Welding-free coil assembling method and device

Abstract

The invention discloses an assembling method and device for a welding-free coil. The assembling method comprises the steps that the coil is positioned so that the coil can be within the detection range of a visual assembly; identifying the state of the coil through a visual component so as to judge whether the coil is qualified or not; if the coil is qualified, the stitch angle of the coil is identified through the visual assembly; and an angle compensation value is provided for a grabbing assembly according to the pin angle so that the grabbing assembly can assemble the coil and the shell at the correct angle. The visual assembly identifies the peak coordinates of the pins, calculates the height difference and the distance and compares the height difference and the distance with the preset threshold value, unqualified coils can be accurately screened out and scrapped, the problem that in the prior art, when multiple coils are pressed, a single coil fails and cannot be identified is solved, and the assembly quality is guaranteed from the source.

Description

TECHNICAL FIELD

[0001] The application belongs to the field of inductance assembly, and particularly relates to an assembly method and device of a solderless coil. BACKGROUND

[0002] The solderless coil in the controller of an electric control brake system can be quickly and effectively mounted with a circuit board; and the assembly of the solderless coil and a shell has gradually become a widely-applied process scheme in the industry.

[0003] In the related art, the assembly of the solderless coil and the shell has two mainstream schemes: one is a manual assembly scheme, in which an operator places the coil into the shell, and a press is used for press-fitting; and the other is that the operator places the coil into a precision positioning tool in advance, and a robot is used for picking up and mounting. However, in the above schemes, the coil PIN needle is inclined in the assembly process, which cannot be recognized by naked eyes in the manual assembly process, and the shell is easily scratched; and the coil press-fitting process adopts multiple coil press-fitting forces and displacement control, and a single coil failure cannot be recognized. SUMMARY

[0004] The application aims to provide an assembly method and device of a solderless coil, and solves the above problems in the related art.

[0005] To this end, the application provides an assembly method of a solderless coil in a first aspect, comprising the following steps: positioning the coil so that the coil is within the detection range of a vision assembly; recognizing the state of the coil by the vision assembly to determine whether the coil is qualified; if the coil is qualified, recognizing the pin angle of the coil by the vision assembly; providing an angle compensation value for a grabbing assembly according to the pin angle so that the grabbing assembly assembles the coil with the shell at a correct angle.

[0006] Preferably, the step of positioning the coil so that the coil is within the detection range of the vision assembly comprises: placing the coil into a coil pipeline and pushing the coil to move in a direction; recognizing the positioning of the coil based on a sensor after the coil moves to a positioning tool, wherein the positioning tool is within the detection range of the vision assembly.

[0007] Preferably, the sensor sends a detection signal to the vision assembly after recognizing that the coil moves to the positioning tool; the vision assembly starts to recognize the state of the coil after receiving the detection signal.

[0008] Preferably, the step of identifying the coil state by the vision component to determine whether the coil is qualified comprises: identifying the peak coordinates of the two pins of the coil by the vision component; calculating the height difference of the peak coordinates of the two pins, if the height difference is within a preset height difference threshold range, the coil is determined to be qualified, if the height difference is outside the preset height difference threshold range, the coil is determined to be scrapped; calculating the distance of the peak coordinates of the two pins, if the distance is within a preset distance threshold range, the coil is determined to be qualified, if the distance is not within the preset distance threshold range, the coil is determined to be scrapped.

[0009] Preferably, the step of identifying the peak coordinates of the two pins of the coil by the vision component comprises: acquiring image data of the pins of the coil by the vision component; converting the image data into a one-dimensional array; finding local maximum points in the one-dimensional array; calculating peak positions according to the local maximum points; finding corresponding actual peak coordinates according to the peak positions.

[0010] Preferably, the step of identifying the pin angle of the coil by the vision component comprises: calculating a first direction vector according to the peak coordinates of the two pins; calculating a second direction vector according to a preset calibration straight line; calculating a cosine value between the pins and the calibration straight line according to the first direction vector and the second direction vector; converting the cosine value into the pin angle of the coil.

[0011] Also provided is an assembly device of a solder-free coil, comprising: a coil positioning component for positioning the coil so that the coil is within the detection range of a vision component; the vision component for identifying the coil state to determine whether the coil is qualified, and identifying the pin angle of the coil by the vision component when the coil is qualified; a grabbing component for grabbing and assembling the coil; an angle compensation control module for providing an angle compensation value for the grabbing component according to the pin angle.

[0012] Preferably, the coil positioning component comprises a cylinder, a coil pipeline, a positioning tool and a sensor, the cylinder is arranged at one end of the coil pipeline, the positioning tool is arranged at the other end of the coil pipeline, and the sensor is arranged above the positioning tool.

[0013] Preferably, the visual assembly and the grabbing assembly are on both sides of the coil positioning assembly.

[0014] Preferably, the angle compensation control module is electrically connected with the visual assembly and the grabbing assembly.

[0015] Advantages: (1) The application provides a welding-free coil assembly method and device, which identifies the pin peak coordinate through a visual assembly, calculates the height difference and the interval and compares them with the preset threshold value, can accurately screen out unqualified coils and scrap them, solves the problem that a single coil failure cannot be identified in the prior art when multiple coils are pressed, and guarantees the assembly quality from the source.

[0016] (2) In the application, the process of coil pipeline pushing, sensor positioning and automatic detection of the visual assembly replaces the manual assembly or the scheme relying on precision positioning tooling in the prior art, avoids the problems of shell scratches and bumps caused by the inability of the naked eye to identify pin tilting during manual assembly, and reduces the uncertainty of manual operation.

[0017] (3) In the application, the visual assembly identifies the pin angle and provides an angle compensation value for the grabbing assembly, so that the installation angle of the coil pin and the shell is accurately matched, avoiding assembly interference or failure caused by angle deviation, and solving the assembly difficulty caused by angle problems in the traditional scheme. BRIEF DESCRIPTION OF DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or the prior art description. Obviously, the drawings in the following description only some embodiments of the application, and for those skilled in the art, other drawings can be obtained without creative labor on the basis of these drawings.

[0019] Figure 1 The method flowchart of the welding-free coil assembly method in the application.

[0020] Figure 2 The method flowchart of S100 of the welding-free coil assembly method in the application.

[0021] Figure 3 The method flowchart of S200 of the welding-free coil assembly method in the application.

[0022] Figure 4 The method flowchart of S210 of the welding-free coil assembly method in the application.

[0023] Figure 5This is a flowchart of step S300 of the assembly method for a solderless coil in this invention.

[0024] Figure 6 This is a schematic diagram of the assembly device for a solderless coil according to the present invention.

[0025] Figure 7 This is a schematic diagram of the coil positioning component of a solderless coil assembly device according to the present invention.

[0026] In the diagram, 1-coil positioning assembly, 11-cylinder, 12-coil pipe, 13-positioning fixture, 14-sensor, 2-vision assembly, 3-grabbing assembly. Detailed Implementation

[0027] The invention will be more readily understood by referring to the following detailed description of preferred embodiments and included examples. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In case of conflict, the definitions in this specification shall prevail.

[0028] like Figure 1 As shown, the first aspect of this embodiment provides a method and apparatus for assembling a solderless coil, including: S100. Position the coil so that it is within the detection range of the vision component; Positioning the coil is fundamental to the coil assembly process. Through the cooperation of mechanical structures and sensors, the coil is precisely moved to the effective detection area of ​​the vision component, providing a stable detection object and position reference for subsequent visual recognition, and solving the problem of detection instability caused by the initial dispersion of the coil position.

[0029] like Figure 2 As shown, step S100 includes: S110. Place the coil into the coil tube and push the coil to move in a specific direction; The coil tubing is the standard packaging for coils, used to provide initial constraint on the coils, preventing them from being bumped or misplaced before transfer, and also accommodating the needs of batch feeding.

[0030] S120. The positioning of the coil is completed after the sensor identifies that the coil has moved to the positioning fixture; The positioning fixture is located within the detection range of the vision component. This fixture marks the final resting position of the coil; its structure matches the coil's shape, restricting its degrees of freedom, such as translation or rotation, to maintain a stable posture. Simultaneously, the position of the positioning fixture is pre-set within the detection range of the vision component, such as the camera's field of view, ensuring the vision component can clearly capture the coil's key features.

[0031] The sensor determines the position of the coil, in some disclosed embodiments, the sensor is optionally a displacement sensor, which detects the position of the coil through the change of distance, in other disclosed embodiments, the sensor is optionally a pressure boat safety, which detects the position of the coil through the change of pressure.

[0032] The sensor detects the coil moving to the positioning tool and sends a detection signal to the vision component; this signal is the trigger condition for the vision component to start working, ensuring that the vision component only starts detection after the coil is in place and stable, avoiding invalid detection caused by the coil not being in place or moving, and improving process efficiency.

[0033] The vision component receives the detection signal and starts recognizing the state of the coil. After receiving the signal, the vision component starts recognizing the state of the coil, realizing seamless connection between positioning and detection, ensuring the accuracy and reliability of the detection data, and providing accurate raw data for subsequent qualification and angle compensation.

[0034] S200, recognizing the state of the coil through the vision component to determine whether the coil is qualified; The vision component accurately detects the key features of the coil, replacing manual visual judgment, solving the problem of manual assembly in the prior art that cannot identify pin inclination and individual coil failure is difficult to detect. Qualified coils are screened from the source, avoiding defects in the coil entering the subsequent assembly process, causing shell scratches, assembly failure, and other problems, providing a basis for subsequent accurate assembly.

[0035] As shown in Figure 3 , wherein step S200 includes: S210, recognizing the peak coordinates of the two pins of the coil through the vision component; The vision component first collects images of the coil on the positioning tool, focusing on obtaining three-dimensional view data of the two pins, and determining the peak coordinates of the two pins through data processing and coordinate matching, to provide accurate data support for subsequent height difference and spacing calculation.

[0036] As shown in Figure 4 , wherein step S210 includes: S211, obtaining image data of the pins of the coil through the vision component; The vision component uses a 3D camera to collect three-dimensional image data of the two pins of the coil on the positioning tool. The data is output in the form of a view file in csv format, containing spatial feature information such as the depth and contour of the pins, providing original image basis for subsequent analysis of the peak position of the pins. Through 3D imaging technology, the physical form of the pins is converted into quantifiable digital information, replacing manual visual observation, and ensuring the objectivity and accuracy of the data.

[0037] S212, convert the image data into a one-dimensional array; The csv file output by the 3D camera of the vision assembly contains a large amount of discrete image data, such as depth values at different positions of the needle pins, which needs to be converted into a format convenient for analysis through data processing. By extracting the feature data of the left and right needle pins respectively, such as the depth value sequence in a certain direction, and using the NumPy library to convert them into one-dimensional arrays respectively, each element of the one-dimensional array corresponds to a quantized value of the needle pin at a certain position, such as depth or height, which simplifies the two-dimensional or three-dimensional image information into a linear sequence, making it convenient to locate the tip of the PIN needle through numerical calculation.

[0038] S213, find the local maximum point in the one-dimensional array; The local maximum point corresponds to the tip of the needle pin, which is the key position that needs to be accurately positioned in the coil assembly. By performing a second-order difference operation on the one-dimensional array, the increasing and decreasing trend of the array is determined according to the change of the difference symbol, and the position where the symbol changes from positive to negative corresponds to the vicinity of the local maximum point. The maximum value index in the second-order difference result is located using the maximum value index function, which is the indirect position identifier of the local maximum point.

[0039] The approximate position of the needle pin tip in the array is accurately located through mathematical operation, avoiding errors in manual judgment.

[0040] S214, calculate the peak position according to the local maximum point; Based on the local maximum point index obtained in step S213, the actual position of the peak in the one-dimensional array is calculated. This is because the second-order difference operation will cause the index to shift, which needs to be corrected by adding 1 to finally determine the accurate sequence number of the peak in the array. This position directly corresponds to the quantized position of the PIN needle tip in the data sequence.

[0041] S215, find the actual peak coordinate corresponding to the peak position.

[0042] The peak position in the one-dimensional array has a one-to-one correspondence with the image taken by the 3D camera: through the preset coordinate mapping rule, the peak position in the array is matched to the spatial coordinate system of the 3D image, and finally the actual three-dimensional coordinates of the needle pin tip are obtained. The three-dimensional coordinates of the needle pin tip are the peak coordinates of the coil needle pin, which are the core data for subsequent calculation of height difference, distance and angle, and provide accurate spatial position basis for coil qualification and angle compensation.

[0043] S220, calculate the height difference of the peak coordinates of the two needle pins, if the height difference is within the preset height difference threshold range, determine that the coil is qualified, if the height difference is outside the preset height difference threshold range, determine that the coil is scrapped; Based on the peak coordinates of the two pins obtained in S210, the numerical value of the height dimension is extracted, the difference between the two is calculated, and the height difference is obtained; The calculated height difference is compared with the preset height difference threshold range, which is set according to the coil assembly standard, such as the allowed pin tilt error range. If the height difference is within the range, it means that the tilt degree of the two pins is within the acceptable range, and the assembly will not cause interference with the shell due to height deviation; if it exceeds the range, it means that the pin is severely tilted or deformed, which will scratch the shell or cannot be normally installed, so it is determined as unqualified and scrapped.

[0044] This step solves the problem that the human eye cannot identify the pin tilt in the prior art by quantitatively detecting the height consistency of the pin, and avoids the risk of scratching the shell during assembly from the source.

[0045] S230, calculate the distance between the peak coordinates of the two pins, if the distance is within the preset distance threshold range, determine that the coil is qualified, if the distance is not within the preset distance threshold range, determine that the coil is scrapped.

[0046] Based on the peak coordinates of the two pins obtained in S210, the straight line distance of the two in the horizontal plane is calculated to obtain the distance; The calculated distance is compared with the preset distance threshold range, which is set according to the distance standard of the shell mounting hole. If the distance is within the range, it means that the relative position of the two pins meets the assembly requirements and can be accurately inserted into the corresponding mounting hole of the shell; if it exceeds the range, it means that the pin is offset or deformed, which will cause it to be unable to be inserted into the mounting hole or to be in poor contact after assembly, so it is determined as unqualified and scrapped.

[0047] This step solves the problem that a single coil cannot be identified in the prior art when multiple coils are pressed, realizes accurate determination of the feasibility of single coil assembly, and guarantees the assembly quality.

[0048] S300, if the coil is qualified, the angle of the pin of the coil is recognized by the visual component; When the coil is determined to be qualified in step S200, the visual component starts to accurately recognize the angle of the pin of the coil. By obtaining the deviation angle between the actual direction of the pin and the preset standard direction, data support is provided for the angle compensation of the subsequent grabbing component, solving the problems of assembly interference, shell scratching and the like caused by the deviation of the angle of the pin in the prior art. The angle recognition result will be directly used for rotation compensation of the manipulator, ensuring that the angle of the coil and the shell is completely matched during assembly.

[0049] As shown in Figure 5 S300 includes: S310, calculate a first direction vector according to the peak coordinates of the two pins; The peak coordinates of the two needle feet are respectively , The two components of the first direction vector are respectively and .

[0050] S320, calculating a second direction vector according to a preset calibration straight line; The calibration straight line is a straight line on which the standard position of the needle foot is located, and the two components of the second direction vector of the calibration straight line are respectively , .

[0051] S330, calculating a cosine value between the needle foot and the calibration straight line according to the first direction vector and the second direction vector; First, the dot product of the first direction vector and the second direction vector is calculated, that is

[0052] Then, the lengths of the vector and the vector are calculated, that is

[0053]

[0054] If or , that is, the vector is a zero vector, has no direction, and the included angle is 0°.

[0055] The cosine value of the included angle is calculated according to

[0056] The calculation result is

[0057] Because the floating-point number calculation error may cause to exceed [-1, 1], it is necessary to limit its range to [-1, 1].

[0058] S340, converting the cosine value into a needle foot angle of the coil.

[0059] According to the inverse trigonometric function, the cosine value is converted into an actual angle, that is, the needle foot angle is obtained. The needle foot angle serves as the angle compensation basis of the gripping assembly, so as to ensure that the mechanical hand can be accurately aligned with the mounting angle of the shell after rotation.

[0060] S400, providing an angle compensation value for the grabbing assembly according to the pin angle so that the grabbing assembly assembles the coil with the shell at a correct angle.

[0061] The grabbing assembly is a mechanical hand and a matched inflatable clamp jaw. The inflatable clamp jaw realizes stable grabbing of the coil by clamping the inside of the coil framework. According to the angle compensation value, the clamp jaw rotates: if the actual pin angle deviates from the calibrated angle by α degrees clockwise, the mechanical hand drives the clamp jaw to rotate anticlockwise by α degrees; if the anticlockwise deviation is β degrees, the clamp jaw rotates clockwise by β degrees, until the direction of the coil pin is completely consistent with the standard direction of the shell installation.

[0062] Through accurate angle compensation, the coil pin can be smoothly inserted into the corresponding installation hole of the shell, preventing the pin from scratching the shell due to inclination or deforming due to forced assembly, avoiding assembly interference caused by angle mismatch, and directly realizing dynamic adjustment through visual compensation without the need for high-cost and easily-worn precision positioning tooling to calibrate the angle of the coil, thereby reducing costs and improving adaptability.

[0063] Also provided is an assembly device for a solderless coil, comprising: A coil positioning assembly 1 is used to position the coil so that the coil is within the detection range of the visual assembly. The coil positioning assembly 1 comprises a pneumatic cylinder 11, a coil pipeline 12, a positioning tool 13, and a sensor 14. The pneumatic cylinder 11 is arranged at one end of the coil pipeline 12, the positioning tool 13 is arranged at the other end of the coil pipeline 12, and the sensor 14 is arranged above the positioning tool 13. The visual assembly and the grabbing assembly are arranged on both sides of the coil positioning assembly 1. The coil is placed in the coil pipeline 12, and the coil is moved in the coil pipeline 12 to the positioning tool 13 by the pneumatic cylinder 11.

[0064] A visual assembly 2 is used to identify the state of the coil to determine whether the coil is qualified, and to identify the pin angle of the coil through the visual assembly 2 when the coil is qualified. A grabbing assembly 3 is used to grab and assemble the coil. An angle compensation control module is used to provide an angle compensation value for the grabbing assembly 3 according to the pin angle. The angle compensation control module is electrically connected with the visual assembly 2 and the grabbing assembly 3.

[0065] The above-described embodiments are only used to illustrate the technical solutions of the present application, and not to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that they can modify the technical solutions recorded in the foregoing embodiments, or equivalently replace some technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application, and should be included in the protection scope of the present application.

Claims

1. A method for assembling a solderless coil, characterized in that, Includes the following steps: The coil is positioned so that it is within the detection range of the vision component; The coil status is identified using a vision component to determine whether the coil is qualified. If the coil is qualified, the pin angle of the coil is identified by the vision component; The gripping assembly is provided with an angle compensation value based on the pin angle so that the gripping assembly assembles the coil with the housing at the correct angle.

2. The method according to claim 1, characterized in that, The step of positioning the coil to bring it within the detection range of the vision component includes: Place the coil into the coil tube and push the coil to move in a specific direction; The positioning of the coil is completed after the sensor identifies that the coil has moved to the positioning fixture, wherein the positioning fixture is within the detection range of the vision component.

3. The method according to claim 2, characterized in that, After the sensor detects that the coil has moved to the positioning fixture, it sends a detection signal to the vision component. Upon receiving the detection signal, the vision component initiates the identification of the coil's state.

4. The method according to claim 1, characterized in that, The step of identifying the coil state using a vision component to determine whether the coil is qualified includes: The peak coordinates of the two pins of the coil are identified by the vision component; Calculate the height difference between the peak coordinates of the two pins. If the height difference is within the preset height difference threshold range, the coil is deemed qualified. If the height difference is outside the preset height difference threshold range, the coil is deemed unqualified. Calculate the distance between the peak coordinates of the two pins. If the distance is within the preset distance threshold range, the coil is deemed qualified. If the distance is not within the preset distance threshold range, the coil is deemed unusable.

5. The method according to claim 4, characterized in that, The step of identifying the peak coordinates of the two pins of the coil using the vision component includes: Image data of the coil pins are acquired through the vision component; Convert the image data into a one-dimensional array; Find the local maximum point in the one-dimensional array; Calculate the peak position based on the local highest point; Find the corresponding actual peak coordinates based on the peak position.

6. The method according to claim 4, characterized in that, The step of identifying the pin angle of the coil using the vision component includes: Calculate the first direction vector based on the peak coordinates of the two pins; Calculate the second direction vector based on the preset calibration line; Calculate the cosine value between the pin and the calibration line based on the first direction vector and the second direction vector; The cosine value is converted into the pin angle of the coil.

7. An assembly device for solderless coils, characterized in that, include: A coil positioning assembly is used to position a coil so that the coil is within the detection range of a vision assembly; A vision component is used to identify the state of the coil to determine whether the coil is qualified, and when the coil is qualified, the vision component identifies the pin angle of the coil. The gripping component is used to grip and assemble the coil; An angle compensation control module is used to provide an angle compensation value for the gripping component based on the pin angle.

8. The apparatus according to claim 7, characterized in that, The coil positioning assembly includes a cylinder, a coil pipe, a positioning fixture, and a sensor. The cylinder is located at one end of the coil pipe, the positioning fixture is located at the other end of the coil pipe, and the sensor is located above the positioning fixture.

9. The apparatus according to claim 7, characterized in that, The vision component and the grasping component are located on either side of the coil positioning component.

10. The apparatus according to claim 7, characterized in that, The angle compensation control module is electrically connected to the vision component and the grasping component.

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