Double-layer automatic measurement system and method

Abstract

The invention provides a double-layer automatic measurement system and method, and belongs to the technical field of intelligent manufacturing and detection. The system comprises a linear motion module, a Z-axis manipulator module, a double-layer feeding module, a lamination test unit and an intelligent electric control system, and multi-station parallel operation is realized through an innovative double-layer collaborative architecture. The linear motion module carries the liftable manipulator to realize accurate positioning in a three-dimensional space, and cooperates with the double-layer feeding table surface and the stacked test unit to form a three-dimensional measurement network. The system integrates the functions of code scanning recognition, self-adaptive clamping and dynamic path planning, and is combined with an AI data management system to realize high throughput of more than 1200 pieces per hour. The specially designed clamping assembly achieves + / -0.05 mm level positioning through a screw-clamping jaw linkage mechanism, and the protection system comprises a four-level safety grating and a sound-light alarm device. The technical problems that traditional detection equipment is low in space utilization rate and limited in test efficiency are effectively solved.

Description

Technical Field

[0001] The present invention relates to the field of intelligent manufacturing detection technology, and in particular to a double-layer automated measurement system and method. Background Art

[0002] In the context of Industry 4.0, the precision manufacturing sector places higher demands on the efficiency and intelligence of testing equipment. Current automated measurement systems commonly suffer from the following technical deficiencies: Low space utilization: Traditional single-layer equipment requires a large footprint, and the linear arrangement of test stations results in excessive production line lengths. For example, PCB inspection lines often exceed 15 meters, severely restricting factory space planning. Testing efficiency bottlenecks: Existing equipment often utilizes a "single robot-single tester" operating mode. Limited by the robot's speed, the actual test throughput struggles to exceed 800 parts per hour. When inspecting automotive electronic components, the robot's idle waiting time accounts for as much as 35%. Poor functional scalability: The existing system's test units are arranged in a flat layout, and adding new equipment requires replanning the production line layout. At one semiconductor company, upgrading its testing project required a production line renovation that took as long as 72 hours. Insufficient intelligence: Most systems lack real-time data analysis capabilities, making it impossible to dynamically optimize test parameters. In optical component inspection, the lack of AI compensation algorithms in traditional equipment results in a 6.2% misjudgment rate. Therefore, there is an urgent need to develop a new type of measurement system with high integration and intelligent scheduling to achieve a double breakthrough in efficiency and accuracy within a limited space. Summary of the Invention

[0003] In view of the above-mentioned technical deficiencies, the purpose of the present invention is to provide a double-layer automated measurement system and method to solve the technical problems of low space utilization and limited testing efficiency of traditional testing equipment.

[0004] To achieve the above object, the present invention adopts the following technical solutions:

[0005] A double-layer automatic measurement system, comprising:

[0006] Linear motion module, equipped with a sliding platform;

[0007] The Z-axis robot module is mounted on a sliding platform and is equipped with a barcode scanner and two gripper modules for grasping different products.

[0008] The feeding module is provided with multiple ones, which are spaced apart along the running direction of the linear motion module; the feeding module is provided with two tables; the two tables are spaced apart and fixedly connected by a bracket;

[0009] The testing machines are configured with multiple sets, which are configured as two stacked sets; the testing machines are arranged at intervals along the running direction of the linear motion module; the feeding module and the testing machines are respectively arranged on both sides of the linear motion module;

[0010] Electric control box, used to control the operation of the system.

[0011] Preferably, it also includes a protective net fence; the protective net fence is equipped with a sliding door, an AI automated measurement display, a placement port and a safety grating; the AI automated measurement display is electrically connected to the electric control box.

[0012] Preferably, the linear motion module is configured with a base, a high-load guide rail, a motion rack and a line drag chain; the high-load guide rail is installed on the base; the sliding platform is installed on the high-load guide rail, and the motion rack is used to drive the sliding platform to move on the high-load guide rail; the linear motion module is powered by the line drag chain; and an adjusting bolt is provided on the base.

[0013] Preferably, the Z-axis manipulator module includes a lifting platform, a controller, and a manipulator; the lifting platform is fixed on the sliding platform; the manipulator is installed on the lifting platform; the controller is fixed on one side of the lifting platform; and the gripper module is installed on the manipulator.

[0014] Preferably, a clamping assembly is mounted on the table of the loading module; the clamping assembly includes a clamping jaw, a screw, a hand crank handle, and a knob fixing handle; the screw is rotatably mounted on the lower portion of the table; the hand crank handle is mounted on one end of the screw; and the clamping jaw is slidably mounted on the table. The clamping jaw is provided with a screw hole that matches the screw; the knob fixing handle is rotatably mounted on the table, with one end abutting against the screw; rotating the hand crank handle drives the screw to rotate, driving the clamping jaw to move along the axis of the screw, and the parts placed on the table are abutted and fixed to the table by the clamping jaw; the position of the clamping jaw is fixed by rotating the knob fixing handle against the screw.

[0015] Preferably, it also includes an audible and visual alarm; the audible and visual alarm is electrically connected to the electric control box.

[0016] A double-layer automated measurement method comprises the following steps:

[0017] S1. The product to be tested is placed on the testing platform;

[0018] S2. Confirm the test items, start the control system of the electric control box, and the Z-axis robot module reads the product code;

[0019] S3, the Z-axis manipulator module takes the material and transports the Z-axis manipulator module to the target testing machine through the linear motion module;

[0020] S4, Z-axis robot module unloads the material, and the gripper module performs secondary positioning, clamping and adsorption;

[0021] S5. The testing machine performs measurement and the data is fed back to the electric control box;

[0022] S6. Raw and clinker materials are exchanged, and after measurement, the Z-axis robot module takes away the product.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] The unique double-layer three-dimensional layout combined with the parallel processing mechanism achieves a qualitative leap in test throughput; the intelligent dynamic scheduling algorithm effectively optimizes the operation timing of the robot and significantly reduces the equipment's idle rate; the collaborative working ability of multiple test units breaks through the physical limitations of traditional systems; the innovative vertical space development strategy significantly compresses the equipment's footprint; the modular architecture achieves a significant increase in three-dimensional space utilization; the compact design perfectly adapts to the standardized production unit layout; the test unit adopts a plug-and-play design, which greatly shortens the equipment changeover cycle; the adaptive clamping mechanism can flexibly respond to the inspection needs of workpieces of various specifications; the multi-modal recognition system is compatible with mainstream industrial identification technology; the multi-layer active protection system has passed international safety certification standards; the quality judgment system based on machine learning significantly reduces the risk of misjudgment; virtual debugging technology realizes health management of the equipment throughout its life cycle; real-time generation of visual maps of key quality indicators of the production process; innovative data storage mechanism ensures the traceability of test results; and the equipment performance analysis system provides accurate decision support. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic diagram of the present invention in use;

[0026] Figure 2 It is a structural schematic diagram of the present invention;

[0027] Figure 3 Schematic diagram of the structure of the Z-axis robot module in the present invention;

[0028] Figure 4 Schematic diagram of the structure of the feeding module in the present invention;

[0029] Figure 5 It is a structural diagram of the testing machine in the present invention;

[0030] Figure 6 It is a structural schematic diagram of the linear motion module in the present invention.

[0031] in:

[0032] 1. Testing machine; 2. Safety light curtain; 3. Placement port; 4. AI automated measurement display; 5. Sliding door; 6. Linear motion module; 7. Loading module; 9. Electric control box; 10. Z-axis robot module; 11. Lifting platform; 12. Gripper module; 13. Robot; 14. Table; 15. Bracket; 16. Line drag chain; 17. High-load guide rail; 18. Sliding platform. DETAILED DESCRIPTION

[0033] The present invention will be further described below with reference to the accompanying drawings.

[0034] like Figures 1 to 6 As shown, a double-layer automatic measurement system includes:

[0035] The linear motion module 6 is equipped with a sliding platform 18;

[0036] The Z-axis robot module 10 is mounted on a sliding platform 18 and is equipped with a barcode scanner and two gripper modules 12 for grasping different products;

[0037] The feeding module 7 is provided with multiple modules, which are spaced apart along the running direction of the linear motion module 6; the feeding module 7 is provided with two tables 14; the two tables 14 are spaced apart and fixedly connected by a bracket 15;

[0038] The testing machines 1 are configured in multiple configurations, configured as two stacked groups; the testing machines 1 are arranged at intervals along the running direction of the linear motion module 6; the feeding module 7 and the testing machines 1 are respectively arranged on both sides of the linear motion module 6;

[0039] The electric control box 9 is used to control the operation of the system.

[0040] In this embodiment, a protective net fence is also included; a sliding door 5, an AI automated measurement display 4, a placement port 3 and a safety grating 2 are configured on the protective net fence; the AI automated measurement display 4 is electrically connected to the electric control box 9.

[0041] In this embodiment, the linear motion module 6 is configured with a base, a high-load guide rail 17, a motion rack and a line drag chain 16; the high-load guide rail 17 is installed on the base; the sliding platform 18 is installed on the high-load guide rail 17, and the motion rack is used to drive the sliding platform 18 to move on the high-load guide rail 17; the linear motion module 6 is powered by the line drag chain 16; and an adjusting bolt is provided on the base.

[0042] In this embodiment, the Z-axis manipulator module 10 includes a lifting platform 11, a controller, and a manipulator 13; the lifting platform 11 is fixed on the sliding platform 18; the manipulator 13 is installed on the lifting platform 11; the controller is fixed on one side of the lifting platform 11; and the gripper module 12 is installed on the manipulator 13.

[0043] In this embodiment, a clamping assembly is mounted on the table 14 of the loading module 7. The clamping assembly includes a clamping jaw, a screw, a crank handle, and a knob-fixing handle. The screw is rotatably mounted at the bottom of the table 14; the crank handle is mounted at one end of the screw; and the clamping jaw is slidably mounted on the table 14. The clamping jaw is provided with a screw hole that matches the screw; the knob-fixing handle is rotatably mounted on the table 14, with one end abutting against the screw. Turning the crank handle rotates the screw, which in turn drives the clamping jaw to move along the axis of the screw, thereby abutting and fixing the part placed on the table 14 to the table 14 through the clamping jaw. The position of the clamping jaw is fixed by rotating the knob-fixing handle against the screw.

[0044] In this embodiment, an audible and visual alarm is also included; the audible and visual alarm is electrically connected to the electric control box 9; when a problem occurs during system operation, maintenance personnel are reminded to handle the problem through audible and visual alarms and voice, thereby reducing equipment downtime and ensuring production progress.

[0045] A double-layer automated measurement method comprises the following steps:

[0046] S1. The product to be tested is placed on the testing platform;

[0047] S2. Confirm the test items, the electric control box 9 starts the control system, and the Z-axis robot module 10 reads the product code;

[0048] S3, the Z-axis manipulator module 10 takes the material and transports the Z-axis manipulator module 10 to the target testing machine 1 through the linear motion module 6;

[0049] S4, Z-axis robot module 10 unloads the material, and the gripper module 12 performs secondary positioning, clamping and adsorption;

[0050] S5, the testing machine 1 performs measurement and the data is fed back to the electric control box 9;

[0051] S6. The raw and clinker materials are exchanged, and after the measurement is completed, the Z-axis robot module 10 takes away the product.

[0052] Example 1: Electronic component rapid detection system Technical Field

[0053] This embodiment relates to a double-layer automated measurement system for batch testing of electronic components, which is suitable for multi-dimensional inspection scenarios of precision components such as semiconductors and PCB boards. DETAILED DESCRIPTION

[0054] The system adopts a dual-station collaborative architecture:

[0055] Structural layout

[0056] The linear motion module uses a 3-meter travel high-rigidity base and is equipped with an IP67 protection grade line drag chain;

[0057] The upper test unit is equipped with 6 high-frequency signal analyzers, and the lower unit is equipped with 6 withstand voltage testers;

[0058] The loading modules are arranged symmetrically on both sides. The double-layer table of each module is equipped with an anti-static ceramic platform with a layer spacing of 300mm.

[0059] Operation process

[0060] (1) The operator places the IC chip to be tested on the lower table and drives the clamping jaws by hand crank to achieve ±0.05mm precision positioning;

[0061] (2) The Z-axis robot reads the chip QR code through a barcode scanner, and the dual pneumatic grippers simultaneously grab four chips;

[0062] (3) The sliding platform moves to test position 3 at a speed of 1.5 m / s, and the manipulator executes a spiral descent path to avoid the protective net;

[0063] (4) After the test machine completes the 10ms continuity test, the robot transfers the good products to the upper finished product table and the defective products are placed in the lower recycling bin;

[0064] (5) The system achieves a test throughput of 1,200 pcs per hour, and the utilization rate is increased to 92%;

[0065] Technical Effects

[0066] The dual-layer dynamic scheduling algorithm maximizes test resource utilization, increasing efficiency by 210% compared to traditional single-layer systems.

[0067] Example 2: Intelligent Optical Detection System Technical Field

[0068] This embodiment integrates AI visual inspection and robotic arm collaborative operation system to meet the needs of optical lens quality inspection.

[0069] The linear module is equipped with a rotation axis (±180°), and the sliding platform is integrated with an inertial navigation module;

[0070] The end of the Z-axis manipulator is equipped with a six-dimensional force sensor and a 3D vision camera;

[0071] The test unit adopts an upper and lower layer design: the upper layer is equipped with 4 white light interferometers, and the lower layer is equipped with 4 sets of laser confocal microscopes;

[0072] Intelligent detection process

[0073] (1) AI display analyzes lens surface defect characteristics in real time;

[0074] (2) The manipulator adopts a variable stiffness grasping strategy and automatically adjusts the clamping force according to the curvature of the lens (adjustable from 0.1 to 5N);

[0075] (3) Introducing digital twin technology into the testing process and implementing it through the MES system:

[0076] -Dynamic matching of test parameters (obtaining process specifications based on scanning code);

[0077] -Temperature compensation (built-in PT100 sensor to correct thermal deformation in real time);

[0078] - Adaptive path planning (avoiding surface defect areas based on point cloud data);

[0079] Technical Effects

[0080] The detection accuracy reaches 0.1μm, the defective product identification accuracy rate is 99.7%, and the changeover time is shortened to 1 / 5 of the traditional system.

Claims

1. A double-layer automatic measurement system, characterized in that: include: A linear motion module (6) is provided with a sliding platform (18); A Z-axis manipulator module (10) is mounted on a sliding platform (18) and is equipped with a barcode scanner and two gripper modules (12) for grasping different products; The feeding module (7) is provided with a plurality of modules, which are spaced apart along the running direction of the linear motion module (6); the feeding module (7) is provided with two tables (14); the two tables (14) are spaced apart and fixedly connected by a bracket (15); The testing machines (1) are configured in a plurality and are configured as two stacked groups; the testing machines (1) are arranged at intervals along the running direction of the linear motion module (6); the feeding module (7) and the testing machines (1) are respectively arranged on both sides of the linear motion module (6); The electric control box (9) is used to control the operation of the system.

2. A double-layer automatic measurement system according to claim 1, characterized in that: It also includes a protective net fence; the protective net fence is equipped with a sliding door (5), an AI automated measurement display (4), a placement port (3) and a safety grating (2); the AI automated measurement display (4) is electrically connected to the electric control box (9).

3. A double-layer automatic measurement system according to claim 1, characterized in that: The linear motion module (6) is equipped with a base, a high-load guide rail (17), a motion rack and a line drag chain (16); the high-load guide rail (17) is installed on the base; the sliding platform (18) is installed on the high-load guide rail (17), and the motion rack is used to drive the sliding platform (18) to move on the high-load guide rail (17); the linear motion module (6) is powered by the line drag chain (16); and an adjusting bolt is provided on the base.

4. A double-layer automatic measurement system according to claim 1, characterized in that: The Z-axis manipulator module (10) comprises a lifting platform (11), a controller, and a manipulator (13); the lifting platform (11) is fixed on the sliding platform (18); the manipulator (13) is installed on the lifting platform (11); the controller is fixed on one side of the lifting platform (11); and the gripper module (12) is installed on the manipulator (13).

5. The double-layer automatic measurement system according to claim 1, characterized in that: A clamping assembly is installed on the table (14) of the feeding module (7); the clamping assembly includes a clamping claw, a screw, a hand crank handle, and a knob fixed handle; the screw is rotatably installed at the lower part of the table (14); the hand crank handle is installed at one end of the screw; the clamping claw is slidably installed on the table (14). A screw hole adapted to the screw is provided on the clamping claw; the knob fixed handle is rotatably installed on the table (14), with one end abutting against the screw; rotating the hand crank handle drives the screw to rotate, driving the clamping claw to move along the axis direction of the screw, and the parts placed on the table (14) are abutted and fixed on the table (14) by the clamping claw; by rotating the knob fixed handle against the screw, the position of the clamping claw is fixed.

6. A double-layer automatic measurement system according to claim 1, characterized in that: It also includes an audible and visual alarm; the audible and visual alarm is electrically connected to the electric control box (9).

7. A double-layer automated measurement method, characterized in that: The following steps are involved: S1. The product to be tested is placed on the testing platform; S2, confirm the test items, the electric control box (9) starts the control system, and the Z-axis manipulator module (10) reads the product code; S3, the Z-axis manipulator module (10) takes the material and transports the Z-axis manipulator module (10) to the target testing machine (1) through the linear motion module (6); S4, Z-axis manipulator module (10) unloads the material, and the gripper module (12) performs secondary positioning, clamping, and adsorption; S5, the testing machine (1) performs measurement and the data is fed back to the electric control box (9); S6. The raw and clinker materials are exchanged, and after the measurement is completed, the Z-axis robot module (10) takes away the product.

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