbench 4. A shuttle module assembly 29 is provided between each pair of adjacent workbench. A manned work unit is located below each shuttle module assembly 29. A six-axis robot arm 5 with an upward vision is installed in the middle of each of the first, second, third, and fourth workbench 4. A combined suction device is installed at the free end of the six-axis robot arm 5, and the combined suction device is detachably connected to the six-axis robot arm 5 via a quick-change tray. This embodiment uses four different types of combined suction devices, which are used to grip the end station, remote control, second-generation electronic control template, and charging box, respectively. A downward vision device, an NG conveyor belt 6, and a quick-change tray support frame are installed on each of the first, second, third, and fourth workbench 4. The quick-change tray support frame is used to hold the different types of combined suction devices.

[0041] The first workbench 1 is equipped with a six-axis robot arm 5 around its center, consisting of a first loading / unloading machine 7, a battery cover vibratory feeder 8, a marking module 9, a roll feeder 10, and a flipping module 11. The battery cover vibratory feeder 8 has a battery cover positioning fixture 12 at its discharge end. The roll feeder 10 provides plastic labels, and the marking module 9 marks product information on the product or the plastic label. In this embodiment, there are two first loading / unloading machines 7 and three sets of roll feeders 10.

[0042] The second workbench 2 is equipped with a second loading / unloading machine 13, a material bin buffer platform 14, a double-tip fastening module 15, a screw arranging machine 16, a hexagonal stud vibratory feeder 17, and an insulating paper feeding module 18, all mounted around a six-axis robotic arm 5 at its center. The screw arranging machine 16 is used to feed PCB screws to the end of the feeder, and the hexagonal stud vibratory feeder 17 is used to feed the external hexagonal studs of the second-generation electronic control module PCB. In this embodiment, there are two second loading / unloading machines 13 and two sets of material bin buffer platforms 14.

[0043] The third workbench 3 is equipped with a six-axis robotic arm 5 around its center, which includes a third loading / unloading machine 19, a three-head locking module 20, an end-station top cover screw feeder, a second-generation electronic control module top cover screw feeder, a new remote control top cover screw feeder, a new remote control PCB screw feeder, a gluing module 21, a semi-finished product loading / unloading station 22, and a reserved welding station 23. The gluing module 21 is used to apply glue to the assembly surface of the end-station top cover, and the semi-finished product loading / unloading station 22 is used to place the glued semi-finished end-station. The third workbench 3 is also equipped with a flipping module 11. In this embodiment, there are two third loading / unloading machines 19 and three sets of semi-finished product loading / unloading stations 22.

[0044] The fourth workbench 4 is equipped with a fourth loading / unloading machine 24, a second-generation electronic control module testing module 25, a charging box testing module 26, an end-point station testing module 27, and a shielding testing module 28, all mounted around a six-axis robotic arm 5 at its center. The fourth workbench 4 also has semi-finished product loading / unloading stations 22. The end-point station testing module 27 can perform power-on and button tests on finished and semi-finished product end-point stations. The shielding testing module 28 can perform power-on and button tests on new and old remote controls and the second-generation electronic control module. In this embodiment, there is one fourth loading / unloading machine, and three sets of semi-finished product loading / unloading stations 22 are provided.

[0045] As a preferred embodiment, the shuttle module assembly 29 includes a travel beam 30, a sliding frame is slidably connected to the travel beam 30, the travel beam 30 is equipped with a motor that drives the sliding frame to move horizontally along the travel beam 30, and a carrier is fixedly connected to the upper end of the sliding frame.

[0046] As a preferred embodiment, each work unit has two workbenches, two sets of information display screens, and specialized workpieces placed on the manual workbenches.

[0047] As a preferred embodiment, the marking module 9 includes a lifting cylinder, a protective cover 31, and a first guide rail 32 disposed on the first worktable 1. The free end of the lifting cylinder is fixedly connected to a marking machine (including fiber optic marking and ultraviolet marking) that extends into the protective cover 31. The first guide rail 32 is located directly below the protective cover 31. A first carrier plate 33 is slidably connected to the first guide rail 32. Several positioning plates 34 of different specifications are fixedly connected to the upper end of the first carrier plate 33. Each positioning plate 34 is used to place the parts of the corresponding product. The marking head of the marking machine is directly facing the positioning plate 34. The first guide rail 32 is equipped with a first linear motor, which is used to drive the first carrier plate 33 to move horizontally along the first guide rail 32.

[0048] As a preferred embodiment, the flipping module 11 includes a support frame, a rotary cylinder is installed at the left end of the support frame, a sliding limit plate is fixedly connected to the output end of the rotary cylinder, and a first slider is slidably connected to both ends of the slide rail of the sliding limit plate. A pneumatic slide is rotatably connected to the right end of the support frame, and a second slider is slidably connected to both ends of the slide rail of the pneumatic slide. A U-shaped clamping plate 35 is fixedly connected between the opposing second slider and the first slider. The pneumatic slide is equipped with a cylinder, which is used to drive the two second sliders on the pneumatic slide to move closer or further apart.

[0049] As a preferred embodiment, the dual-head locking module 15 includes a support beam and a second guide rail 36 mounted on the second workbench 2. A vertical plate is slidably connected to the support beam, and two telescopic cylinders are mounted on the outer side of the vertical plate. An electric screwdriver is mounted on the free end of each of the two telescopic cylinders. The support beam is equipped with a second linear motor, which drives the vertical plate to move horizontally along the support beam. The second guide rail 36 is located directly below the support beam and is perpendicular to the support beam. A second carrier plate 37 is slidably connected to the second guide rail 36. The upper end of the second carrier plate 37 is also provided with multiple positioning plates 34 of different specifications. The second guide rail 36 is equipped with a motor that drives the second carrier plate 37 to move horizontally along the second guide rail 36.

[0050] As a preferred embodiment, the insulating paper feeding module 18 includes an insulating paper feeder 38 and a standard baffle pager 39 disposed on the second workbench 2. The standard baffle pager 39 is used to page the insulating paper supplied by the insulating paper feeder 38. A bracket 40 fixedly connected to the second workbench 2 is disposed on one side of the standard baffle pager 39. A height adjustment cylinder 41 is installed at the upper end of the bracket 40. An insulating paper suction cup 42 is fixedly connected to the free end of the height adjustment cylinder 41. The insulating paper suction cup 42 is located directly above the second guide rail 36.

[0051] As a preferred embodiment, the three-head locking module 20 includes a U-shaped frame with a slidably connected bracket on it. The U-shaped frame is equipped with a linear motor that drives the bracket to move horizontally along the U-shaped frame. Two electric screwdrivers are installed on the left side of the bracket, and one electric screwdriver is installed on the right side. The electric screwdrivers on both sides of the bracket are raised and lowered by a pneumatic slide. A third guide rail 43 is fixedly connected to the third workbench 3 below the U-shaped frame. The third guide rail 43 is perpendicular to the U-shaped frame. A third carrier plate 44 is slidably connected to the third guide rail 43. The upper end of the third carrier plate 44 is also equipped with multiple positioning plates 34 of different specifications. The third guide rail 43 is equipped with a motor that drives the third carrier plate 44 to move horizontally along the third guide rail 43.

[0052] In a preferred embodiment, the glue application module 21 includes a stand 45, with a sliding seat slidably connected to the upper end of the stand 45. The stand 45 is equipped with a linear motor that drives the sliding seat to move horizontally along the stand 45. A linear guide rail is provided on the outer side of the sliding seat, and a glue injector is slidably connected to the linear guide rail. The linear guide rail is equipped with a linear motor that drives the glue injector to move up and down along the linear guide rail. A fourth guide rail 46 is provided below the stand 45 and is fixedly connected to the third workbench 3. The fourth guide rail 46 is perpendicular to the stand 45. A fourth carrier plate 47 is slidably connected to the fourth guide rail 46. A positioning plate 34 for placing the end station is provided at the upper end of the fourth carrier plate 47. The fourth guide rail 46 is equipped with a motor that drives the fourth carrier plate 47 to move horizontally along the fourth guide rail 46.

[0053] As a preferred embodiment, the positioning plate 34, the flipping module 11, and the NG belt 6 are all equipped with positioning sensors.

[0054] The process steps for assembling and testing the end station using the production line of this invention are as follows:

[0055] First workbench 1:

[0056] The end station bottom shell is fed simultaneously by two first loading and unloading machines 7 (with the marking surface of the end station bottom shell facing upwards). A six-axis robot 5 with a combined suction device grabs the end station bottom shell from the material box of the first loading and unloading machine 7 and places the end station bottom shell on the positioning plate 34 of the first carrier plate 33 corresponding to the end station bottom shell. Then, under the action of the first linear motor, it moves along the first guide rail 32 to the bottom of the marking machine, thereby marking the product information onto the end station bottom shell. The product with OK marking is grabbed by the six-axis robot 5 and placed in the flipping module 11. The end station bottom shell that has completed flipping is placed on the carrier of the shuttle module assembly 29 by the six-axis robot 5 and flows to the next station. The product with NG marking is grabbed by the robot and placed on the NG belt line 6.

[0057] Manual operation unit 1:

[0058] The bottom shell of the end station passes directly through the station and flows to the second workbench 2;

[0059] Second workbench 2:

[0060] The six-axis robot 5 places the bottom shell of the end station of the shuttle module component 29 onto the positioning plate 34 corresponding to the double-head locking module 15. Then, the two second loading and unloading machines 13 simultaneously load the inner PCB of the end station (if the quantity of materials in a single box is sufficient, only one second loading and unloading machine 13 can be used). After that, the six-axis robot 5 takes the PCB from the material box of the second loading and unloading machine 13 and puts it into the bottom shell of the end station. After the inner PCB of the end station is placed, the double-head locking module 15 automatically locks the PCB screws. Products that are locked and OK are transported by the six-axis robot 5 to the carrier of the shuttle module component 29 and flow to the next station. Products that are locked and NG are picked up by the six-axis robot 5 and placed on the NG conveyor belt 6.

[0061] Manual operation unit 2:

[0062] The product is manually taken from the carrier of the shuttle module component 29, manually assembled into the end station air plug, and the assembled product is placed back onto the carrier of the shuttle module component 29 and flows to the next station.

[0063] Third workbench 3:

[0064] Before dispensing: The product passes directly through the station;

[0065] After the semi-finished product tests are passed: the AGV places the semi-finished product end station (which has passed the fourth workbench 4) into the glue-filling carrier at the semi-finished product loading / unloading station 22. A six-axis robot 5 then picks up the semi-finished product from the glue-filling carrier at the semi-finished product loading / unloading station 22 and places it onto the end station positioning plate 34 of the glue-applying module 21. The glue-applying module 21 automatically glues the top cover assembly surface of the end station and visually inspects the glue application effect. Products that pass the glue application are transported by the six-axis robot 5 to the corresponding positioning plate 34 of the third-batch locking module 20. Products that fail the glue application are transported by the six-axis robot... 5. The material is transported to the NG conveyor belt 6. Two third loading and unloading machines 19 can simultaneously load the top cover of the end station (if the quantity of material in a single box is sufficient, only one third loading and unloading machine 19 can be used). Then, the six-axis robot 5 takes the top cover from the third loading and unloading machine 19 and installs it on the semi-finished product after gluing. After that, the third batch head locking mold automatically locks the top cover screws. The locked OK products are transported by the six-axis robot 5 to the carrier of the shuttle module assembly 29 and flow to the next station. The locked NG products are picked up by the six-axis robot 5 and placed on the NG conveyor belt 6.

[0066] Manual operation unit 3:

[0067] The products pass directly through the station and flow to the fourth workbench 4;

[0068] Fourth workbench 4:

[0069] Before glue dispensing: The six-axis robot 5 picks up the product from the carrier of the shuttle module component 29 and places it in the semi-finished product testing station of the end station test module 27 for semi-finished product testing. The product that passes the test is picked up by the six-axis robot 5 and placed in the glue dispensing carrier of the semi-finished product loading and unloading station 22. Then, the tested semi-finished products placed in the glue dispensing carrier are transferred to the third workbench 3 by AGV. The product that fails the test is picked up by the six-axis robot 5 and placed in the NG belt line 6.

[0070] After gluing:

[0071] The six-axis robot 5 picks up the products from the shuttle module component 29 and places them on the end station test module 27 for finished product testing. Products that pass the test are transported by the six-axis robot 5 to the material box carrier of the fourth loading and unloading machine for tray unloading. Products that fail the test are picked up by the six-axis robot 5 and placed on the NG conveyor belt 6.

[0072] The process steps for assembling and testing the second-generation electronic control module using the production line of this invention are as follows:

[0073] First workbench 1:

[0074] The second-generation electronic control module top cover (with the marking side facing up) is simultaneously fed by two first loading and unloading machines 7. The six-axis robot 5 grabs the top cover from the material box of the first loading and unloading machine 7 and places it on the positioning plate 34 corresponding to the marking module 9. The marking module 9 marks the product information onto the top cover. Then, the visual inspection on the six-axis robot 5 is used to check the marking effect. Products with OK marking are grabbed by the six-axis robot 5 and placed on the carrier of the shuttle module component 29 and flow to the next station; products with NG marking are grabbed by the six-axis robot 5 and placed on the NG conveyor belt 6.

[0075] Manual operation unit 1:

[0076] The top cover of the second-generation electronic control module passes directly through the station and flows to the second workbench 2;

[0077] Second workbench 2:

[0078] The second-generation electronic control module bottom shell and the first layer PCB of the second-generation electronic control module are respectively loaded by two second loading and unloading machines 13. The bottom shell is picked up from the second loading and unloading machine 13 by a six-axis robot 5 and placed on the corresponding positioning plate 34 of the double screwdriver locking module 15. The insulating paper is automatically loaded into the bottom shell by the insulating paper feeding module 18. Then, the first layer PCB is picked up from the second loading and unloading machine 13 by the six-axis robot 5 and loaded into the bottom shell. After that, the double screwdriver locking module 15 is started to automatically lock the PCB screws. The bottom shell and PCB that are locked are picked up by the six-axis robot 5 and placed on the carrier of the shuttle module assembly 29 and flow to the next station. The bottom shell and PCB that are locked are picked up by the six-axis robot 5 and placed on the NG belt line 6.

[0079] The top cover of the product flows to the second workbench 2, is picked up by the six-axis robot arm 5 and placed on the carrier of the shuttle module assembly 29, and then flows to the third workbench 3.

[0080] Manual operation unit 2:

[0081] The assembled bottom shell and PCB are manually taken from the carrier of the shuttle module component 29, the two-layer PCB is manually assembled, the flexible flat cable is plugged in, and after the assembly is completed, the product is placed back on the carrier of the shuttle module component 29 and flows to the third workbench 3.

[0082] Third workbench 3:

[0083] A six-axis robot arm 5 picks up the bottom shell assembly (assembled bottom shell and PCB) from the carrier of the shuttle module assembly 29 and places it on the corresponding positioning plate 34 of the three-head locking module 20. Then, the six-axis robot arm 5 picks up the top cover of the product from the carrier of the shuttle module assembly 29 and inserts it into the bottom shell assembly (the bottom shell assembly is first received by the shuttle module assembly 29, and then the top cover is sent to this station from the marking module 9 via the material call). After the top cover is stably placed on the bottom shell assembly, the three-head locking module 20 is started to automatically lock the top cover screws. Products that are successfully locked are transported by the six-axis robot arm 5 to the carrier of the shuttle module assembly 29 and flow to the next station. Products that are not successfully locked are picked up by the six-axis robot arm 5 and placed on the NG conveyor belt 6.

[0084] Manual operation unit 3:

[0085] Products pass through the station directly;

[0086] Fourth workbench 4:

[0087] The six-axis robot 5 picks up the products from the shuttle module component 29 and places them in the second-generation electronic control module test module 25 for finished product testing. Products that pass the test are transported by the six-axis robot 5 to the material box carrier of the fourth loading and unloading machine for tray unloading. Products that fail the test are picked up by the six-axis robot 5 and placed on the NG belt line 6.

[0088] The assembly and testing process for the new remote control using the production line of this invention is as follows:

[0089] First workbench 1:

[0090] The new remote control base shell is simultaneously fed by two first loading and unloading machines 7 (with the marking side facing up). The six-axis robot 5 picks up the base shell from the material bin of the first loading and unloading machine 7 and places it on the corresponding positioning plate 34 of the marking module 9. Then, the six-axis robot 5 picks up the plastic label from the roll feeder 10 and affixes it to the product base shell. After the plastic label is affixed, the marking module 9 is started to mark the product information onto the plastic label. Then, the visual inspection on the six-axis robot 5 is used to check the marking effect. Products with OK marking are picked up by the six-axis robot 5 and placed on the carrier of the shuttle module component 29 to flow to the next station; products with NG marking are picked up by the six-axis robot 5 and placed on the NG conveyor belt 6.

[0091] Manual operation unit 1:

[0092] The new remote control has a directly interchangeable bottom shell;

[0093] Second workbench 2:

[0094] The new remote control has a directly interchangeable bottom shell;

[0095] Manual operation unit 2:

[0096] Manually retrieve products from the carrier of shuttle module component 29, manually assemble the bottom shell PCB component, battery, plug-in flexible flat cable, etc., and place the assembled products back into the carrier of shuttle module component 29 (back side up) and flow to the next station.

[0097] Third workbench 3:

[0098] The new remote control cover assembly is automatically fed by two third loading and unloading machines 19. The cover assembly is picked up from the material box of the first loading and unloading machine 7 by a six-axis robot 5 and placed into the corresponding positioning plate 34 of the three-head locking module 20. The bottom shell assembly is picked up from the carrier of the shuttle module assembly 29 by the six-axis robot 5 and placed on the flipping module 11 to be flipped 180°. After the flipping is completed, the bottom shell assembly and the cover assembly are assembled by the six-axis robot 5. After assembly, the three-head locking module 20 is started to automatically lock the cover screws. The products that are locked OK are transported by the six-axis robot 5 to the flipping module 11 to be flipped 180°. After the flipping is completed, they are transported to the carrier of the shuttle module assembly 29 and flow to the next station. The products that are locked NG are picked up by the six-axis robot 5 and placed on the NG belt line 6.

[0099] Manual operation unit 3:

[0100] Products pass through the station directly;

[0101] Fourth workbench 4:

[0102] The six-axis robot 5 picks up the products from the shuttle module assembly 29 and places them at the new remote control test station of the shielded test module 28 for finished product testing; the products that pass the test are transported by the six-axis robot 5 to the material box carrier of the third loading and unloading machine 19 for tray unloading; the products that fail the test are picked up by the six-axis robot 5 and placed on the NG belt line 6.

[0103] The assembly and testing process for older remote controls on the production line of this invention is as follows:

[0104] First workbench 1:

[0105] The old remote control bottom shells (with the marking side facing up) are simultaneously fed by two first loading / unloading machines 7. The six-axis robot 5 picks up the bottom shells from the material bins of the first loading / unloading machines 7 and places them on the corresponding positioning plate 34 of the marking module 9. Then, the six-axis robot 5 picks up plastic labels from the roll feeder 10 and affixes them to the product bottom shells. After the plastic labels are affixed, the marking module 9 is started to mark the product information onto the plastic labels. Then, the visual inspection on the six-axis robot 5 is used to check the marking effect. Products with OK marking are picked up by the six-axis robot 5 and placed on the carrier of the shuttle module component 29 to flow to the next station; products with NG marking are picked up by the six-axis robot 5 and placed on the NG conveyor belt 6.

[0106] Manual operation unit 1:

[0107] Offline production mode: The bottom shell of the remote control is directly transferred to the production line;

[0108] Online production mode: The workers manually pick up the products from the shuttle module assembly 29 and assemble them. After assembly, the products are placed in the shuttle module assembly 29 to flow to the next station.

[0109] Second workbench 2:

[0110] Offline production mode: The robotic arm picks up the bottom shell of the product from the shuttle module component 29 and places it into the material box of the second loading and unloading machine 13 for tray unloading;

[0111] Online production mode: Products pass through stations;

[0112] Manual operation unit 2:

[0113] Offline production mode: Products pass through stations;

[0114] Online production mode: Manually pick up products from shuttle module component 29 for assembly, and after assembly, place them on the carrier of shuttle module component 29 and flow to the next station;

[0115] Third workbench 3:

[0116] Offline production mode: The old remote control finished products are automatically fed by two third feeding machines. The six-axis robot arm 5 grabs the products from the material box of the third feeding machine 19 and places them on the carrier of the shuttle module carrier component, and flows to the next station.

[0117] Online production mode: Products pass through stations;

[0118] Manual operation unit 3:

[0119] Offline production mode: Products pass through stations;

[0120] Online production mode: Manually pick up products from shuttle module component 29 for assembly, and after assembly, place them on the carrier of shuttle module component 29 and flow to the next station;

[0121] Fourth workbench 4:

[0122] The six-axis robot 5 picks up the products from the shuttle module component 29 and places them at the old remote control test station of the shielded test module 28 for finished product testing. Products that pass the test are transported by the six-axis robot 5 to the material box carrier of the fourth loading and unloading machine for tray unloading. Products that fail the test are picked up by the six-axis robot 5 and placed on the NG conveyor belt 6.

[0123] The assembly and testing process for the charging box on the production line of this invention is as follows:

[0124] First workbench 1:

[0125] The charging box bottom shell is simultaneously fed by two first loading and unloading machines 7 (with the marking side facing up). The six-axis robot 5 picks up the bottom shell from the material bin of the first loading and unloading machine 7 and places it on the corresponding positioning plate 34 of the marking module 9. Then, the six-axis robot 5 picks up the plastic label from the roll feeder 10 and affixes it to the bottom shell of the product. After the plastic label is affixed, the marking module 9 is started to mark the product information onto the plastic label. Then, the visual inspection on the six-axis robot 5 is used to check the marking effect. Products with OK marking are picked up by the six-axis robot 5 and placed on the carrier of the shuttle module component 29 and flow to the next station; products with NG marking are picked up by the six-axis robot 5 and placed on the NG conveyor belt 6.

[0126] Manual operation unit 1:

[0127] Offline production mode: Products pass through stations;

[0128] Online production mode: Manually pick up materials from shuttle module component 29 to assemble products. After assembly, the products are placed on the carrier of shuttle module component 29 and flow to the next station.

[0129] Second workbench 2:

[0130] Offline production mode: The six-axis robot arm 5 picks up the bottom shell of the product from the shuttle module component 29 and places it into the material box of the second loading and unloading machine 13 for tray unloading;

[0131] Online production mode: Products pass through stations;

[0132] Manual operation unit 2:

[0133] Offline production mode: Products pass through stations;

[0134] Online production mode: Manually pick up materials from shuttle module component 29 to assemble products. After assembly, the products are placed on the carrier of shuttle module component 29 and flow to the next station.

[0135] Third workbench 3:

[0136] Offline production mode: The finished charging boxes are automatically fed by two third feeding machines. The six-axis robot arm 5 grabs the products from the material box of the third feeding machine 19 and places them on the carrier of the shuttle module carrier component, so that they can flow to the next station.

[0137] Online production mode: Products pass through stations;

[0138] Manual operation unit 3:

[0139] Offline production mode: Products pass through stations;

[0140] Online production mode: Manually pick up products from shuttle module component 29 for assembly, and after assembly, place them on the carrier of shuttle module component 29 and flow to the next station;

[0141] Fourth workbench 4:

[0142] The six-axis robot 5 picks up the products from the shuttle module component 29 and places them at the charging box testing station of the charging box testing module 26 for finished product testing. Products that pass the test are transported by the six-axis robot 5 to the material box carrier of the fourth loading and unloading machine for tray unloading. Products that fail the test are picked up by the six-axis robot 5 and placed on the NG conveyor belt 6.

[0143] The assembly and testing process for the battery back cover on the production line of this invention is as follows:

[0144] First workbench 1:

[0145] Battery back covers are fed through a vibratory feeder 8. A six-axis robot 5 picks up the battery back covers from the receiving platform of the vibratory feeder 8 and places them into a positioning fixture. Then, the six-axis robot 5 picks up plastic labels from the feeder 10 and attaches them to the battery back covers. After the plastic labels are attached, the six-axis robot 5 visually inspects the attachment effect. Products that are successfully attached are picked up by the six-axis robot 5 and placed into the material bin of the first unloading machine 7. After unloading, manual assembly is performed. Products that are not successfully attached are picked up by the six-axis robot 5 and placed on the NG conveyor belt 6.

[0146] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the protection scope of the present invention.

Claims

1. An assembly and testing production line for various small products, characterized in that: The system includes a first workbench (1), a second workbench (2), a third workbench (3), and a fourth workbench (4). A shuttle module assembly (29) is provided between each two adjacent workbench. A manual operation unit is provided below each shuttle module assembly (29). A six-axis robot arm (5) with an upper vision is provided in the middle of each of the first workbench (1), the second workbench (2), the third workbench (3), and the fourth workbench (4). A combined suction device is provided at the free end of the six-axis robot arm (5). The combined suction device is detachably connected to the six-axis robot arm through a quick-change plate. A lower vision, an NG belt line (6), and a quick-change plate support frame are provided on each of the first workbench (1), the second workbench (2), the third workbench (3), and the fourth workbench (4). The quick-change plate support frame is used to place different types of combined suction devices. The first workbench (1) is equipped with a first loading and unloading machine (7), a battery cover vibratory feeder (8), a marking module (9), a roll feeder (10), and a flipping module (11) around the six-axis robot arm (5). The battery cover vibratory feeder (8) is provided with a battery cover positioning fixture (12) at its discharge end. The roll feeder (10) is used to provide plastic labels. The marking module (9) is used to mark product information on the product or plastic label. The second workbench (2) is equipped with a second loading and unloading machine (13), a material box buffer platform (14), a double bit locking module (15), a screw arranging machine (16), a hexagonal stud vibrating plate (17), and an insulating paper feeding module (18) around the six-axis robot (5). The screw arranging machine (16) is used for screw loading, and the hexagonal stud vibrating plate (17) is used for hexagonal stud vibration loading. The third workbench (3) is equipped with a third loading and unloading machine (19), a three-head locking and attaching module (20), an end station top cover screw feeder, a second-generation electronic control module top cover screw feeder, a new remote control top cover screw feeder, a new remote control PCB screw feeder, a glue application module (21), a semi-finished product loading and unloading station (22), and a reserved welding station (23) around the six-axis robot arm (5). The glue application module (21) is used to apply glue to the assembly surface of the end station top cover. The semi-finished product loading and unloading station (22) is used to place the semi-finished end station after glue application. The third workbench (3) is also equipped with a flipping module. The fourth workbench (4) is equipped with a fourth loading / unloading machine (24), a second-generation electronic control module test module (25), a charging box test module (26), an end station test module (27), and a shielding test module (28) around the six-axis robot arm (5). The fourth workbench (4) is also equipped with a semi-finished product loading / unloading station. The end station test module (27) can perform power-on tests and button tests on finished and semi-finished end stations. The shielding test module (28) can perform power-on tests and button tests on new remote controls, old remote controls, and second-generation electronic control modules.

2. The assembly and testing production line for various small products according to claim 1, characterized in that: The shuttle module assembly (29) includes a travel beam (30), a sliding frame is slidably connected to the travel beam (30), the travel beam (30) is equipped with a motor that drives the sliding frame to move horizontally along the travel beam (30), and a carrier is fixedly connected to the upper end of the sliding frame.

3. The assembly and testing production line for various small products according to claim 2, characterized in that: The manual operation unit includes a manual operation workbench, an information display screen, and specialized workpieces placed on the manual operation workbench.

4. The assembly and testing production line for various small products according to claim 3, characterized in that: The marking module (9) includes a lifting cylinder, a protective cover (31) and a first guide rail (32) set on the first workbench (1). The free end of the lifting cylinder is fixedly connected to a marking machine that extends into the protective cover (31). The first guide rail (32) is located directly below the protective cover (31). A first carrier plate (33) is slidably connected on the first guide rail (32). The upper end of the first carrier plate (33) is provided with several positioning plates (34) of different specifications. The positioning plates (34) are used to place the parts of the corresponding products. The marking head of the marking machine is directly facing the positioning plate (34). The first guide rail (32) is equipped with a first linear motor. The first linear motor is used to drive the first carrier plate (33) to move horizontally along the first guide rail (32).

5. The assembly and testing production line for various small products according to claim 4, characterized in that: The flipping module (11) includes a support frame. One end of the support frame is provided with a rotary cylinder. The output end of the rotary cylinder is fixedly connected to a sliding limit plate. Both ends of the slide rail of the sliding limit plate are provided with first sliders. The other end of the support frame is rotatably connected to a pneumatic slide table. Both ends of the slide rail of the pneumatic slide table are slidably connected with second sliders. The oppositely arranged second sliders and the first sliders are fixedly connected with a U-shaped clamp (35). The pneumatic slide table is equipped with a cylinder. The cylinder is used to drive the two second sliders on the pneumatic slide table to move closer or further apart.

6. The assembly and testing production line for various small products according to claim 5, characterized in that: The dual-head locking module (15) includes a support beam and a second guide rail (36) set on the second workbench (2). A vertical plate is slidably connected to the support beam. Two telescopic cylinders are installed on the outside of the vertical plate. Electric screwdrivers are installed on the free ends of the telescopic cylinders. The support beam is equipped with a second linear motor. The second linear motor is used to drive the vertical plate to move horizontally along the support beam. The second guide rail (36) is located directly below the support beam. The second guide rail (36) is perpendicular to the support beam. A second carrier plate (37) is slidably connected to the second guide rail (36). The upper end of the second carrier plate (37) is also equipped with multiple positioning plates (34) of different specifications. The second guide rail (36) is equipped with a motor that drives the second carrier plate (37) to move horizontally along the second guide rail (36).

7. The assembly and testing production line for various small products according to claim 6, characterized in that: The insulating paper feeding module (18) includes an insulating paper feeder (38) and a standard baffle pager (39) set on the second workbench. The standard baffle pager (39) is used to page the insulating paper provided by the insulating paper feeder (38). A bracket (40) is provided on one side of the standard baffle pager (39). A height adjustment cylinder (41) is provided at the upper end of the bracket (40). An insulating paper suction cup (42) is fixedly connected to the free end of the height adjustment cylinder (41). The insulating paper suction cup (42) is located directly above the second guide rail (36).

8. The assembly and testing production line for various small products according to claim 7, characterized in that: The three-head locking module (20) includes a U-shaped frame, on which a card holder is slidably connected. The U-shaped frame is equipped with a linear motor that drives the card holder to move horizontally along the U-shaped frame. Two electric screwdrivers are provided on the left side of the card holder, and one electric screwdriver is provided on the right side of the card holder. The electric screwdrivers on both sides of the card holder are adjusted by a pneumatic slide table. A third guide rail (43) is provided below the U-shaped frame. The third guide rail (43) is perpendicular to the U-shaped frame. A third carrier plate (44) is slidably connected on the third guide rail (43). The upper end of the third carrier plate (44) is also provided with multiple positioning plates (34) of different specifications. The third guide rail (43) is equipped with a motor that drives the third carrier plate (44) to move horizontally along the third guide rail (43).

9. The assembly and testing production line for various small products according to claim 8, characterized in that: The adhesive application module (21) includes a stand (45), a sliding seat is slidably connected to the upper end of the stand (45), the stand (45) is equipped with a linear motor that drives the sliding seat to move horizontally along the stand (45), a linear guide rail is provided on the outer side of the sliding seat, an adhesive injector is slidably connected on the linear guide rail, the linear guide rail is equipped with a linear motor that drives the adhesive injector to move up and down along the linear guide rail, a fourth guide rail (46) is provided below the stand (45), the fourth guide rail (46) is perpendicular to the stand (45), a fourth carrier plate (47) is slidably connected on the fourth guide rail (46), a positioning plate (34) for placing the end station is provided on the upper end of the fourth carrier plate (47), and the fourth guide rail (46) is equipped with a motor that drives the fourth carrier plate (47) to move horizontally along the fourth guide rail (46).

10. The assembly and testing production line for various small products according to claim 9, characterized in that: The positioning plate (34), the flipping module (11), and the NG belt (6) are all equipped with positioning sensors.

Images