A false solder void detection system

Abstract

The application discloses a kind of virtual welding cavity detection systems, comprising: pushing unit, detection unit and discharge unit;Wherein, pushing unit is used to push material or stop pushing material to detection unit;Detection unit is used to receive material and collect the image of material, and according to image analysis whether material is qualified, and for conveying qualified material to discharge unit;Discharge unit is used to adjust the distance relative to material and output material.The virtual welding cavity detection system, by unit modular design, whether material can accurately detect whether there is virtual welding cavity, by mechanical automation and the combination of optical detection, realizes the quick, accurate, full-automatic sorting of LED welding quality, with efficiency, precision and reliability, suitable for large-scale electronic manufacturing scene.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of testing, and particularly relates to a virtual welding cavity detection system. BACKGROUND

[0002] In the LED manufacturing process, the welding quality such as virtual welding and cavity directly affects the reliability and performance of the product. The traditional detection method mainly relies on manual visual inspection or simple mechanical testing, which has the following problems: manual detection is low in efficiency, for example, it is easy to be affected by subjective factors and has a high rate of missed detection, depending on the experience of operators; manual detection is slow and difficult to match the high rhythm demand of the automatic production line; mechanical contact detection has limitations, for example, some devices detect by physical probe contact, which may damage the LED or PCB board and cannot identify small welding defects such as virtual welding and solder crack; in addition, the traditional optical detection has deficiencies, for example, the early automatic optical detection (AOI) system relies on fixed light source and simple algorithm, and has poor adaptability to reflection, shadow or complex solder joints; it lacks cooperative control with the feeding and unloading mechanism, and the detection and sorting processes are disconnected; the degree of automation is low, and manual intervention is required in the aspects of pushing and sorting, which affects the overall production efficiency and makes it difficult to realize data interaction with the intelligent manufacturing system. SUMMARY

[0003] To solve the above problems, the primary purpose of the present application is to provide a virtual welding cavity detection system to solve the technical problem that the current virtual welding cavity detection system cannot accurately detect whether the material such as LED has virtual welding cavity.

[0004] To achieve the above purpose, the technical scheme of the present application is as follows:

[0005] The present application provides a virtual welding cavity detection system, comprising:

[0006] a pushing unit, a detection unit and a discharging unit; wherein,

[0007] the pushing unit is used for pushing the material to the detection unit or stopping pushing the material;

[0008] the detection unit is used for receiving the material and collecting the image of the material, and is used for analyzing whether the material is qualified according to the image, and is used for conveying the qualified material to the discharging unit;

[0009] the discharging unit is used for adjusting the distance relative to the material and outputting the material; wherein,

[0010] the pushing unit comprises:

[0011] a shell;

[0012] A pushing mechanism is arranged in the shell and includes a pushing member and a sensor. The pushing member is slidingly connected to the shell. The sensor is connected to or disconnected from the pushing member. When the pushing member pushes the material towards the detection unit, the sensor is disconnected from the pushing member. When the pushing member stops pushing the material, the sensor is connected to the pushing member.

[0013] A first elastic member is arranged between the outer circumferential surface of the pushing member and the shell to automatically reset the pushing member; and / or,

[0014] A connecting rod penetrates the pushing member and extends to the outer circumferential surface of the pushing member. The shell is provided with a clearance groove on both sides. The two ends of the connecting rod are slidingly arranged in the clearance grooves, respectively; and,

[0015] A folding mechanism includes a first rotating member arranged on one side of the shell, a second rotating member arranged on the side of the first rotating member away from the shell and rotatingly connected to the first rotating member, a clamping portion arranged on the first rotating member, and a positioning member arranged on the second rotating member and detachably connected to the clamping portion.

[0016] Further, the pushing unit further includes a guide mechanism arranged on one side of the shell, which includes:

[0017] A guide frame is recessed from the upper surface of the guide frame towards the interior of the guide frame to sequentially form a first groove and a second groove. The shell is arranged in the first groove.

[0018] A guide support wheel is rotatingly arranged in the second groove to support the shell slidingly fitted in the first groove.

[0019] Further, the pushing unit further includes:

[0020] A support frame is oppositely arranged between the shell and the first rotating member.

[0021] A first driving mechanism is connected to the shell to drive the shell to move the pushing mechanism to push the material.

[0022] The folding mechanism, the guide mechanism, and the first driving mechanism are arranged in the support frame.

[0023] Further, the discharging unit includes:

[0024] A pushing arm;

[0025] A pushing plate is connected to the pushing arm and encloses a clearance groove.

[0026] The pushing block is arranged on one side of the pushing plate facing the pushing arm, is arranged in the avoiding groove, and is hinged to the pushing plate to adjust the distance of the stop block relative to the material.

[0027] Through the cooperative design of the pushing arm, the pushing plate and the pushing block, the distance relative to the material can be adjusted, the pushing position of the material can be flexibly controlled, the movable arrangement of the pushing block enables the stop block to adapt to materials of different sizes or positions, the adjustability of the distance of the stop block is realized, the universality of the discharging is improved, and the avoiding groove avoids structural interference. The combined design of the avoiding groove and the pushing block solves the problem of inconvenient adjustment of the traditional fixed stop block.

[0028] The pushing block is hinged to the pushing plate, so that the pushing block can be rotated to adjust the position of the stop block, the operation is simple and the structure is stable, and the pushing block is suitable for scenes requiring frequent adjustment and reduces mechanical wear. Thus, the hinged design enables the pushing block to be rotatable to adjust the position of the stop block, and the operation is simple; the stop block rotates between the pushing plate and the avoiding groove to avoid structural interference.

[0029] Further, the pushing block comprises a first matching block and a second matching block connected to each other, the first matching block is movably arranged in the avoiding groove, and the stop block is arranged at one end of the first matching block away from the second matching block.

[0030] When the first matching block is in contact with the pushing plate, the stop block protrudes from the end of the pushing block away from the avoiding groove.

[0031] The first matching block is used to realize the material blocking function, and the second matching block is used to provide support, so as to enhance the structural reliability and adjustability; the stop block is arranged at one end of the first matching block away from the second matching block, and the stop block rotates with the pushing block in the avoiding groove, so as to expand the adjustment range of the discharging unit. By protruding from the end of the pushing plate away from the avoiding groove, the stop block can effectively block the material when blocking the material, so as to avoid material leakage or position deviation and improve the discharging accuracy.

[0032] Further, the discharging unit further comprises:

[0033] A magnetic attraction structure is arranged at one end of the second matching block away from the stop block, and the magnetic attraction structure is used for magnetic attraction with the pushing plate; wherein,

[0034] When the magnetic attraction structure is magnetically attracted to the pushing plate, the end of the stop block away from the second matching block is located between the pushing plate and the avoiding groove.

[0035] The pusher plate engages with either the first mating block or the second mating block to achieve bidirectional limiting, ensuring balanced force distribution during pusher block movement. The second mating block's engagement with the pusher plate enhances stability and prevents wobbling. A magnetic structure secures the pusher block during material blocking, preventing displacement due to vibration or impact, and eliminates the need for additional locking components, simplifying operation. When not in use, the stop block is retracted between the pusher plate and the clearance groove, preventing interference with materials or equipment, saving space, and preventing damage from accidental collisions.

[0036] Furthermore, the detection unit is an automatic optical detection unit, used to analyze whether the material has poor solder joints and / or voids. If poor solder joints and / or voids are present, the material is deemed unqualified; otherwise, the material is deemed qualified.

[0037] Furthermore, the frame is provided with a material box and a second drive mechanism; the material box is used to place materials in layers at intervals; the second drive mechanism is connected to the material box and is used to drive the material box to move relative to the frame.

[0038] Furthermore, the discharge unit also includes a third drive mechanism for moving the pusher arm.

[0039] Furthermore, the first mating block and the second mating block form a first included angle, the first included angle being in the range of 90° to 180°.

[0040] Compared with existing technologies, the beneficial effects of this application are as follows: The weld void detection system includes a feeding unit, a detection unit, and a discharging unit. The feeding unit is used to feed material to the detection unit or stop feeding material. The detection unit is used to collect images of the material, analyze whether the material is qualified based on the images, and transport qualified material to the discharging unit. The discharging unit is used to adjust the distance relative to the material and output the material. This weld void detection system feeds material to the detection unit or stops feeding material to the detection unit, collects and acquires images of the material to analyze whether the material is qualified based on the images, and transports qualified material to the discharging unit. The discharging unit adjusts the distance relative to the qualified material to improve the versatility of the discharging process. This weld void detection system, through modular design, solves the problems of difficult automated control of feeding and easy jamming during discharging in traditional weld void detection systems, making it particularly suitable for automated processing scenarios involving multiple specifications of materials. Therefore, this solder joint void detection system significantly improves reliability and material handling efficiency in automated production lines through its modular, adaptive, and low-interference design. It is especially suitable for testing scenarios that require high-precision sorting or positioning, such as for electronic component testing. Attached Figure Description

[0041] Figure 1It is the whole structure schematic diagram of a virtual welding cavity detection system.

[0042] Figure 2 It is Figure 1 The partial enlarged schematic diagram of the pushing unit.

[0043] Figure 3 It is the local structure schematic diagram of a virtual welding cavity detection system.

[0044] Figure 4 It is Figure 3 The partial enlarged schematic diagram of the detection unit.

[0045] Figure 5 It is the three-dimensional schematic diagram of the pushing unit of a virtual welding cavity detection system.

[0046] Figure 6 It is Figure 5 The partial enlarged schematic diagram of the folding mechanism.

[0047] Figure 7 It is Figure 5 The partial enlarged schematic diagram of the pushing mechanism.

[0048] Figure 8 It is Figure 5 The partial enlarged schematic diagram of the first driving mechanism.

[0049] Figure 9 It is Figure 5 The structure schematic diagram of the pushing mechanism of the pushing unit after removing the shell.

[0050] Figure 10 It is Figure 9 The partial enlarged schematic diagram of the first driving mechanism.

[0051] Figure 11 It is Figure 9 The partial enlarged schematic diagram of the folding mechanism.

[0052] Figure 12 It is Figure 9 The partial enlarged schematic diagram of the pushing mechanism.

[0053] Figure 13 It is the assembly schematic diagram of the pushing mechanism and the guide mechanism of the pushing unit.

[0054] Figure 14 It is the structure schematic diagram of the folding mechanism of the pushing unit from another perspective.

[0055] Figure 15 It is Figure 14 The partial enlarged schematic diagram of the folding mechanism.

[0056] Figure 16is a structural schematic view of the discharging unit.

[0057] Figure 17 is a partial structural schematic view of the discharging unit.

[0058] In the figure: 1, virtual welding cavity detection system; 2, pushing unit; 3, bearing plate; 10, shell; 101, first avoiding groove; 21, pushing piece; 22, inductor; 23, first elastic piece; 24, connecting rod; 30, folding mechanism; 31, first rotating piece; 32, second rotating piece; 33, clamping part; 34, positioning piece; 35, support frame; 341, pin structure piece; 342, second elastic piece; 40, guide mechanism; 41, guide support wheel; 411, first groove; 412, second groove; 42, guide support wheel; 50, rack; 51, second driving mechanism; 52, material box; 60, first driving mechanism; 61, first cylinder; 62, first lead screw; 63, first sliding block; 70, pushing arm; 701, second avoiding groove; 71, first surface; 72, second surface; 80, pushing plate; 81, first plate body; 82, second plate body; 90, pushing block; 91, stop block; 92, first matching block; 93, second matching block; 94, magnetic attraction structure; 95, second cylinder; 96, second lead screw; 97, second sliding block; 100, detection unit. DETAILED DESCRIPTION

[0059] In order to make the purpose, technical scheme and advantages of the present application more clear, the present application is further described in detail below in combination with the drawings and examples. It should be understood that the specific examples described herein are only used to explain the present application, and are not used to limit the present application.

[0060] In order to achieve the above-mentioned purpose, the technical scheme of the present application is as follows:

[0061] Referring to Figures 1-17 As shown in the figure, the present application provides a virtual welding cavity detection system 1, which comprises a pushing unit 2, a detection unit 100 and a discharging unit; wherein the pushing unit 2 is used to push or stop pushing material to the detection unit 100; the detection unit 100 is used to receive material and collect images of the material, and is used to analyze whether the material is qualified according to the images, and is used to transport qualified material to the discharging unit; the discharging unit is used to adjust the distance relative to the material and output the material.

[0062] The pushing unit 2, the detection unit 100 and the discharging unit of the virtual welding cavity detection system 1, the pushing unit 2 is used for pushing or stopping pushing the material to the detection unit 100, the detection unit 100 is used for collecting the material and collecting the image of the material, so as to analyze whether the material is qualified according to the image, and is used for conveying the qualified material to the discharging unit, and adjusting the distance of the qualified material through the discharging unit to improve the universality of discharging. The material detected by the virtual welding cavity detection system 1 is preferably LED, and the modular design of the unit solves the problems of difficult automatic control during pushing of the material by the traditional virtual welding cavity detection system and easy jamming of the material during discharging, and is especially suitable for automatic processing of multiple specifications of materials. Therefore, the virtual welding cavity detection system 1 improves the reliability and material processing efficiency in the automatic production line through the modular, adaptive and low-interference design, and is especially suitable for test scenes requiring high-precision sorting or positioning, such as electronic component detection.

[0063] Further, the pushing unit 2 comprises a shell 10 and a pushing mechanism, the pushing mechanism is arranged in the shell 10, the pushing mechanism comprises a pushing piece 21 and a sensor 22, the pushing piece 21 is slidingly connected to the shell 10, the sensor 22 is connected or disconnected with the pushing piece 21, when the sensor 22 is disconnected with the pushing piece 21, the pushing piece 21 pushes the material away from the shell 10, the pushing piece 21 is used for pushing or stopping pushing the material to the detection unit 100, when the sensor 22 is connected with the pushing piece 21, the pushing piece 21 stops pushing the material to the detection unit 100.

[0064] By connecting or disconnecting the sensor 22 with the pushing piece 21, it is realized that whether the pushing piece 21 pushes the material to the detection unit 100 is automatically started and stopped, and the automatic cycle of the pushing operation can be completed without manual intervention, thereby improving the accuracy and consistency of the material pushing.

[0065] It should be noted that the shell 10 is provided with a hollow cavity, the pushing mechanism is arranged in the hollow cavity, the shell 10 is made of aluminum alloy and surrounds to form the hollow cavity. The sensor 22 is a contact switch, and the pushing piece 21 and the sensor 22 are both rod structures, and the pushing piece 21 and the sensor 22 are connected or disconnected, so that the hollow cavity of the shell 10 is an ultra-long cavity to accommodate the pushing piece 21 and the sensor 22. The shell 10 is designed as an ultra-light structure to prevent the end of the shell 10 from falling down due to its length, thereby preventing the shell 10 from driving the pushing piece 21 inside to produce false pushing, such as preventing the pushing piece 21 from pushing other materials due to positioning error.

[0066] Further, the pushing mechanism further comprises a first elastic member 23, which is sleeved between the outer circumferential surface of the pushing member 21 and the shell 10; in order to realize automatic resetting of the first elastic member 23, a recess is arranged in the shell 10 for accommodating the first elastic member 23, and the shell 10 is used for abutting against the first elastic member 23 to realize automatic resetting of the first elastic member 23, and the recess is used for allowing the pushing member 21 to pass through transversely. The arrangement of the first elastic member 23 enables the pushing member 21 to be automatically reset, the sliding connection of the pushing member 21 to the shell 10 reduces the frictional resistance of movement, the overall structure is simple and compact, easy to install and maintain, and only energy is consumed when pushing is needed, the elastic resetting mechanism reduces the additional power requirement, improves the energy utilization efficiency, the mechanical structure is simple, and the failure rate is low. In addition, the inductive control between the inductor 22 and the pushing member 21 avoids the risk of overload, the elastic buffer protection of the first elastic member 23 prolongs the service life of the pushing mechanism, is suitable for pushing materials of different size characteristics, can be flexibly integrated into various automatic production lines, and can adapt to different pushing force requirements by adjusting the parameters of the first elastic member 23.

[0067] Further, the shell 10 is provided with first avoiding grooves 101 on both sides; the pushing mechanism further comprises a connecting rod 24, which penetrates the pushing member 21 and extends to the outer circumferential surface of the pushing member 21; the two ends of the connecting rod 24 are respectively arranged in the first avoiding grooves 101 in a sliding manner. The connecting rod 24 penetrates the pushing member 21 and extends to the first avoiding grooves 101 on both sides of the shell 10 to slide with each other, so that the pushing member 21 remains stable during sliding in the shell 10 and is prevented from deviating or being stuck; the length of the first avoiding grooves 101 can adjust the pushing stroke to adapt to the pushing requirements of materials of different sizes; the first avoiding grooves 101 limit the movement range of the connecting rod 24 to prevent the pushing member 21 from being separated from the shell 10 and avoid mechanical failure or safety hazards.

[0068] Further, the pushing unit 2 further comprises a folding mechanism 30, which comprises: a first rotating member 31 arranged on one side of the shell 10; a second rotating member 32 arranged on the side of the first rotating member 31 away from the shell 10 and rotationally connected with the first rotating member 31; a clamping portion 33 arranged on the first rotating member 31; and a positioning member 34 arranged on the second rotating member 32 and detachably connected with the clamping portion 33. The rotation design between the first rotating member 31 and the second rotating member 32 enables the folding mechanism 30 to drive the pushing mechanism to be folded, thereby reducing the occupied space and facilitating transportation and storage; in addition, the rotation connection design allows the pushing mechanism to adjust the angle within a certain range to adapt to the pushing requirements of materials in different directions; and the folding mechanism 30 or the pushing mechanism can be quickly unfolded or folded, the operation efficiency is improved, and the folding mechanism 30 is suitable for working conditions that need to be adjusted frequently; the folding of the pushing mechanism reduces the exposed part of the equipment, and reduces the risk of accidental touch or collision by personnel.

[0069] Further, the positioning member 34 comprises a pin structure 341 arranged between the second rotating member 32 and the clamping portion 33, and a second elastic member 342 arranged on the outer circumferential surface of the pin structure 341 and having both ends located between the second rotating member 32 and the clamping portion 33. By pulling the pin structure 341 to compress the second elastic member 342 and make the pin structure 341 disengage from the clamping portion 33, the locking between the first rotating member 31 and the second rotating member 32 can be released; after the external force is released, the second elastic member 342 pushes the pin structure 341 back to the clamping portion 33 to automatically restore the locking state and reduce manual intervention; thereby, the folding or unfolding action of the folding mechanism 30 is more convenient and the adjustment time is saved. In addition, the combination structure of the pin structure 341 and the second elastic member 342 is simple and can be quickly replaced when damaged, thereby reducing the maintenance cost.

[0070] Further, the pushing unit 2 further comprises a guide mechanism 40 arranged on one side of the shell 10, the guide mechanism 40 comprising a guide bracket 41, a first groove 411 and a second groove 412 are sequentially formed on the upper surface of the guide bracket 41 towards the inside of the guide bracket 41, and the shell 10 is arranged in the first groove 411; a guide support wheel 42 is rotatably arranged in the second groove 412 and used to support the shell 10 to be slidingly fitted in the first groove 411. The shell 10 is accommodated in the first groove 411 to provide basic positioning; the guide support wheel 42 in the second groove 412 restricts the movement track of the shell 10 to ensure that the pushing mechanism smoothly slides along the preset path without deviation or jamming; the shell 10 is wrapped and supported by the first groove 411 to avoid direct scraping of the edges of the shell 10, thereby protecting the surface coating or precision structure; and the rolling friction of the guide support wheel 42 replaces the traditional sliding friction, which greatly reduces the moving resistance of the shell 10 and makes the pushing action smoother, especially suitable for high-frequency or long-stroke operation. Therefore, the guide mechanism 40 is combined with the positioning of the first groove 411 and the second groove 412 and the rolling support of the rolling wheel, which is comprehensively optimized in terms of precision, durability and maintainability, and is especially suitable for industrial pushing scenes with high frequency, high load or long service life requirements.

[0071] Further, the pushing unit 2 further comprises a first driving mechanism 60 connected with the shell 10, used for driving the shell 10 to move to push the material; wherein the first driving mechanism 60 comprises a first cylinder 61, a first screw rod 62 connected with the first cylinder 61, and a first sliding block 63 slidingly arranged on the first screw rod 62, the shell 10 being connected with the first sliding block 63, and the first cylinder 61 being used for driving the first sliding block 63 to move the shell 10 along the first screw rod 62. In the first driving mechanism 60, the first cylinder 61 drives the first screw rod 62 to rotate, the first screw rod 62 drives the first sliding block 63 to move linearly along the first screw rod 62, the first sliding block 63 is fixedly connected with the outer surface of the shell 10, the shell 10 drives the internal pushing mechanism to move as a whole, the pushing part 21 of the pushing mechanism pre-presses the surface of the material, so that high-speed and high-precision pushing operation is realized; the first driving mechanism 60 is particularly suitable for packaging, electronic assembly and other automated production lines requiring high-speed and precise pushing, and the comprehensive efficiency is improved.

[0072] Further, the pushing unit 2 further comprises a support frame 35 arranged oppositely between the shell 10 and the first rotating part 31. The pushing mechanism, the folding mechanism 30 and the guiding mechanism 40 are arranged on the support frame 35. The design of the support frame 35 can realize integrated effect of the pushing unit, has flexibility and maintainability while ensuring structural rigidity, and provides a reliable solution for high-load industrial applications. Specifically, the support frame 35 is used for bearing the shell 10, the folding mechanism 30 and the guiding mechanism 40, significantly improves the overall mechanical strength, prevents deformation or vibration during pushing operation, and ensures long-term stable operation; the support frame 35 serves as a unified installation base, modularly integrates the pushing mechanism, the folding mechanism 30 and the guiding mechanism 40, simplifies the assembly process, and improves production and maintenance efficiency; through the three-dimensional space arrangement of the support frame 35, the occupied volume of the pushing mechanism is reasonably compressed, which is particularly suitable for space-limited automated production lines; the pushing force is evenly dispersed to the folding mechanism 30 and the guiding mechanism 40 through the support frame 35, avoiding local stress concentration and reducing the risk of failure of key components.

[0073] Further, the false solder hole detection system 1 further comprises: a rack 50, the support frame 35 is rotatably connected between the rack 50 and the first rotating part 31; the support frame 35 is connected with the rack 50 and forms a first included angle, the range of the first included angle is 0-90°, when the support frame 35 is folded relative to the rack 50, the support frame 35 is located on the same side of the rack 50; the first rotating part 31 is installed on the rack 50, and the support frame 35 is rotatably connected relative to the first rotating part 31, so that the support frame 35 can be folded on the same side of the rack 50, or the support frame 35 and the rack 50 are relatively unfolded. The support frame 35 can be completely folded and attached to the rack 50, so that the device greatly reduces the volume in the non-working state, significantly improves the storage and transportation efficiency. The thickness of the support frame 35 and each mechanism thereon is reduced after folding, allowing multiple devices to be arranged side by side in a limited space, improving the space utilization rate of the production line; the support frame 35 can be adjusted at a continuous angle of 0-90° relative to the rack 50, adapting to various working conditions such as horizontal pushing and inclined feeding. Therefore, the rack 50 can make the pushing device have the stability of large equipment and the flexibility of portable equipment, and is particularly suitable for modern intelligent factories that need to frequently change working sites or have limited space, and the comprehensive equipment utilization rate is improved.

[0074] Further, the rack 50 is provided with a material box 52 and a second driving mechanism 51; the material box 52 is used to stack and space the material, and the material is preferably an LED; the second driving mechanism 51 is connected with the material box 52 and is used to drive the material box 52 to move up and down along the linear guide rail relative to the rack 50, so that each piece of the to-be-pushed board material provided by the material box 52 is horizontally aligned with the pushing part 21 of the pushing unit 2, so as to facilitate the pushing part 21 to push the to-be-pushed board material, and the pushing unit 2 is used to complete the pushing of the PCB boards in the material box 52 piece by piece.

[0075] The use process of the pushing unit 2 of the false solder hole detection system 1 of the present application is as follows:

[0076] Power transmission stage: the pushing arm 70 receives external driving such as a cylinder, a motor, etc., pushes the pushing plate 80 to move forward, and transports the material to the target position; the second avoiding groove 701 is provided with a movable pushing block 90, the pushing block 90 moves synchronously with the pushing plate 80, but can be independently rotated and adjusted.

[0077] The material blocking adjustment stage: the pushing block 90 includes a first matching block 92 and a second matching block 93, both of which are rotated in the second avoiding groove 701 through a hinged shaft; when the blocking block 91 blocks the output material, the blocking block 91 blocks the material on the bearing plate 3, when the material accumulation reaches the limit value, in order to prevent the blocking block 91 from continuing to push the material and causing damage to the material, so that the blocking block 91 is pushed by the reaction force of the material and rotates counterclockwise until the reaction force is less than the magnetic attraction force between the magnetic attraction structure 94 and the pushing plate 80, the magnetic attraction structure 94 drives the second matching block 93 to rotate until the magnetic attraction structure 94 is connected with the second plate body 82, and the position of the blocking block 91 is locked, wherein when the second matching block 93 is in contact with the second plate body 82, the end of the blocking block 91 away from the second matching block 93 is located between the first plate body 81 and the second avoiding groove 701.

[0078] Therefore, the pushing unit 2 provided by the present application realizes automatic start-stop control of whether the pushing piece 21 pushes the material by connecting or disconnecting the inductor 22 and the pushing piece 21, so that the automatic cycle of the pushing operation can be completed without manual intervention, and the accuracy and consistency of the material pushing are improved; the first elastic piece 23 enables the pushing piece 21 to be automatically reset, the sliding connection of the pushing piece 21 to the shell 10 reduces the movement friction resistance, the overall structure is simple and compact, easy to install and maintain, the mechanical structure is simple, and the failure rate is low.

[0079] Further, in the virtual welding cavity detection system 1, the discharging unit includes a pushing arm 70, a pushing plate 80 and a pushing block 90. The pushing plate 80 is connected with the pushing arm 70 and encloses to form a second avoiding groove 701; the pushing block 90 is arranged on the side of the pushing plate 80 facing the pushing arm 70 and is arranged in the second avoiding groove 701, the pushing block 90 is provided with a blocking block 91, and the pushing block 90 is hinged to the pushing plate 80 to adjust the distance of the blocking block 91 relative to the material.

[0080] The discharging unit is designed by the pushing arm 70, the pushing plate 80 and the pushing block 90, which can adjust the distance of the pushing block 90 relative to the material, realize flexible control of the material pushing position, the movable connection of the pushing block 90 and the pushing plate 80 enables the blocking block 91 to adapt to materials of different sizes or positions, improves the universality of discharging, and the second avoiding groove 701 avoids structural interference. The discharging unit of the virtual welding cavity detection system 1 is designed in a modular and adjustable manner, solves the problems of poor adaptability and easy material jamming in the traditional discharging mode, and considers the structural strength and operation convenience, and is especially suitable for automatic processing scenes of multiple specifications of materials.

[0081] The pushing block 90 is hinged with the pushing plate 80, so that the pushing block 90 can rotate between the pushing plate 80 and the second avoiding groove 701, so that one end of the pushing block 90 is attached to the pushing plate 80, so that the pushing block 90 drives the blocking block 91 to achieve the blocking function, or the blocking block 91 stops the blocking function, which is simple to operate and stable in structure, and is suitable for frequent adjustment, and reduces mechanical wear.

[0082] Further, the pushing block 90 comprises a first matching block 92 and a second matching block 93 connected with each other, the first matching block 92 is movably arranged in the second avoiding groove 701, and the blocking block 91 is arranged at one end of the first matching block 92 away from the second matching block 93. When the first matching block 92 is in contact with the pushing plate 80, the blocking block 91 protrudes from one end of the pushing plate 80 away from the second avoiding groove 701, and the blocking block 91 rotates with the pushing block 90 in the second avoiding groove 701. When the reaction force of the material acts on the pushing block 90, the pushing block 90 rotates relative to the pushing plate 80 around the hinge point, and drives the blocking block 91 to rotate synchronously, so as to expand the adjustment range of the discharging unit of the virtual welding cavity detection system 1 relative to the material. Therefore, the blocking block 91 is used to achieve the blocking function, and the second matching block 93 is used to provide support, enhance the structural reliability and adjustability.

[0083] Further, in the virtual welding cavity detection system 1, the discharging unit further comprises a magnetic attraction structure 94 arranged at one end of the second matching block 93 away from the blocking block 91, and the magnetic attraction structure 94 is used for magnetic attraction with the pushing plate 80.

[0084] Further, the pushing plate 80 comprises a first plate body 81 and a second plate body 82 connected with each other; the first plate body 81 protrudes from the first surface 71 of the pushing arm 70, and the first matching block 92 is used for contact with the first plate body 81; the second plate body 82 protrudes from the second surface 72 of the pushing arm 70, and the second matching block 93 is used for contact with the second plate body 82. Through the contact between the first plate body 81 and the first matching block 92, or the contact between the second plate body 82 and the second matching block 93, bidirectional limiting is realized; through the contact between the second matching block 93 and the second plate body 82, stability is enhanced, and shaking is prevented.

[0085] Further, when the magnetic attraction structure 94 is magnetically attracted with the second plate body 82, one end of the blocking block 91 away from the second matching block 93 is located between the first plate body 81 and the second avoiding groove 701. The magnetic attraction structure 94 is used for fixing the position of the pushing block 90 during blocking, preventing displacement caused by vibration or impact, and simplifying the operation without additional locking components.

[0086] Further, when the first matching block 92 is attached to the first plate body 81, the stop block 91 protrudes from one end of the first plate body 81 away from the second avoiding groove 701. By protruding from the end of the first plate body 81, the stop block 91 effectively blocks the material when blocking the material, avoiding material leakage or position deviation, and improving the material discharge accuracy.

[0087] Further, when the second matching block 93 is in contact with the second plate body 82, the end of the stop block 91 away from the second matching block 93 is located between the first plate body 81 and the second avoiding groove 701. That is, with the rotation of the material pushing block 90, the protruding height of the stop block 91 relative to the first plate body 81 of the material pushing plate 80 changes dynamically, so that the material blocking range of the stop block 91 changes. The stop block 91 rotates counterclockwise and gradually moves towards the direction of the second avoiding groove 701 until the magnetic attraction structure 94 is connected with the second plate body 82, and the stop block 91 rotates to the end between the first plate body 81 and the second avoiding groove 701, thereby avoiding interference with subsequent materials.

[0088] Further, the hinge design of the material pushing block 90 allows the stop block 91 to rotate passively, and the magnetic attraction structure 94 provides a breakable adsorption force threshold to realize the overload protection function. The magnetic attraction structure 94 is used to fix the position of the material pushing block 90 when blocking the material, preventing displacement caused by vibration or impact, and at the same time, without the need for additional locking components, simplifying the operation.

[0089] Further, in the virtual welding cavity detection system 1, the material discharging unit further comprises a third driving mechanism; the third driving mechanism comprises: a second air cylinder 95; a second lead screw 96 connected to the second air cylinder 95; a second sliding block 97 slidingly arranged on the second lead screw 96, and a material pushing arm 70 connected to the second sliding block 97. A driving assembly for pushing the material pushing arm 70 to move; the driving assembly is used to push the material pushing arm 70 to move the stop block 91 forward and backward.

[0090] Further, the material pushing plate 80 is integrally connected with the material pushing arm 70; and / or, the first plate body 81 is integrally connected with the second plate body 82; and / or, the first matching block 92 is integrally connected with the second matching block 93; and / or, the stop block 91 is integrally connected with the first matching block 92. By integrally connecting the material pushing plate 80 with the material pushing arm 70, the first plate body 81 with the second plate body 82, the first matching block 92 with the second matching block 93, and the stop block 91 with the first matching block 92, the integrally formed connection mode can reduce the assembly link, improve the overall structural strength, reduce the failure rate, and facilitate maintenance.

[0091] Further, the first matching block 92 and the second matching block 93 form a first included angle, and the range of the first included angle is 90°-180°; and / or, the first plate body 81 and the second plate body 82 are connected to form a flat plate.

[0092] Further, the first fitting block 92 and the first plate body 81 form a second included angle therebetween, and the second included angle ranges from 0 to 90 degrees; and / or, the second fitting block 93 and the second plate body 82 form a third included angle therebetween, and the third included angle ranges from 0 to 90 degrees.

[0093] Therefore, in the discharging unit of the virtual soldering cavity detection system 1, the second avoiding groove 701 is formed by the connection of the pushing plate 80 and the pushing arm 70; the pushing block 90 is arranged on the side of the pushing plate 80 facing the pushing arm 70 and extends in the second avoiding groove 701; the pushing block 90 is provided with the blocking block 91, and the pushing block 90 is movably connected with the pushing plate 80 to adjust the distance between the blocking block 91 and the material.

[0094] Therefore, in the discharging unit of the virtual soldering cavity detection system 1, the position of the blocking block 91 can be flexibly adjusted by the movable design of the pushing block 90 in the second avoiding groove 701 to adapt to materials of different sizes or positions and improve the versatility; the second avoiding groove 701 is formed by the connection of the pushing plate 80 and the pushing arm 70 to avoid structural interference, and the pushing block 90 can move in the second avoiding groove 701 to ensure stable pushing of the material; the pushing block 90 is divided into the first fitting block 92 and the second fitting block 93 to optimize the stress distribution and enhance the stability and durability; the magnetic attraction structure 94 is arranged on the pushing block 90 to automatically attract and fix the pushing plate 80 when blocking the material, preventing deviation caused by vibration or impact and reducing the need for manual adjustment; the key components are designed in one piece, such as the pushing plate 80 and the pushing arm 70, and the blocking block 91 and the second fitting block 93, to improve the structural strength and reduce the assembly complexity; the second included angle or the third included angle between the pushing block 90 and the pushing plate 80 is controlled to ensure close contact of the contact surface when blocking the material and reduce the risk of material jamming. Therefore, the virtual soldering cavity detection system 1 can adjust the position of the blocking block 91, is compatible with different specifications of materials, uses magnetic attraction fixation and split design to reduce the influence of vibration, and optimizes the angle to ensure smooth discharging. The discharging unit of the virtual soldering cavity detection system 1 is especially suitable for scenarios such as automatic production lines, test equipment, and material sorting systems, and takes into account efficiency and reliability.

[0095] It should be noted that the virtual welding cavity detection system 1 comprises the above-mentioned pushing unit 2, the discharging unit and the detection unit 100, further comprises an electrical detection unit and a mechanical stress test unit. Further, the detection unit 100 is an automatic optical detection unit, which is used to analyze whether the material has virtual welding and / or cavity. If there is virtual welding and / or cavity, the detected material is unqualified, otherwise, the material is determined to be qualified. The detection unit 100 is used to improve the image acquisition quality by using multi-angle light source and high-resolution camera; and is used to improve the identification accuracy of virtual welding / leakage welding by combining machine learning or deep learning. Thus, the virtual welding cavity detection system 1 realizes full-process automation through the cooperative control of the pushing unit 2, the detection unit 100 and the discharging unit, and is used to solve the problem of virtual welding and / or cavity of the material, especially the plate material. The working principle of the virtual welding cavity detection system 1 mainly depends on high-precision detection technology and intelligent analysis algorithm, and the detection process is realized as follows:

[0096] 1. Contact the solder joint or PCB circuit with a probe and apply a small current to measure the resistance value. When the resistance value abnormally increases, it represents virtual welding. When the resistance is infinite and the circuit is completely disconnected, it represents a cavity.

[0097] 2. Through automatic optical (AOI) detection, a high-resolution camera is used to shoot a 2D image of the solder joint, and an AI algorithm is used to analyze whether the solder shape has abnormalities such as less solder and incomplete solder ball, and whether the component is shifted or tilted.

[0098] 3. Through X-ray detection, hidden solder joints such as BGA (ball grid array package) and QFN (quad flat no-lead package) are detected by penetrating the PCB, and the solder filling rate is analyzed by grayscale value.

[0099] 4. Through micro-vibration test, high-frequency micro-vibration is applied to the solder joint, and the impedance change is monitored by a sensor. Virtual solder joints will cause signal fluctuation due to poor contact.

[0100] 5. Through push-pull force test, a precision mechanical arm is used to apply axial force to the component to detect whether the solder joint is off or has a cavity, or whether the solder joint is insufficient in strength, i.e., virtual welding.

[0101] The virtual welding cavity detection system 1 provided by the present application can push or stop pushing the material to the detection unit 100, collect and acquire the image of the material through the detection unit 100, analyze whether the material is qualified according to the image, and transport the qualified material to the discharge unit, and adjust the distance of the qualified material through the discharge unit to improve the universality of the discharge. The virtual welding cavity detection system 1 solves the problems of difficult automatic control of traditional virtual welding cavity detection system and easy blockage of discharge through modular design of unit, and is especially suitable for automatic processing of multi-specification materials. Therefore, the virtual welding cavity detection system 1 is suitable for automatic equipment through modular, adaptive and low-interference design, and improves the material sorting or positioning accuracy. The virtual welding cavity detection system 1 can improve the material processing efficiency and adaptability, and is especially suitable for testing scenes requiring high-precision sorting or positioning, such as electronic component detection requirements.

[0102] The virtual welding cavity detection system 1 provided by the present application realizes efficient and accurate detection of the quality of LED welding through modular design and automatic detection technology. The pushing unit 2 adopts mechanical linkage, such as pushing piece 21, inductor 22, first elastic piece 23 and first driving mechanism, realizes automatic pushing and stopping of the material, reduces manual intervention and improves production efficiency. The folding mechanism 30 and the guide mechanism 40 of the pushing unit 2 are designed to ensure smooth pushing of the material and reduce the risk of blockage or deviation. The support frame 35, guide frame 41 and other structures provide overall rigidity to adapt to the high-frequency use demand in industrial environment. The discharge unit is designed with adjustable pushing block 90 and magnetic attraction structure 94 to flexibly adapt to the output demand of different size materials and ensure the continuity of the sorting process. The hinged pushing block 90 and the magnetic attraction structure 94 of the discharge unit can dynamically adjust the position of the blocking block 91 to adapt to different material thickness and ensure the stability of the output. The detection unit 100, specifically the AOI automatic optical detection unit, can quickly identify defects such as virtual welding and cavity through image acquisition and analysis, determine the qualification, avoid subjective errors of manual visual inspection, improve the detection accuracy, replace manual screening with automatic detection, reduce labor cost, find welding defects early, avoid defective products from flowing into subsequent processes, reduce rework rate and material waste. The units of the virtual welding cavity detection system 1 are independently designed and work cooperatively, which is convenient for maintenance or upgrading, such as replacing different specifications of pushing piece 21 or detection algorithm. The virtual welding cavity detection system 1 realizes rapid, accurate and fully automatic sorting of LED welding quality through the combination of mechanical automation and optical detection, and has efficiency, accuracy and reliability, which is suitable for large-scale electronic manufacturing scenes and significantly improves production yield and economic benefits.

[0103] The above is only a preferred embodiment of the present application and is not intended to limit the present application. Any modification, equivalent replacement and improvement made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A false solder void detection system, characterized by, The application relates to a material pushing device, which comprises a material pushing unit, a detection unit and a material outputting unit. The material pushing unit is used for pushing material to the detection unit or stopping pushing material. The detection unit is used for receiving material and collecting images of the material, and is used for analyzing whether the material is qualified according to the images and for conveying qualified material to the material outputting unit. The material outputting unit is used for adjusting the distance from the material and outputting the material. The material pushing unit comprises a shell, a material pushing mechanism arranged in the shell, a first elastic member and a connecting rod. The material pushing mechanism comprises a material pushing piece and a sensor. The material pushing piece is slidably connected to the shell. The sensor is connected to or disconnected from the material pushing piece. When the material pushing piece pushes material towards the detection unit, the sensor is disconnected from the material pushing piece. When the material pushing piece stops pushing material, the sensor is connected to the material pushing piece. The first elastic member is arranged between the outer circumferential surface of the material pushing piece and the shell.

2. A system for detecting a false solder void as claimed in claim 1, wherein The connecting rod penetrates through the material pushing piece and extends to the outer circumferential surface of the material pushing piece. The shell is provided with avoiding grooves on both sides. The two ends of the connecting rod are slidably arranged in the avoiding grooves.

3. A system for detecting a false solder void as claimed in claim 2, wherein The material pushing unit further comprises a folding mechanism. The folding mechanism comprises a first rotating piece arranged on one side of the shell, a second rotating piece arranged on the side of the first rotating piece away from the shell and rotationally connected to the first rotating piece, a clamping part arranged on the first rotating piece and a positioning piece arranged on the second rotating piece and detachably connected to the clamping part. The material pushing unit further comprises a guiding mechanism arranged on one side of the shell. The guiding mechanism comprises a guiding support and a guiding support wheel.

4. A system for detecting a false solder void as recited in claim 1, wherein The shell is arranged in the first recess. The guiding support wheel is rotationally arranged in the second recess and is used for supporting the shell to be slidably matched with the first recess. The material pushing unit further comprises a support frame arranged between the shell and the first rotating piece. A first driving mechanism is connected to the shell and is used for driving the shell to move the material pushing mechanism to push material.

5. A system for detecting a false solder void as claimed in claim 4, wherein The folding mechanism, the guiding mechanism and the first driving mechanism are arranged in the support frame. The material outputting unit comprises a material pushing arm, a material pushing plate connected to the material pushing arm and surrounding to form an avoiding groove, and a material pushing block arranged on the side of the material pushing plate towards the material pushing arm and arranged in the avoiding groove.

6. A system for detecting a false solder void as claimed in claim 5, wherein The material pushing block is provided with a stop block and is hingedly connected to the material pushing plate to adjust the distance of the stop block from the material. The material pushing block comprises a first matching block and a second matching block connected to each other. The first matching block is movably arranged in the avoiding groove. The stop block is arranged on the end of the first matching block away from the second matching block. When the first matching block is in contact with the material pushing plate, the stop block protrudes from the end of the material pushing block away from the avoiding groove. The material outputting unit further comprises a magnetic attraction structure arranged on the end of the second matching block away from the stop block and used for being magnetically attracted to the material pushing plate. The magnetic attraction structure comprises a magnetic piece and a magnetic plate. When the magnetic attraction structure is matched with the pushing plate, the end of the stopper away from the second matching block is located between the pushing plate and the avoiding groove.

7. A system for detecting a false solder void as recited in claim 1, wherein The detection unit is an automatic optical detection unit, which is used for analyzing whether the material has virtual welding and / or cavity. If the material has virtual welding and / or cavity, the material is unqualified. Otherwise, the material is qualified.

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