Press-fitting process effectiveness control method and press-fitting equipment

Abstract

The invention relates to a press-fitting process effectiveness control method and press-fitting equipment. The press-fitting process effectiveness control method comprises the following steps that datum point calibration is conducted on a press-fitting working face of an electrical box product; establishing a pressure threshold control curve about the travel; performing press fitting on each electrical element point location, and continuously acquiring relative coordinates of a real-time pressure value and a real-time displacement value of each electrical element point location in a press fitting process at a high speed; and carrying out risk alarm on the relative coordinates exceeding the range of the pressure threshold management and control curve related to the travel. According to the invention, the defect that the existing press-fitting equipment cannot effectively and accurately monitor the press-fitting process of the electrical element and the wiring terminal is overcome, and the press-fitting process of the electrical element and the wiring terminal can be effectively and accurately monitored; and early warning is performed in time when the pressure exceeds the relative coordinates in the range of the pressure threshold control curve related to the stroke, so that the press-fitting problem is quickly judged, and measures are quickly taken.

Description

Technical Field

[0001] This application relates to the field of press fitting technology, and in particular to a method for controlling the effectiveness of the press fitting process and press fitting equipment. Background Technology

[0002] Automotive wiring harness electrical boxes are responsible for power distribution, control signal distribution, and overload and short-circuit protection for various automotive components. To adapt to different vehicle models and electrical systems, electrical box configurations must meet the market demands for flexible adjustments and diverse customization. Currently, the vast majority of automotive wiring harness electrical boxes on the market have embedded terminals. The terminal structures and types within each electrical box vary widely; for example, fuses themselves are products with large dimensional tolerances, resulting in poor dimensional consistency and weather resistance. Manual assembly of electrical components such as relays or fuses in automotive wiring harness electrical boxes cannot efficiently handle the changing needs of multiple models on the same platform, leading to a high rate of false alarms due to over-assembly, under-assembly, or incorrect assembly. Therefore, automated mechanical equipment has emerged to replace manual labor. This equipment, specifically press-fitting equipment, presses electronic components into the terminals within the electrical box using a press head, replacing the repetitive manual insertion work and significantly improving production efficiency.

[0003] However, current pressing equipment lacks effective control strategies and methods for the pressing process. Therefore, even when pressing equipment is used, it is difficult to guarantee the relative position and consistency of terminals and electrical components after the terminals and wiring harnesses are assembled. It cannot determine whether the pins of electrical components and terminals are effectively engaged, and pressing problems such as terminal insertion failure may still occur. Furthermore, the pressing equipment cannot effectively and accurately monitor the pressing process of electrical components and terminals, and the holding force between electrical components and terminals after pressing cannot be directly observed. Summary of the Invention

[0004] Therefore, the purpose of this invention is to overcome the shortcomings of existing pressing equipment in effectively and accurately monitoring the pressing process of electrical components and terminals, and to provide a pressing process effectiveness control method and pressing equipment. This invention can effectively and accurately monitor the pressing process of electrical components and terminals, and provide timely warnings when relative coordinates exceed the pressure threshold control curve range related to the stroke, thereby quickly identifying pressing problems and taking rapid measures.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A method for controlling the effectiveness of a pressing process specifically includes the following steps: The pressure head is used to calibrate the reference points on the pressing surface of the electrical box product. Based on the calibration data of the reference point, the pressing stroke with respect to displacement is obtained, and a pressure threshold control curve with respect to the stroke is established; Pressing is performed on each electrical component point according to the pressing stroke, and the real-time pressure value and real-time displacement value of each electrical component point are continuously and at high speed during the pressing process, and the relative coordinates of the real-time pressure value and real-time displacement value are obtained. Risk alarms are triggered for relative coordinates that exceed the range of the pressure threshold control curve for the travel distance.

[0006] This invention calibrates reference points on the pressing working surface before pressing to address the dimensional tolerances that inevitably exist between electrical boxes of the same model. This allows for the determination of the pressing stroke for each electrical component within the dimensions of each pressed electrical box. Based on the calibration data of the reference points, the pressing stroke related to displacement is obtained, and a pressure threshold control curve related to the stroke is established. This results in a more accurate pressure threshold control curve during pressing operations, enabling effective and precise monitoring of the pressing process between electrical components and terminals. Relative coordinates exceeding the pressure threshold control curve range provide timely warnings, allowing operators to intervene promptly. Furthermore, the relative relationship between the relative coordinates and the pressure threshold control curve accurately identifies potential pressing problems, visually indicating the likelihood of defects. Operators can quickly determine the location of pressing problems and take swift action.

[0007] Furthermore, the specific steps for calibrating the reference point are as follows: Preset the pressure head calibration feedback force and the calibration displacement value under that feedback force; The pressure head is controlled to press the electrical box product onto the pressing surface, and the actual displacement value when the pressure head contacts the pressing surface and reaches the calibrated feedback force is obtained. Determine whether the actual displacement value is within the error standard of the calibrated displacement value; When the actual displacement value is within the error standard, it is considered a valid calibration. The actual position value is then recorded as the valid displacement value, thus completing the calibration of a reference point.

[0008] Furthermore, at least 3 or more effective displacement values ​​from different reference points should be obtained.

[0009] Furthermore, the method for establishing the pressing stroke is as follows: Calibrate the reference point position of the electrical box product ; = + … ) / n; in For different reference points, n represents the effective displacement value, where n is the number of reference points; Calculate the pressing stroke L for each electrical component point on the electrical box product based on the calibrated reference point position; L= -ab; Where a is the theoretical value of the pressure fitting from the reference point to the electrical component position, and b is the limit tolerance of the electrical component itself.

[0010] It should be noted that the pressing stroke of each electrical component in this invention can be adjusted according to the actual size of the electrical box product to be pressed. Even if each batch of electrical box products is of uniform specifications, there will inevitably be some dimensional tolerance in each electrical box product. Due to the existence of dimensional tolerance, when performing the pressing stroke, an abnormal pressing stroke may not be able to press the electrical component with dimensional tolerance into place, or there may be a risk of overpressure. This invention calibrates each electrical box product before pressing and adjusts the pressing stroke of each electrical box product based on the calibration data, which greatly ensures the effectiveness and accuracy of the pressing stroke. The pressure value feedback collected under this pressing stroke is more accurate.

[0011] Furthermore, the pressure threshold control curve for the stroke is as follows: Based on the pressing stroke, test pressing is performed on each electrical component point of the electrical box product, and the pressure value of each electrical component point at each stroke position is collected; Collect a certain number of real-time production curves showing pressure values ​​and stroke positions during the trial pressure assembly process, and fit a pressure value curve related to the stroke based on these real-time production curves. ; The upper and lower limit constants e are controlled by preset pressure values ​​at each stroke position based on the pressure value curve. Calculate the threshold control start point for the travel based on the calibrated reference point location. and threshold control endpoint : -2a-b; -ab; The pressure threshold control curve for the stroke is obtained as follows: ±e, where .

[0012] This invention's pressure threshold control curve enables data acquisition and representation throughout the entire press-fitting process, and controls data at a certain threshold starting point. and threshold control endpoint Risk management will be implemented, and the starting point of this trip will be controlled. and control endpoint Based on the precise quantification of the dimensions of each electrical box product, an alarm is promptly triggered for any abnormal pressure values ​​within the stroke range, greatly reducing the occurrence of major press-fitting accidents, enabling timely detection of risk points, and reducing production cost losses.

[0013] Furthermore, the upper and lower limit constants e are calculated and determined by the upper and lower limit values ​​of the pressure value range at each stroke position of each electrical component.

[0014] Furthermore, the range of risk alarms is the threshold control starting point. To the threshold control endpoint Within the scope of the itinerary.

[0015] This invention also provides a pressing equipment that applies the pressing process effectiveness control method described above, comprising a pressing platform with a pressing station and an inspection station, a switching and positioning unit disposed on the pressing platform and located between the pressing station and the inspection station, an identification unit disposed on one side of the pressing station for acquiring the pressing model, a pressing execution unit mounted above the pressing station, a vision inspection unit mounted above the inspection station, a calibration unit disposed on one side of the pressing execution unit, and a control system respectively connected to the switching and positioning unit, the identification unit, the pressing execution unit, the calibration unit, and the vision inspection unit; the pressing execution unit includes a three-axis motion mechanism and a pressing head disposed at the output end of the three-axis motion mechanism, the pressing head being provided with a pressure sensor, the three-axis motion mechanism being provided with a servo encoder, and the pressure sensor and the servo encoder being connected to the control system.

[0016] The control logic of the control system of this invention implements the effective control method of the pressing process. It obtains pressing force feedback data from the pressure sensor on the press head and pressing pressure formation feedback data from the servo encoder, so as to effectively control the pressing process and monitor risks.

[0017] Furthermore, the switching and positioning unit includes a station switching drive rail connecting the pressing station and the inspection station respectively, a positioning fixture on the station switching drive rail for placing the electrical box product, and a drive cylinder connected to the station switching drive rail for driving the positioning fixture to reciprocate; the vision inspection unit includes a vision camera assembly mounted above the inspection station, an inspection darkroom surrounding the inspection station, and a light source located on one side of the inspection station; the calibration unit includes a support frame fixed on the pressing platform, a calibration probe located at the end of the support frame, and a calibration force sensor mounted on the calibration probe; the drive cylinder, vision camera assembly, light source, and calibration force sensor are respectively connected to the control system.

[0018] Furthermore, the pressing platform consists of an upper frame and a lower frame, the switching positioning unit and the calibration unit are located on the lower frame, and the identification unit, the pressing execution unit and the visual inspection unit are located on the upper frame; the control system includes an input / output unit, an audible and visual alarm unit and a processor.

[0019] The working principle of the press-fitting equipment is as follows: When the equipment is powered on, the control system executes a calibration self-checking procedure. The pressure head of the press-fitting execution unit contacts the calibration probe, acquires data from the calibration force sensor and the pressure sensor, and compares them. If the data is within a reasonable range, production can continue. If the deviation exceeds the set threshold, the pressure sensor is considered to be faulty and needs to be repaired. This power-on self-checking action ensures that the data collected by the sensors on the pressure head is correct and valid, thereby verifying the correctness and stability of the equipment's data. After self-inspection, the operator places the electrical box product into the positioning fixture of the switching positioning unit. At this time, the positioning work is located at a certain loading position. The identification unit scans the barcode of the electrical box product to obtain the model of the electrical box product. The control system automatically retrieves the formula to be installed for the electrical box product and generates a schematic diagram of the relay / fuse types and positions. The operator places the relay / fuse into the corresponding holes according to the schematic diagram and starts the equipment. The drive cylinder transports the positioning fixture from the switching drive rail to the pressing station. The three-axis motion mechanism of the pressing execution unit presses the relay / fuse into place one by one according to the trajectory generated by the barcode. The pressure sensor and servo encoder collect the displacement and force during the pressing process. The control system generates a pressure threshold control curve according to the effective control method of the pressing process. During the pressing process, it continuously and at high speed acquires the real-time pressure value and real-time displacement value of each electrical component point during the pressing process, and acquires the relative coordinates of the real-time pressure value and real-time displacement value. For the relative coordinates that exceed the range of the pressure threshold control curve related to the stroke, a risk alarm is triggered and locked to prevent risky products from flowing out. After pressing is completed, the three-axis motion mechanism of the pressing execution unit will remove the pressing head from the pressing range, and the drive cylinder will transport the positioning fixture with the electrical box product from the switching drive guide to the inspection station. Within the range of the inspection darkroom, the light source illuminates the electrical box product, and the vision camera component will start taking pictures to obtain image information, which will be transmitted to the control system for comparison. After visual inspection is completed, the drive cylinder transports the positioning fixture containing the electrical box from the switching drive guide to the loading position. Qualified products are unlocked and the results are uploaded to the control system to complete data storage. Unqualified products are locked and await processing by quality personnel to prevent risky products from being mixed and released.

[0020] Compared with the prior art, the beneficial effects of the present invention are: This invention calibrates reference points on the pressing working surface before pressing to address the dimensional tolerances that inevitably exist between electrical boxes of the same model. This allows for the determination of the pressing stroke for each electrical component within the dimensions of each pressed electrical box. Based on the calibration data of the reference points, the pressing stroke related to displacement is obtained, and a pressure threshold control curve related to the stroke is established. This results in a more accurate pressure threshold control curve during pressing operations, enabling effective and precise monitoring of the pressing process between electrical components and terminals. Relative coordinates exceeding the pressure threshold control curve range provide timely warnings, allowing operators to intervene promptly. Furthermore, the relative relationship between the relative coordinates and the pressure threshold control curve accurately identifies potential pressing problems, visually indicating the likelihood of defects. Operators can quickly determine the location of pressing problems and take swift action. Attached Figure Description

[0021] Figure 1 This is a flowchart of the steps of a method for controlling the effectiveness of the pressing process in one embodiment; Figure 2 This is a flowchart illustrating the steps for benchmark calibration in one embodiment; Figure 3 This is a schematic diagram of the pressure threshold control curve in one embodiment; Figure 4 This is a schematic diagram of the overall structure of the press-fitting equipment in another embodiment; Figure 5 This is a schematic diagram of the internal structure of the press-fitting equipment in one embodiment; Figure 6 This is a structural schematic diagram of the internal structure of the press-fitting equipment in one embodiment, viewed from another perspective. Figure 7 for Figure 5 A magnified view of a section at point A in the middle; Figure 8 This is a schematic diagram of the press-fitting execution unit in one embodiment; Figure 9 This is a schematic diagram of the structure of the switching positioning unit in one embodiment; Figure 10 This is a schematic diagram of the structure of a visual detection unit in one embodiment.

[0022] 11-Pressure fitting station, 12-Inspection station, 13-Upper frame, 14-Lower frame, 141-Module installation platform, 15-Inspection darkroom, 2-Switching positioning unit, 21-Station switching drive guide rail, 22-Positioning fixture, 23-Drive cylinder, 24-Pressure fitting guide template, 3-Identification unit, 4-Pressure fitting execution unit, 41-Three-axis motion mechanism, 42-Pressure head, 43-Pressure sensor, 5-Vision inspection unit, 51-Vision camera assembly, 52-Light source, 6-Calibration unit, 61-Support frame, 62-Calibration probe, 63-Calibration force sensor, 71-Input / output unit, 72-Audio-visual alarm unit, 73-Processor. Detailed Implementation

[0023] The present invention will be further described below with reference to specific embodiments. The accompanying drawings are for illustrative purposes only, representing schematic diagrams rather than actual physical objects, and should not be construed as limiting the scope of this patent. To better illustrate the embodiments of the present invention, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0024] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0025] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present patent. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0026] Example 1 like Figure 1 As shown, a method for controlling the effectiveness of the pressing process specifically includes the following steps: The pressure head is used to calibrate the reference points on the pressing surface of the electrical box product. Based on the calibration data of the benchmark point, the press-fit stroke with respect to displacement is obtained, and a pressure threshold control curve with respect to the stroke is established; Pressing is performed on each electrical component point according to the pressing stroke, and the real-time pressure value and real-time displacement value of each electrical component point are continuously and at high speed during the pressing process, and the relative coordinates of the real-time pressure value and real-time displacement value are obtained. Risk alarms are triggered for relative coordinates that exceed the range of the pressure threshold control curve for the travel.

[0027] This embodiment calibrates the reference points on the pressing working surface before pressing to address the dimensional tolerances that inevitably exist between electrical boxes of the same model. This allows for the determination of the pressing stroke for each electrical component based on its own dimensions for each electrical box being pressed. The pressing stroke related to displacement is obtained based on the calibration data of the reference points, and a pressure threshold control curve related to the stroke is established. This results in a more accurate pressure threshold control curve during the pressing operation, enabling effective and precise monitoring of the pressing process between electrical components and terminals. Relative coordinates exceeding the pressure threshold control curve range are promptly alerted, allowing operators to intervene in a timely manner. Furthermore, the relative relationship between the relative coordinates and the pressure threshold control curve accurately identifies potential pressing problems, thus visually indicating the possibility of pressing defects. Operators can quickly identify the pressing problem and take swift action.

[0028] like Figure 2 As shown, the specific steps for benchmark calibration are as follows: Preset the pressure head calibration feedback force and the calibration displacement value under that feedback force; The pressure head is controlled to press the electrical box product onto the pressing surface, and the actual displacement value when the pressure head contacts the pressing surface to reach the calibrated feedback force is obtained. Determine whether the actual displacement value is within the error standard of the calibrated displacement value; When the actual displacement value is within the error standard, it is considered a valid calibration. The actual position value is then recorded as the valid displacement value, thus completing the calibration of a reference point.

[0029] In this embodiment, at least 3 or more effective displacement values ​​from different reference points are obtained.

[0030] Specifically, the preset pressure head 42 has a calibration feedback force of 30N and a calibration displacement value of 50mm±3mm. When the pressure head 42 presses down onto the pressing surface of the electrical box product until the pressure head 42 has a calibration feedback force of 30N, the actual displacement value obtained is 52mm. Then, this reference point is a valid reference point, and the actual displacement value of 52mm is the valid displacement value. If the actual displacement value obtained is 45mm, then this reference point is invalid, and another reference point needs to be recalibrated until at least 3 different reference points have valid displacement values.

[0031] In this embodiment, the method for establishing the pressing stroke is as follows: Calibrate the reference point position of the electrical box product ; = + … ) / n; in For different reference points, n represents the effective displacement value, where n is the number of reference points; Calculate the pressing stroke L for each electrical component point on the electrical box product based on the calibrated reference point position; L= -ab; Where a is the theoretical value of the pressure fitting from the reference point to the electrical component position, and b is the limit tolerance of the electrical component itself.

[0032] It should be noted that the pressing stroke of each electrical component in this embodiment can be adjusted according to the actual size of the electrical box product to be pressed. Even if each batch of electrical box products is of uniform specifications, there will inevitably be some dimensional tolerance in each electrical box product. Due to the existence of dimensional tolerance, when performing the pressing stroke, an abnormal pressing stroke may not be able to press the electrical component with dimensional tolerance into place, or there may be a risk of overpressure. In this embodiment, each electrical box product is calibrated before pressing, and the pressing stroke of each electrical box product is adjusted based on the calibration data, which greatly ensures the effectiveness and accuracy of the pressing stroke. The pressure value feedback collected under this pressing stroke is more accurate.

[0033] In this embodiment, the pressure threshold control curve for the stroke is as follows: Based on the pressing stroke, test pressing is performed on each electrical component point of the electrical box product, and the pressure value of each electrical component point at each stroke position is collected; Collect a certain number of real-time production curves showing pressure values ​​and stroke positions during the trial pressure assembly process, and fit a pressure value curve related to the stroke based on these real-time production curves. ; The upper and lower limit constants e are controlled by preset pressure values ​​at each stroke position based on the pressure value curve. Calculate the threshold control start point for the travel based on the calibrated reference point location. and threshold control endpoint : -2a-b; -ab; The pressure threshold control curve for the stroke is obtained as follows: ,in .

[0034] like Figure 3As shown, specifically, the pressure threshold control curve for the stroke is... and The two form a control range. If the relative coordinates of the real-time pressure value and the real-time displacement value exceed this control range, a risk alarm will be triggered. This embodiment can not only monitor risks, but also accurately distinguish potential pressing problems in the pressing process based on the relative relationship between the relative coordinates and the pressure threshold control curve, thus intuitively reflecting the possibility of pressing defects. Operators can quickly determine the location of pressing problems. like Figure 3 As shown, such as when at the threshold control starting point In the initial 1-2mm, if the relative coordinates of the real-time pressure and displacement values ​​exceed the upper limit of the pressure threshold control curve range, there may be pressing problems such as component pins being misaligned and not falling into the terminal guide port, excessive electrical components, or electrical components being placed backwards. In this case, a risk alarm should be issued immediately, and pressing should be stopped to prevent damage to the fuse box or terminals being forced out. Within the threshold control stroke range, such as 3-5mm before the electrical component enters the terminal inlet, if the relative coordinates exceed the upper limit of the pressure threshold control curve range, the error type is that the terminal hole is too small or the terminal spring is too tight. If the relative coordinates exceed the lower limit of the pressure threshold control curve range, the error type is that the terminal or component pin structure is missing or the terminal hole is too large, etc., indicating pressing problems. Within the threshold control stroke range, such as at the threshold control end point... During the final 0.2mm pressing stroke, if the relative coordinate exceeds the lower limit of the pressure threshold control curve range, the error will manifest as the electrical component's external dimensions being unqualified, or the electrical component and the electrical box product being outside the dimensional tolerance.

[0035] The relative positional relationship between the relative coordinates and the pressure threshold control curve reflects the pre-set correlation of pressing problems. The control system can provide prompts and alarms through the output device at the same time as the risk alarm, intuitively showing the possibility of pressing defects. Operators can quickly judge the pressing problem and take corresponding troubleshooting measures to improve the efficiency of operation and reduce the expansion of pressing risks and production losses.

[0036] This embodiment uses a pressure threshold control curve to achieve data acquisition and representation throughout the entire press-fitting process, and controls data at a certain threshold starting point. and threshold control endpoint Risk management will be implemented, and the starting point of this trip will be controlled. and control endpoint Based on the precise quantification of the dimensions of each electrical box product, an alarm is promptly triggered for any abnormal pressure values ​​within the stroke range, greatly reducing the occurrence of major press-fitting accidents, enabling timely detection of risk points, and reducing production cost losses.

[0037] In this embodiment, the upper and lower limit constants e are calculated and determined by the upper and lower limit values ​​of the pressure value range at each stroke position of each electrical component.

[0038] In this embodiment, the range of risk alarm is the threshold control starting point. To the threshold control endpoint Within the scope of the itinerary.

[0039] Example 2 This embodiment also provides a pressing equipment that applies the pressing process effectiveness control method as described in Embodiment 1 above. The pressing equipment executes the relevant control logic of the pressing process effectiveness control method during the pressing process. like Figure 4 , Figure 5 and Figure 6 As shown, a pressing equipment includes a pressing platform with a pressing station 11 and an inspection station 12, a switching and positioning unit 2 disposed on the pressing platform and located between the pressing station 11 and the inspection station 12, an identification unit 3 disposed on one side of the pressing station 11 and used to obtain the pressing model, a pressing execution unit 4 mounted above the pressing station 11, a vision inspection unit 5 mounted above the inspection station 12, a calibration unit 6 disposed on one side of the pressing execution unit 4, and a control system that connects the switching and positioning unit 2, the identification unit 3, the pressing execution unit 4, the calibration unit 6 and the vision inspection unit 5 respectively. like Figure 8 As shown, the press-fitting execution unit 4 includes a three-axis motion mechanism 41 and a press head 42 located at the output end of the three-axis motion mechanism 41. The press head 42 is equipped with a pressure sensor 43, and the three-axis motion mechanism 41 is equipped with a servo encoder. The pressure sensor 43 and the servo encoder are connected to the control system.

[0040] In this embodiment, the control system executes the control logic of the press-fitting process effectiveness control method, obtains press-fitting force feedback data from the pressure sensor 43 on the press head 42, obtains press-fitting downward pressure formation feedback data from the servo encoder, and performs effective press-fitting control and risk monitoring for the entire press-fitting process.

[0041] like Figure 9 As shown, the switching and positioning unit 2 includes a station switching drive rail 21 that is connected to the pressing station 11 and the inspection station 12 respectively, a positioning fixture 22 that is disposed on the station switching drive rail 21 and used to place the electrical box product, and a drive cylinder 23 that is connected to the station switching drive rail 21 and used to drive the positioning fixture 22 to reciprocate. like Figure 10As shown, the visual inspection unit 5 includes a visual camera assembly 51 mounted above the inspection station 12, an inspection darkroom 15 surrounding the inspection station 12, and a light source 52 located on one side of the inspection station 12; the visual camera assembly 51 includes a visual camera and a lens mounted on the visual camera. like Figure 7 As shown, the calibration unit 6 includes a support frame 61 fixed on the pressing platform, a calibration probe 62 located at the end of the support frame 61, and a calibration force sensor 63 on the calibration probe 62; the drive cylinder 23, the vision camera assembly 51, the light source 52 and the calibration force sensor 63 are respectively connected to the control system.

[0042] like Figure 9 As shown, the positioning fixture 22 also includes a pressing guide template 24. During the pressing process of the pressing head 42 of the pressing equipment, in order to ensure that the electrical components are inserted into the track correctly during the pressing process and reduce the risk of electrical component insertion deviation and torsion, the electrical box product is usually equipped with a pressing guide template 24 to guide the pressing head to prevent deviation and reduce production accidents such as electrical component damage or pressing head damage caused by alignment problems.

[0043] In this embodiment, the identification unit 3 is a barcode scanner, which retrieves the pressing specifications and the formula of the visual inspection unit 5 by reading the barcode of the electrical box product.

[0044] The working principle of the press-fitting equipment in this embodiment is as follows: When the equipment is powered on, the control system executes a calibration self-checking procedure. The pressure head 42 of the pressing execution unit 4 contacts the calibration probe 62, acquires data from the calibration force sensor 63 and the pressure sensor 43, and compares the data. If the data is within a reasonable range, production can continue. If the deviation exceeds the set threshold, the pressure sensor 43 is considered to be faulty and needs to be repaired. This power-on self-checking action ensures that the data collected by the sensor on the pressure head 42 is correct and valid, thus verifying the correctness and stability of the equipment's data. After self-inspection, the operator places the electrical box product into the positioning fixture 22 of the switching positioning unit 2. At this time, the positioning work is located at a certain loading position. The identification unit 3 scans the barcode of the electrical box product to obtain the model of the electrical box product. The control system automatically retrieves the formula to be installed for the electrical box product and generates a schematic diagram of the relay / fuse types and positions. The operator puts the relay / fuse into the corresponding hole according to the schematic diagram and starts the equipment. The drive cylinder 23 transports the positioning fixture 22 from the switching drive guide rail to the pressing station 11. The three-axis motion mechanism 41 of the pressing execution unit 4 presses the relay / fuse into place one by one according to the trajectory generated by the barcode. The pressure sensor 43 and the servo encoder collect the displacement and force during the pressing process. The control system generates a pressure threshold control curve according to the effective control method of the pressing process. During the pressing process, it continuously and at high speed acquires the real-time pressure value and real-time displacement value of each electrical component point during the pressing process, and acquires the relative coordinates of the real-time pressure value and real-time displacement value. It performs risk alarm and locks the relative coordinates that exceed the range of the pressure threshold control curve related to the stroke to prevent risky products from flowing out. After pressing is completed, the three-axis motion mechanism 41 of the pressing execution unit 4 will remove the pressing head 42 from the pressing range, and the drive cylinder 23 will transport the positioning fixture 22 with the electrical box product from the switching drive guide rail to the inspection station 12. Within the range of the inspection dark chamber 15, the light source 52 illuminates the electrical box product, and the vision camera component 51 will start taking pictures to obtain image information, which will be transmitted to the control system for comparison. After visual inspection is completed, the drive cylinder 23 transports the positioning fixture 22 with the electrical box from the switching drive guide to the loading position. Qualified products are unlocked and the results are uploaded to the control system to complete data storage. Unqualified products are locked and await processing by quality personnel to prevent risky products from being mixed and released.

[0045] Example 3 This embodiment is similar to Embodiment 2, except that in this embodiment: like Figure 1 and Figure 2 As shown, the pressing platform consists of an upper frame 13 and a lower frame 14. The lower frame 14 is equipped with a module installation platform 141. The switching positioning unit 2 and the calibration unit 6 are located on the lower frame 14. The identification unit 3, the pressing execution unit 4 and the visual inspection unit 5 are located on the upper frame 13. The control system includes an input / output unit 71, an audible and visual alarm unit 72 and a processor 73.

[0046] like Figure 1 and Figure 3 As shown, in this embodiment, the input / output unit 71 is a display panel that can be input via buttons or touch screen; the processor 73 includes an electronic control unit and logic processing hardware, etc.

[0047] like Figure 1As shown, in this embodiment, the upper frame 13 and the lower frame 14 are frame structures connected by necessary outer plates. The visual inspection unit 5 is located on the upper frame 13, and the darkroom 15 is formed by the outer plate of the upper frame 13 wrapping the outer plate of the visual inspection unit 5.

[0048] In this embodiment, casters and support seats are also provided at the four bottom corners of the lower frame 14 to enable the free movement and fixed support of the equipment.

[0049] The other structures and principles of this embodiment are the same as those of Embodiment 2.

[0050] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A method for controlling the effectiveness of a pressing process, characterized in that, Specifically, the following steps are included: The pressure head is used to calibrate the reference points on the pressing surface of the electrical box product. Based on the calibration data of the reference point, the pressing stroke with respect to displacement is obtained, and a pressure threshold control curve with respect to the stroke is established; Pressing is performed on each electrical component point according to the pressing stroke, and the real-time pressure value and real-time displacement value of each electrical component point are continuously and at high speed during the pressing process, and the relative coordinates of the real-time pressure value and real-time displacement value are obtained. Risk alarms are triggered for relative coordinates that exceed the range of the pressure threshold control curve for the travel distance.

2. The method for controlling the effectiveness of the pressing process according to claim 1, characterized in that, The specific steps for benchmark point calibration are as follows: Preset the pressure head calibration feedback force and the calibration displacement value under that feedback force; The pressure head is controlled to press the electrical box product onto the pressing surface, and the actual displacement value when the pressure head contacts the pressing surface and reaches the calibrated feedback force is obtained. Determine whether the actual displacement value is within the error standard of the calibrated displacement value; When the actual displacement value is within the error standard, it is considered a valid calibration. The actual position value is then recorded as the valid displacement value, thus completing the calibration of a reference point.

3. The method for controlling the effectiveness of the pressing process according to claim 2, characterized in that, Obtain effective displacement values ​​from at least 3 different reference points.

4. The method for controlling the effectiveness of the pressing process according to claim 3, characterized in that, The method for establishing the pressing stroke is as follows: Calibrate the reference point position of the electrical box product ; = + … ) / n； in For different reference points, n represents the effective displacement value, where n is the number of reference points; Calculate the pressing stroke L for each electrical component point on the electrical box product based on the calibrated reference point position; L= -a-b; Where a is the theoretical value of the pressure fitting from the reference point to the electrical component position, and b is the limit tolerance of the electrical component itself.

5. The method for controlling the effectiveness of the pressing process according to claim 1, characterized in that, The pressure threshold control curve for the stroke is as follows: Based on the pressing stroke, test pressing is performed on each electrical component point of the electrical box product, and the pressure value of each electrical component point at each stroke position is collected; Collect a certain number of real-time production curves showing pressure values ​​and stroke positions during the trial pressure assembly process, and fit a pressure value curve related to the stroke based on these real-time production curves. ; The upper and lower limit constants e are controlled by preset pressure values ​​at each stroke position based on the pressure value curve. Calculate the threshold control start point for the travel based on the calibrated reference point location. and threshold control endpoint : -2a-b; -a-b; The pressure threshold control curve for the stroke is obtained as follows: ±e, where .

6. The method for controlling the effectiveness of the pressing process according to claim 5, characterized in that, The upper and lower limit constants e are calculated and determined by the upper and lower limit values ​​of the pressure value range at each stroke position of each electrical component.

7. The method for controlling the effectiveness of the pressing process according to claim 5, characterized in that, The range of risk alarms is the threshold control starting point. To the threshold control endpoint Within the scope of the itinerary.

8. A pressing equipment that applies the pressing process effectiveness control method as described in any one of claims 1-7, characterized in that, The device includes a pressing platform with a pressing station (11) and an inspection station (12), a switching and positioning unit (2) located on the pressing platform and between the pressing station (11) and the inspection station (12), an identification unit (3) located on one side of the pressing station (11) for obtaining the pressing model, a pressing execution unit (4) mounted above the pressing station (11), a vision inspection unit (5) mounted above the inspection station (12), and a calibration unit (6) located on one side of the pressing execution unit (4). The control system is connected to the switching positioning unit (2), the identification unit (3), the pressing execution unit (4), the calibration unit (6) and the vision detection unit (5) respectively; the pressing execution unit (4) includes a three-axis motion mechanism (41) and a pressure head (42) located at the output end of the three-axis motion mechanism (41). The pressure head (42) is provided with a pressure sensor (43). The three-axis motion mechanism (41) is provided with a servo encoder. The pressure sensor (43) and the servo encoder are connected to the control system.

9. A pressing device according to claim 8, characterized in that, The switching and positioning unit (2) includes a station switching drive rail (21) connecting the pressing station (11) and the inspection station (12) respectively, a positioning fixture (22) for placing electrical box products on the station switching drive rail (21), and a drive cylinder (23) connected to the station switching drive rail (21) and used to drive the positioning fixture (22) to reciprocate; the vision inspection unit (5) includes a vision camera assembly (51) mounted above the inspection station (12), surrounding The detection darkroom (15) is located on the periphery of the detection station (12), and the light source (52) is located on one side of the detection station (12); the calibration unit (6) includes a support frame (61) fixed on the pressing platform, a calibration probe (62) located at the end of the support frame (61), and a calibration force sensor (63) is provided on the calibration probe (62); the drive cylinder (23), the vision camera assembly (51), the light source (52) and the calibration force sensor (63) are respectively connected to the control system.

10. A pressing device according to claim 8, characterized in that, The pressing platform consists of an upper frame (13) and a lower frame (14). The switching positioning unit (2) and calibration unit (6) are located on the lower frame (14), and the identification unit (3), pressing execution unit (4) and visual inspection unit (5) are located on the upper frame (13). The control system includes an input / output unit (71), an audible and visual alarm unit (72), and a processor (73).

Images