Coil wire harness automatic assembling and welding equipment and process method

Abstract

The invention discloses automatic coil wire harness assembling and welding equipment and a process method. The equipment comprises a rotating disc, a feeding unit, a welding unit, a detecting unit and a discharging unit, wherein the feeding unit, the welding unit, the detecting unit and the discharging unit are arranged in a surrounding mode. After a coil assembly is automatically fed and fixed to a rotary disc carrier, a wire harness is manually assembled, a connector of the wire harness is in butt joint with a carrier socket, and a wire rod is contained in a carrier basket; skip welding is carried out on the non-adjacent PINs on the terminal row in sequence through the plurality of tin soldering mechanisms, so that bridging is effectively prevented; after welding, welding quality visual inspection, power-on performance testing and internal pole claw overlapping visual inspection are conducted in sequence, and suspected defective products are rechecked and confirmed through a manual screen; and qualified products are automatically assembled and the insulating covers are ultrasonically welded, and finally, good products and defective products are distinguished by a discharging unit to finish discharging. Efficient and full-automatic assembling and welding of the coil module are achieved, and through multi-station cooperation and multiple quality detection, the production efficiency and the product percent of pass are remarkably improved.

Description

Technical Field

[0001] This invention belongs to the field of automation equipment technology, and in particular relates to an automatic assembly and welding equipment and process method for coil wire harnesses. Background Technology

[0002] In the modern electronics and automotive industries, coil modules (such as various solenoid valves and relay coils) are core driving components with huge demand and extremely high requirements for consistency and reliability. These modules typically consist of coil assemblies, circuit board wiring harnesses soldered to terminal blocks, and external insulating covers. Traditional assembly and soldering processes heavily rely on manual labor or semi-automatic equipment, and suffer from several technical bottlenecks.

[0003] Firstly, in the soldering process between the coil assembly and the circuit board, the spacing between the pins on the terminal blocks is becoming increasingly smaller (e.g., six pins or more). When traditional single soldering mechanisms solder adjacent pins sequentially, defects such as bridging (short circuits) and cold solder joints are easily caused by heat accumulation and solder residue. This not only seriously affects product yield, but also greatly increases production costs for subsequent rework.

[0004] Secondly, the entire assembly process involves multiple steps, including coil loading, card installation, wire harness assembly, multiple welding operations, and insulation cover pressing, making the process complex. Existing equipment often has low workstation integration and inefficient material flow, requiring frequent manual intervention and handling, resulting in low production efficiency. Furthermore, the instability of manual operation directly affects product consistency. In addition, if the pole claws (or ratchets) inside the coil overlap during manufacturing, it will lead to abnormal magnetic fields and potential short-circuit risks. Automated detection of this internal defect is difficult, often resulting in the waste of qualified products or the outflow of defective products due to misjudgment.

[0005] Finally, wire harness assemblies (especially flexible wires) are difficult to manage on automated production lines. They are prone to tangling and pulling with rotating equipment, leading to component damage or equipment downtime, which seriously affects the continuity and safety of production.

[0006] Therefore, the industry urgently needs a highly integrated and automated assembly and welding equipment that can effectively solve the problem of reliable welding of micro-pitch PIN pins, achieve stable and efficient production throughout the entire process, and have accurate and reliable quality inspection capabilities in order to break through the technical bottlenecks of the existing production model and meet the market's demand for large-scale production of high-quality coil modules. Summary of the Invention

[0007] The main objective of this invention is to provide an automatic assembly and welding equipment and process for coil harnesses. By employing a multi-soldering mechanism to perform skip soldering on non-adjacent pins, using a turntable carrier with multiple workstations to achieve full-process automation, and introducing a dual quality inspection mechanism of "equipment inspection - manual verification," this invention effectively solves the technical problems of bridging and poor soldering when welding coil components to circuit boards, difficulty in ensuring assembly positioning accuracy, and high misjudgment rate in product quality inspection.

[0008] The present invention achieves the above objectives through the following technical solution: an automatic coil harness assembly and welding equipment, used to weld a wire harness assembly and an insulating cover onto a coil assembly to obtain a coil module, wherein the wire harness assembly includes a wire body, a circuit board located at one end of the wire body, and a connector located at the other end of the wire body; The automatic coil harness assembly and welding equipment includes: A turntable, on which a plurality of first carriers are arranged at equal angles, the first carriers including a positioning seat for carrying the coil assembly, a first socket for the connector to be inserted into, and a second socket electrically connected to the first socket; The coil feeding unit includes a coil feeding conveyor line for conveying coil assemblies along the X direction, a card pressing mechanism located above the coil feeding conveyor line, a first conveying mechanism disposed at one end of the coil feeding conveyor line, a receiving and transferring mechanism for receiving coil assemblies from the first conveying mechanism and transferring them along the Y direction, a laser welding mechanism disposed on the conveying path of the receiving and transferring mechanism for welding and fixing cards to the coil assemblies, and a second conveying mechanism for removing coil assemblies from the receiving and transferring mechanism and transferring them to the first carrier; the second carrier is conveyed on the coil feeding conveyor line. Wire harness loading station; Several soldering mechanisms, each soldering mechanism is used to complete the soldering of at least two non-adjacent PIN pins on the coil assembly to the circuit board; The first detection unit includes a first vision camera that detects whether the soldering of the coil assembly and the circuit board is qualified, and a power-on module that is plugged into the second socket. The second detection unit includes a second vision camera that detects whether there is an overlap of the pole claws inside the detection coil assembly; The insulating cover assembly and welding unit includes an insulating cover feeding module for supplying insulating covers, a dispensing module that connects to the output end of the insulating cover feeding module and separates the insulating covers one by one, a third conveying mechanism that transports the insulating covers on the dispensing module to the first carrier and assembles them together with the coil assembly, and an ultrasonic welding mechanism that welds the insulating covers together with the coil assembly. The unloading unit; the coil feeding and loading unit, the wire harness loading station, the plurality of soldering mechanisms, the first detection unit, the second detection unit, the insulating cover assembly and welding unit, and the unloading unit are arranged sequentially around the turntable.

[0009] Furthermore, the first carrier also includes a fifth support plate fixed on the turntable and used to support the positioning seat, a pair of first clamping assemblies disposed on the positioning seat and used to clamp the two sides of the circuit board, a second clamping assembly for clamping the coil assembly in a horizontal axial direction, and a mounting plate fixed on the fifth support plate and located beside the positioning seat; the first socket is mounted on the front surface of the mounting plate, and the second socket is mounted on the rear surface of the mounting plate.

[0010] Furthermore, a basket for supporting the wire body is provided at the lower end of the fifth support plate.

[0011] Furthermore, the positioning seat is provided with a second bearing groove for carrying the coil assembly. The second bearing groove extends horizontally rearward from the front surface of the positioning seat, and an inlet and outlet for the coil assembly to enter and exit are formed on the front surface of the positioning seat. A limiting plate is formed on the rear side of the second bearing groove to limit one end of the coil assembly in the axial direction. The second pressing assembly presses the coil assembly axially to the limiting plate from the front side of the coil assembly. An operation opening is provided above the second bearing groove to facilitate the installation and soldering of the circuit board.

[0012] Furthermore, the first carrier also includes an opening clamping mechanism that drives the second clamping component to switch to the open state; the opening clamping mechanism is provided below the turntable at the positions corresponding to the coil feeding unit and the unloading unit.

[0013] Furthermore, the card pressing mechanism includes a first cylinder, a pressure plate that moves up and down driven by the first cylinder, and a sensor that detects whether there is a second carrier under the pressure plate; The first conveying mechanism includes a second cylinder, a first support plate that moves along the Y direction driven by the second cylinder, a third cylinder fixed on the first support plate, and a first gripper assembly that moves up and down driven by the third cylinder. The material receiving and transfer mechanism includes a first driving member, a second support plate driven by the first driving member to move along the Y direction, a first receiving plate rotatably disposed on the second support plate about the X axis, and a fifteenth cylinder fixed on the second support plate and driving the first receiving plate to reciprocate between a horizontal state and a standing state; the first receiving plate is provided with a first bearing groove for bearing and positioning the coil assembly.

[0014] Furthermore, the second conveying mechanism includes a fourth cylinder, a third support plate driven by the fourth cylinder around the Z-axis, a fifth cylinder fixed on the third support plate, a fourth support plate driven by the fifth cylinder to move horizontally, and a second gripper assembly fixed on the fourth support plate.

[0015] Furthermore, the wire harness loading station is equipped with a first display screen for displaying image information acquired by the first vision camera and a second display screen for displaying image information acquired by the second vision camera, a first OK button configured to send a signal indicating that the welding quality of the coil assembly and the circuit board is acceptable, a first NG button configured to send a signal indicating that the welding quality of the coil assembly and the circuit board is unacceptable, a second OK button configured to send a signal indicating that there is no overlap of the internal pole claws of the coil assembly, and a second NG button configured to send a signal indicating that there is overlap of the internal pole claws of the coil assembly.

[0016] Furthermore, the material distribution module includes a ninth cylinder and a second receiving plate driven by the ninth cylinder and perpendicular to the material feeding direction of the insulating cover feeding module. The second receiving plate is provided with a receiving groove for supporting the insulating cover. The third conveying mechanism includes a second driving member, a seventh support plate driven by the second driving member to move horizontally, a tenth cylinder fixed on the seventh support plate, an eighth support plate driven by the tenth cylinder to move up and down, and an adsorption block provided on the eighth support plate for adsorbing the insulating cover. The adsorption block has a suction nozzle embedded inside, and the lower surface of the adsorption block is provided with a limiting stop around the suction nozzle for limiting the position of the insulating cover.

[0017] Furthermore, the unloading unit includes a third driving member, a ninth support plate driven by the third driving member to move horizontally, a first clamping module fixed on the ninth support plate for clamping the coil module, a second clamping module fixed on the ninth support plate for clamping the connector inserted into the first socket, and an ejection unloading module that pushes the coil module radially outward from the rear of the first carrier; the ejection unloading module includes a thirteenth cylinder located behind the first carrier and a push rod driven by the thirteenth cylinder to move radially along the turntable.

[0018] Another object of the present invention is to provide a process method based on the above-described automatic coil harness assembly and welding equipment, which includes the following steps: S1. Coil assembly feeding and loading: S11. Insert the card into the coil assembly, place the coil assembly in a horizontal position in the second carrier, and transport it to the card pressing mechanism below the coil feeding conveyor. The card pressing mechanism presses the card on the coil assembly into place, and then transports it to the designated position through the coil feeding conveyor. S12. The first conveying mechanism takes out the coil assembly from the second carrier on the coil feeding conveyor line and places it in a lying position into the receiving and transferring mechanism. The receiving and transferring mechanism receives the coil assembly and moves it to below the laser welding mechanism. S13. The laser welding mechanism welds and fixes the card onto the coil assembly, and then moves it to the designated position through the material receiving and transfer mechanism; S14. The receiving and transferring mechanism drives the coil assembly to a standing position, and the second conveying mechanism takes out the standing coil assembly from the receiving and transferring mechanism and places it into the first carrier on the turntable. S2. The turntable rotates with the coil assembly to the wire harness loading station. The operator assembles the wire harness assembly onto the coil assembly. Specifically, the connector of the wire harness assembly is inserted into the first socket, the circuit board is assembled into the designated position on the coil assembly, and the wire body is placed in the basket on the first carrier to complete the loading of the wire harness assembly. S3. The turntable rotates together with the coil assembly and the wire harness assembly to the first soldering mechanism position, and solders at least two non-adjacent PINs on the coil assembly to the circuit board through the first soldering mechanism; then rotates to the second soldering mechanism position, and completes the soldering of at least two other non-adjacent PINs to the circuit board through the second soldering mechanism position, and so on, until all PINs on the coil assembly are soldered to the circuit board. S4. The turntable rotates with the coil assembly to the first detection unit. The first vision camera checks whether the coil assembly and the circuit board are properly soldered. At the same time, the power module is plugged into the second socket to perform electrical performance testing. If all tests are OK, proceed to the next step. If the first vision camera fails the test, an alarm is issued and image information is simultaneously uploaded to the first display screen. The operator makes a secondary judgment based on the image information on the first display screen. If the coil assembly and the circuit board are deemed to be properly soldered, the first OK button is pressed and the next step is executed. If they are deemed to be unqualified, the first NG button is pressed, and the turntable rotates to the unloading unit, where it is processed as a defective product. S5. The turntable rotates with the coil assembly to the position of the second detection unit. The second vision camera checks whether there is any overlap between the pole claws inside the coil assembly. If there is no overlap, proceed to the next step. If there is overlap, an alarm is issued and image information is uploaded to the second display screen. The operator makes a second judgment based on the image information on the second display screen. If it is determined that there is no overlap between the pole claws, the second OK button is pressed and the next step is executed. If it is determined that there is overlap between the pole claws, the second NG button is pressed and the turntable rotates to the unloading unit, where it is processed as a defective product. S6. The turntable rotates the coil assembly to the insulation cover assembly and welding unit. The insulation cover feeding module automatically and continuously supplies the insulation cover in an orderly manner. The third conveying mechanism transports the insulation cover onto the coil assembly in the first carrier. The ultrasonic welding mechanism welds the insulation cover and the coil assembly together, completing the welding assembly of the insulation cover and obtaining the coil module. S7. The turntable rotates with the coil assembly to the unloading unit, and the unloading unit performs the product unloading operation according to the detection results of steps S4 and S5.

[0019] Compared with the prior art, the beneficial effects of the automatic assembly and welding equipment and process method for coil harnesses of the present invention are as follows: (1) Improved welding quality and efficiency: By adopting multiple soldering mechanisms to cooperate and perform jump soldering on at least two non-adjacent PIN pins, defects such as bridging and cold solder joints caused by small pin spacing are effectively avoided, and efficient parallel soldering is achieved while ensuring the consistency of solder joints. (2) Full-process automation and precise positioning are achieved: The equipment integrates a series of automated operations such as automatic feeding, pressing, welding, testing and unloading, realizing the fully automated assembly, welding and testing process of coil modules; and the use of turntable and special carrier ensures the precise positioning and stable clamping of coil components during circulation and processing, ensuring assembly accuracy and process reliability. (3) A multi-level quality inspection system was constructed: visual inspection and electrical performance testing were comprehensively used, and a manual review mechanism was introduced for suspected defective products. Through the dual guarantee of "equipment judgment + manual confirmation", the misjudgment rate was significantly reduced and the pass rate of the final product was effectively guaranteed. (4) Optimized wire harness management and equipment layout: The vehicle is specially equipped with flower baskets to store wires, which avoids the wire harness from getting tangled or interfering during rotation. This not only protects the wire harness components, but also makes the inside of the equipment neat and orderly, improving the stability and safety of operation. (5) Multiple welding methods are integrated to meet the process requirements of coil module assembly: laser welding is used to realize the welding assembly of coil components and cards, tin soldering is used to realize the welding of PIN pins on coil components and circuit boards, and ultrasonic welding is used to realize the welding assembly of insulating covers on coil components. Attached Figure Description

[0020] Figure 1 This is a top view of the structure according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the coil assembly in an embodiment of the present invention; Figure 3 This is a schematic diagram of the coil feeding unit in an embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of the second conveying mechanism in an embodiment of the present invention; Figure 5 This is a schematic diagram of the structure of the coil assembly and the circuit board assembled together in an embodiment of the present invention; Figure 6 This is a schematic diagram of the structure of the first vehicle in an embodiment of the present invention; Figure 7 This is a partial structural schematic diagram of the first vehicle in an embodiment of the present invention; Figure 8 This is a schematic diagram of the soldering mechanism in an embodiment of the present invention; Figure 9 This is a schematic diagram of the structure of the power-on module in an embodiment of the present invention; Figure 10 This is a schematic diagram of the structure of the insulating cover assembly and welding unit in an embodiment of the present invention; Figure 11 This is a schematic diagram of the coil module structure in an embodiment of the present invention; Figure 12 This is a partial structural schematic diagram of the insulating cover assembly and welding unit in an embodiment of the present invention; Figure 13 This is a schematic diagram of the structure of the adsorption block in an embodiment of the present invention; Figure 14 This is a schematic diagram of the feeding unit in an embodiment of the present invention; The numbers in the image represent: 100 - Automatic assembly and welding equipment for coil harnesses; 200 - Coil assemblies; 201 - Pole claws; 300 - Circuit boards; 400 - Insulating covers; 500 - Cards; 1- Turntable; 2-First carrier, 21-Fifth support plate, 22-Positioning seat, 221-Second bearing groove, 222-Limiting plate, 2221-Avoidance perforation, 223-Operating opening, 23-First clamping assembly, 231-Mounting block, 232-First connecting rod, 233-Pressure block, 234-First spring, 235-Second spring, 24-Second clamping assembly, 241-Second connecting rod, 2411-Fasting part, 242-Third connecting rod, 25-Mounting upright plate, 26-First socket, 27-Flower basket, 28-Second socket, 29-Clamping mechanism, 291-Fourteenth cylinder, 292-Drive push rod; 3-Coil feeding and loading unit, 31-Coil feeding conveyor line, 311-Second carrier, 32-Card pressing mechanism, 321-First cylinder, 322-Pressure plate, 323-Sensor, 33-First handling mechanism, 331-Second cylinder, 332-First support plate, 333-Third cylinder, 334-First gripper assembly, 34-Receiving and transferring mechanism, 341-First driving component, 342-Second support plate, 343-First receiving plate, 3431-First bearing groove, 344-Fifteenth cylinder, 35-Laser welding mechanism, 36-Second handling mechanism, 361-Fourth cylinder, 362-Third support plate, 363-Fifth cylinder, 364-Fourth support plate, 365-Second gripper assembly; 4- Soldering mechanism, 41- First soldering mechanism, 411- XZ axis transfer module, 412- Sixth support plate, 413- Sixth cylinder, 414- Soldering head, 415- Carrier positioning module, 4151- Seventh cylinder, 4152- Limiting fork plate, 42- Second soldering mechanism, 43- Third soldering mechanism; 5-First detection unit; 51-First vision camera; 52-Powered module; 521-Eighth cylinder; 522-Pin bar; 6-Second detection unit; 7-Insulating cover assembly and welding unit, 71-Insulating cover feeding module, 72-Distribution module, 721-Ninth cylinder, 722-Second receiving plate, 7221-Receiving groove, 73-Second conveying mechanism, 731-Second driving component, 732-Seventh support plate, 733-Tenth cylinder, 734-Eighth support plate, 735-Adsorption block, 7351-Suction nozzle, 7352-Limiting stop, 74-Ultrasonic welding mechanism, 75-Support module; 8-Unloading unit, 81-Third driving component, 82-Ninth support plate, 83-First clamping module, 831-Eleventh cylinder, 832-Third gripper assembly, 84-Second clamping module, 841-Twelfth cylinder, 842-Fourth gripper assembly, 85-Unloading ejection module, 851-Thirteenth cylinder, 852-Push rod; 9 - Material feeding conveyor line; 10 - First display screen; 20 - Second display screen; 30 - First OK button; 40 - First NG button; 50 - Second OK button; 60 - Second NG button; 70 - NG material box. Detailed Implementation

[0021] Example 1: Please refer to Figures 1-14 This embodiment is an automatic coil harness assembly and welding equipment 100, used to weld the wire harness assembly and the insulating cover 400 on the coil assembly 200 to obtain a coil module. The wire harness assembly includes a wire body, a circuit board 300 located at one end of the wire body, and a connector (not shown in the figure) located at the other end of the wire body.

[0022] This embodiment of an automatic coil harness assembly and welding device 100 includes a turntable 1, several first carriers 2 arranged at equal angles on the turntable 1, a coil feeding and loading unit 3 arranged sequentially around the turntable 1, a harness loading station, several soldering mechanisms 4, a first detection unit 5, a second detection unit 6, an insulating cover assembly and welding unit 7, a unloading unit 8, and a unloading conveyor line 9 that receives the coil modules from the unloading unit 8 and outputs them. The coil feeding and loading unit 3 supplies coil assemblies 200 and loads them into the first carriers 2 on the turntable 1. The first carriers 2 rotate to the harness loading station, where the operator installs a circuit board 300 onto the coil assembly 200, places the wire body in a basket specifically for carrying the wire on the first carrier 2, and inserts the connector into a socket on the first carrier 2, completing the loading of the harness assembly. The first carriers 2 then pass through several soldering mechanisms 4 to solder the circuit board 300 to the terminal blocks on the coil assembly 200. The first detection unit 5 is used to detect the circuit board... The 300 terminal block has good appearance and welding quality. On the other hand, the electrical performance of the wire harness assembly is tested by power-on. The second detection unit 6 is used to detect whether there is overlap of the pawl in the coil assembly 200. The insulating cover assembly and welding unit 7 is used to automatically supply the insulating cover 400, transport the insulating cover 400 to the first carrier 2 and assemble it with the coil assembly 200. Then, the insulating cover 400 is welded and fixed to the coil assembly 200, completing the insulation cover supply, transportation assembly and welding fixation. The unloading unit 8 is used to take the assembled coil module out from the first carrier 2 and place it on the unloading conveyor line 9 to realize unloading.

[0023] In this embodiment, the coil assembly 200 has a row of terminal blocks. The circuit board 300 in the wire harness assembly needs to be soldered to the terminal blocks. The terminal blocks have six pins, and the spacing between adjacent pins is small. If the adjacent pin is soldered immediately after one pin is soldered, bridging (short circuit) is likely to occur. In addition, there are risks such as cold solder joints and uneven solder joint quality. To solve this problem and improve soldering efficiency, this embodiment provides multiple soldering mechanisms 4. Each soldering mechanism 4 is responsible for soldering two non-adjacent pins. Specifically, this embodiment provides three soldering mechanisms: a first soldering mechanism 41, a second soldering mechanism 42, and a third soldering mechanism 43. The pins are numbered sequentially. The first soldering mechanism 41 is responsible for soldering the 1st and 4th pins, the second soldering mechanism 42 is responsible for soldering the 2nd and 5th pins, and the third soldering mechanism 43 is responsible for soldering the 3rd and 6th pins.

[0024] In other embodiments, two soldering mechanisms 4 may be provided, namely a first soldering mechanism and a second soldering mechanism. The first soldering mechanism completes the soldering of the 1st pin, the 3rd pin and the 5th pin, and the second soldering mechanism completes the soldering of the 2nd pin, the 4th pin and the 6th pin.

[0025] When the coil assembly 200 is loaded onto the first carrier 2, a card 500 also needs to be mounted on it. Therefore, the coil feeding and loading unit 3 in this embodiment includes a coil feeding conveyor line 31 that conveys the coil assembly along the X direction, a card pressing mechanism 32 located above the coil feeding conveyor line 31, a first conveying mechanism 33 located at one end of the coil feeding conveyor line 31, a receiving and transferring mechanism 34 that receives the coil assembly on the first conveying mechanism 33 and transfers it along the Y direction, a laser welding mechanism 35 located on the conveying path of the receiving and transferring mechanism 34 and welding and fixing the card onto the coil assembly 200, and a second conveying mechanism 36 that removes the coil assembly 200 from the receiving and transferring mechanism 34 and transfers it onto the first carrier 2; the second carrier 311 is conveyed on the coil feeding conveyor line 31. The receiving and transferring mechanism 34 reciprocates between the receiving position, the welding position, and the feeding position. The operator places the coil assembly 200 in a horizontal position (i.e., the axis of the coil assembly is vertically distributed) on the second carrier 311 and inserts a card 500 on the coil assembly 200. The coil feeding conveyor 31 drives the second carrier 311 to move the coil assembly 200 under the card pressing mechanism 32, and the card pressing mechanism 32 presses the card into place. The second carrier 311 then moves to the end. The first conveying mechanism 33 takes the coil assembly 200 out of the second carrier 311, transports it to the receiving position, and places it on the receiving and transferring mechanism 34. The receiving and transferring mechanism 34 carries the coil assembly 200 to the welding position, and the card 500 is welded and fixed to the coil assembly 200 by the laser welding mechanism 35. The receiving and transferring mechanism 34 then moves to the feeding position, and the card 500 is taken out by the second conveying mechanism 36 and transported to the first carrier 2.

[0026] The card pressing mechanism 32 includes a first cylinder 321, a pressing plate 322 driven by the first cylinder 321 to move up and down, and a sensor 323 for detecting whether there is a second carrier 311 under the pressing plate 322. The first cylinder 321 drives the pressing plate 322 to move downwards, pressing the card 500 into place. The second carrier 311 ensures the position of the coil assembly 200, facilitating effective pressing of the card 500 by the pressing plate 322.

[0027] The first conveying mechanism 33 includes a second cylinder 331, a first support plate 332 driven by the second cylinder 331 to move along the Y direction, a third cylinder 333 fixed on the first support plate 332, and a first gripper assembly 334 driven by the third cylinder 333 to move up and down. The first gripper assembly 334 uses an internal support method to pick up the coil assembly 200 on the second carrier 311.

[0028] The material receiving and transfer mechanism 34 includes a first driving member 341, a second support plate 342 driven by the first driving member 341 to move along the Y direction, a first receiving plate 343 rotatably mounted on the second support plate 342 about the X-axis, and a fifteenth cylinder 344 fixed on the second support plate 342 and driving the first receiving plate 343 to reciprocate between a horizontal state and a standing state. The first receiving plate 343 is provided with a first bearing groove 3431 for bearing and positioning the coil assembly 200.

[0029] The second conveying mechanism 36 includes a fourth cylinder 361, a third support plate 362 driven by the fourth cylinder 361 around the Z-axis, a fifth cylinder 363 fixed on the third support plate 362, a fourth support plate 364 driven by the fifth cylinder 363 to move horizontally, and a second gripper assembly 365 fixed on the fourth support plate 364. After the first driving member 341 in the receiving and transferring mechanism 34 drives the first receiving plate 343 to move to the feeding position, the fifteenth cylinder 344 drives the first receiving plate 343 to rotate from a horizontal state to an upright state. At this time, the coil assembly 200 located on the first receiving plate 343 is in a standing state (i.e., the axis of the coil assembly is horizontally distributed). The fifth cylinder 363 drives the second gripper assembly 365 to move horizontally to take the coil assembly 200 out of the first receiving plate 343 and push it horizontally into the first carrier 2.

[0030] The first carrier 2 includes a fifth support plate 21 fixed on the turntable 1, a positioning seat 22 fixed on the fifth support plate 21 for carrying the coil assembly 200, a pair of first clamping assemblies 23 disposed on the positioning seat 22 for pressing the circuit board 300 on both sides, a second clamping assembly 24 for horizontally clamping the coil assembly 200, a mounting plate 25 fixed on the fifth support plate 21 and located beside the positioning seat 22, a first socket 26 disposed on the front surface of the mounting plate 25 for mating with the connector in the wire harness assembly, and a basket 27 fixed below the end of the fifth support plate 21 for loading the wire body.

[0031] The positioning seat 22 is provided with a second bearing groove 221, which extends horizontally rearward from the front surface of the positioning seat 22. An inlet / outlet (not shown in the figure) for the coil assembly to enter and exit is formed on the front surface of the positioning seat 22. A limiting plate 222 is formed behind the second bearing groove 221 to limit the position of one axial end of the coil assembly 200. The second pressing component 24 presses the coil assembly 200 axially backward onto the limiting plate 222 from the front side of the coil assembly 200. An operation opening 223 is provided above the second bearing groove 221 to facilitate the installation and soldering of the circuit board 300. The soldering mechanism 4 solders the PIN pins on the coil assembly 200 to the circuit board 300 at the operation opening 223. The coil assembly 200 is placed into the second bearing groove 221 through the inlet and outlet. The contoured structure design of the second bearing groove 221 defines the circumferential position of the coil assembly 200. The second clamping assembly 24 axially clamps the coil assembly 200 onto the limiting plate 222, thus defining the axial position of the coil assembly 200 and achieving precise and reliable positioning of the coil assembly 200. Furthermore, after the circuit board 300 is assembled onto the coil assembly 200, the first clamping assembly 23 clamps both sides of the circuit board 300, thereby fixing the position of the circuit board 300 and ensuring stable and reliable positioning of the circuit board 300 during subsequent soldering.

[0032] The first clamping assembly 23 includes a mounting block 231 mounted on the side of the positioning seat 22, a first connecting rod 232 rotatably mounted on the mounting block 231 about the X-axis (i.e., the front-back direction) and extending upward, a pressure block 233 rotatably mounted on the top of the first connecting rod 232 about the X-axis, a first spring 234 that drives the first connecting rod 232 toward the second bearing groove 221, and a second spring 235 that drives the pressure block 233 to remain in a downward pressing state.

[0033] The second clamping assembly 24 includes a second connecting rod 241, which is rotatably mounted on the positioning seat 22 about the Y-axis and located below the second bearing groove 221, and a third spring (not shown in the figure) that drives one end of the second connecting rod 241 to clamp upward. The front end of the second connecting rod 241 is provided with a clamping part 2411 that axially clamps the coil assembly 200 in the second bearing groove 221. The rear end of the second connecting rod 241 is rotatably connected to a third connecting rod 242. The front end of the second connecting rod 241 is driven by the third spring to maintain an upward rotational tendency. The third connecting rod 242 is movably mounted on the fifth support plate 21. Through the up and down movement of the third connecting rod 242 and the elastic restoring action of the third spring, the clamping part 2411 is driven to switch between the clamping and loosening states.

[0034] When loading the coil assembly 200 at the coil assembly 200 loading station and unloading the coil module at the coil module unloading station, the second clamping component 24 needs to be in an open state. Therefore, in this embodiment, an opening clamping mechanism 29 for opening the second clamping component 24 is provided at both the coil assembly 200 loading station and the coil module unloading station. The opening clamping mechanism 29 includes a fourteenth cylinder 291 and a drive push rod 292 that is driven by the fourteenth cylinder 291 to move up and down and drives the third connecting rod 242 to move upward to switch the fastening part 2411 to the loosened state.

[0035] The basket 27 is used to load the wire body in the wire harness assembly. It can ensure that after the wire harness assembly is assembled onto the coil assembly 200, the wire body will not get tangled with other mechanisms during the process of rotating with the first carrier 2 to each station, thus affecting the normal rotation of the turntable 1 or damaging the wire harness assembly. It also ensures the cleanliness of the wire harness assembly on site and prevents it from appearing messy.

[0036] Behind the mounting plate 25, there is also a second socket 28 for easy electrical performance testing. The second socket 28 is electrically connected to the first socket 26.

[0037] The first soldering mechanism 41, the second soldering mechanism 42, and the third soldering mechanism 43 have the same structure and each includes an XZ-axis transfer module 411, a sixth support plate 412 located at the movable end of the XZ-axis transfer module 411, a sixth cylinder 413 fixed on the sixth support plate 412, a soldering head 414 driven by the sixth cylinder 413 to move in the X direction, and a carrier positioning module 415 for positioning the first carrier 2 rotated to the position of the soldering mechanism 4. The carrier positioning module 415 includes a seventh cylinder 4151 and a limiting fork plate 4152 driven by the seventh cylinder 4151 to limit the horizontal position of the positioning seat 22. The limiting groove on the limiting fork plate 4152 limits the position of the positioning seat 22 in three peripheral directions to prevent the turntable 1 from shaking and affecting the soldering of the coil assembly 200 and the circuit board 300.

[0038] The first detection unit 5 includes a first vision camera 51 and a power-on module 52 that plugs into the second socket 28. The power-on module 52 includes an eighth cylinder 521 and a pin array 522 that is driven by the eighth cylinder 521 to move horizontally and is inserted into the second socket 28. The pin array 522 is electrically connected to an electrical performance testing system (not shown in the figure). The first vision camera 51 detects whether the soldering quality between the coil assembly 200 and the circuit board 300 meets the requirements. The eighth cylinder 521 drives the pin array 522 to insert into the second socket 28, energizing the coil assembly 200 after soldering the circuit board 300, and performing electrical performance testing using the testing software within the electrical performance testing system.

[0039] The coil assembly 200 has several pole claws 201 inside. If adjacent pole claws 201 overlap, it may cause changes in the spacing between the coil windings, increasing the risk of short circuits. In the event of a short circuit, the coil may overheat or even burn out. Overlapping pole claws can also lead to uneven magnetic field distribution, affecting the normal operation of the coil module and hindering its intended function. Therefore, to ensure the normal operation and stable performance of the coil module, this embodiment includes a second detection unit 6 to detect whether there is overlap between the pole claws 201 inside the coil assembly 200. A second vision camera is installed at the second detection unit 6.

[0040] To ensure the accuracy of the detection results of the first detection unit 5 and the second detection unit 6 and to prevent misjudgment, this embodiment also includes a first display screen 10 and a second display screen 20 located at the wire harness loading station for displaying image information acquired by the first detection unit 5, a first OK button 30 configured to send a signal indicating that the welding quality of the coil assembly 200 and the circuit board 300 is qualified, a first NG button 40 configured to send a signal indicating that the welding quality of the coil assembly 200 and the circuit board 300 is unqualified, a second OK button 50 configured to send a signal indicating that there is no overlap of the internal pole claws of the coil assembly, and a second NG button 60 configured to send a signal indicating that there is overlap of the internal pole claws of the coil assembly.

[0041] When the first vision camera 51 in the first detection unit 5 detects that the welding quality of the coil assembly 200 and the circuit board 300 does not meet the requirements, it issues an alarm to notify manual handling. At the same time, the first display screen 10 displays the image information acquired by the first vision camera 51. The operator further judges whether the welding quality of the coil assembly 200 and the circuit board 300 is qualified based on the image information on the first display screen 10. If the operator judges that the welding quality is qualified, the operator presses the first OK button 30, and the turntable 1 drives the first carrier 2 to rotate to the next station. If the operator judges that the welding quality is unqualified, the operator presses the first NG button 40, and determines that the welding of the coil assembly is defective. The subsequent welding of the insulating cover 400 is not required, and the coil assembly is unloaded as a defective product in the unloading unit 8.

[0042] When the second vision camera in the second detection unit 6 detects an overlap of the pole claws 201 inside the coil assembly 200, an alarm is issued to notify manual handling. At the same time, the second display screen 20 displays the image information acquired by the second detection unit 6. The operator further judges whether there is an overlap of the pole claws 201 inside the coil assembly 200 based on the image information on the second display screen 20. If the operator judges that there is no overlap, the second OK button 50 is pressed, and the turntable 1 drives the first carrier 2 to rotate to the next station. If the operator judges that there is overlap, the second NG button 60 is pressed, and the coil assembly is determined to be defective. The insulation cover 400 does not need to be welded afterward, and the coil assembly is unloaded as a defective product in the unloading unit 8.

[0043] The insulating cover assembly and welding unit 7 includes an insulating cover feeding module 71 that supplies insulating covers 400, a material dispensing module 72 that connects to the output end of the insulating cover feeding module 71 and separates the insulating covers 400 output by the insulating cover feeding module 71 one by one, a third conveying mechanism 73 that transports the insulating covers 400 on the material dispensing module 72 to the first carrier 2 and assembles them together with the coil assembly 200, an ultrasonic welding mechanism 74 located above the first carrier 2 and welding the insulating covers 400 together with the coil assembly 200, and a support module 75 located below the first carrier 2 and supporting the lower part of the first carrier 2 when the ultrasonic welding mechanism 74 is in operation.

[0044] The material dispensing module 72 includes a ninth cylinder 721 and a second receiving plate 722 driven by the ninth cylinder 721 and perpendicular to the material feeding direction of the insulating cover feeding module 71. The second receiving plate 722 is provided with a receiving groove 7221 for supporting the insulating cover 400.

[0045] The third conveying mechanism 73 includes a second driving member 731, a seventh support plate 732 driven by the second driving member 731 to move horizontally, a tenth cylinder 733 fixed on the seventh support plate 732, an eighth support plate 734 driven by the tenth cylinder 733 to move up and down, and an adsorption block 735 disposed on the eighth support plate 734 for adsorbing the insulating cover 400. In order to adsorb the insulating cover 400 more accurately and ensure that the insulating block 400 and the coil assembly 200 can be accurately assembled, a suction nozzle 7351 is embedded inside the adsorption block 735, and a limiting stop 7352 is provided around the suction nozzle 7351 to limit the position of the insulating cover 400.

[0046] The unloading unit 8 includes a third driving member 81, a ninth support plate 82 driven by the third driving member 81 to move horizontally, a first clamping module 83 fixed on the ninth support plate 82 for clamping the coil module, a second clamping module 84 fixed on the ninth support plate 82 for clamping the connector inserted into the first socket 26, and an ejection unloading module 85 that pushes the coil module radially outward from the rear of the first carrier 2. The first clamping module 83 includes an eleventh cylinder 831 fixed on the ninth support plate 82 and a third gripper assembly 832 driven by the eleventh cylinder 831 to move up and down. The second clamping module 84 includes a twelfth cylinder 841 fixed on the ninth support plate 82 and a fourth gripper assembly 842 driven by the twelfth cylinder 841 to move up and down. The ejection and unloading module 85 includes a thirteenth cylinder 851 located behind the first carrier 2 and a pusher rod 852 driven by the thirteenth cylinder 851 to move radially along the turntable 1. The limiting plate 222 has a clearance hole 2221 for the pusher rod 852 to pass through. When the first carrier 2 moves to the corresponding position of the unloading unit 8, the clamping mechanism 29 drives the second clamping assembly 24 to the open state. Then, the thirteenth cylinder 851 drives the pusher rod 852 to extend, pushing the coil module in the first carrier 2 horizontally out of the second bearing groove 221. The pushed coil module is sleeved on the pusher rod 852. The first clamping module 83 clamps the coil module on the pusher rod 852, and the second clamping module 84 clamps the connector in the wire harness assembly and pulls it off the first socket 26. The pusher rod 852 retracts, and the unloading unit 8 clamps the entire coil module and places it on the unloading conveyor line 9 to achieve unloading.

[0047] Due to space limitations, there is insufficient area around the equipment to accommodate the material feeding conveyor line 9. To optimize space utilization and facilitate material connection with downstream equipment, the material feeding conveyor line 9 is designed as a sunken structure, passing beneath the turntable 1. It extends from one X-axis side of the turntable 1 to the other X-axis side, with one end extending below the working area of ​​the material feeding unit 8 to receive the coil modules released by the unit. An NG (Not From Good) material box 70 for receiving defective products is also provided within the working area of ​​the material feeding unit 8.

[0048] This embodiment also provides a process method based on an automatic coil harness assembly and welding equipment 100, which includes the following steps: S1. Feeding and loading of coil assembly 200: S11. Insert the card 500 into the coil assembly 200, place the coil assembly 200 in a horizontal position in the second carrier 311, and transport it to the card pressing mechanism 32 below through the coil feeding conveyor 31. The card pressing mechanism 32 presses the card 500 on the coil assembly 200 into place, and then transports it to the designated position through the coil feeding conveyor 31. S12, the first conveying mechanism 33 takes out the coil assembly 200 from the second carrier 311 on the coil feeding conveyor line 31 and places it in a lying position into the receiving and transferring mechanism 34. The receiving and transferring mechanism 34 receives the coil assembly 200 and moves it to below the laser welding mechanism 35. S13, the laser welding mechanism 35 welds and fixes the card 500 onto the coil assembly 200, and then moves it to the designated position through the receiving and transfer mechanism 34; S14. The receiving and transferring mechanism 34 drives the coil assembly 200 to a standing position. The second conveying mechanism 36 takes out the standing coil assembly 200 from the receiving and transferring mechanism 34 and places it into the first carrier 2 on the turntable 1. The second pressing component 24 in the first carrier 2 presses and fixes it. S2. Turntable 1 rotates with coil assembly 200 to the wire harness loading station. The operator assembles the wire harness assembly onto coil assembly 200. Specifically, the connector of the wire harness assembly is inserted into the first socket 26, the circuit board 300 is assembled on the coil assembly 200 at the designated position, and the circuit board 300 is pressed and fixed by the first clamping component 23. The wire body is placed in the basket 27 to complete the loading of the wire harness assembly. S3. Turntable 1 rotates together with coil assembly 200 and wire harness assembly to the position of the first soldering mechanism 4. The first soldering mechanism 4 solders at least two non-adjacent pins on coil assembly 200 to circuit board 300. Then it rotates to the position of the second soldering mechanism 4. The second soldering mechanism 4 completes the soldering of at least two other non-adjacent pins to circuit board 300. This process continues until all pins on coil assembly 200 are soldered to circuit board 300. S4. Turntable 1 rotates with coil assembly 200 to the position of the first detection unit 5. The first vision camera 51 checks whether the coil assembly 200 and circuit board 300 are properly soldered. At the same time, the power module 52 is plugged into the second socket 28 to perform electrical performance testing. If the test is OK, proceed to the next step. If the first vision camera 51 fails the test, an alarm is issued and image information is uploaded to the first display screen 10. The operator makes a second judgment based on the image information on the first display screen 10. If the soldering of coil assembly 200 and circuit board 300 is deemed to be qualified, the first OK button 30 is pressed and the next step is executed. If it is deemed to be unqualified, the first NG button 40 is pressed and the turntable 1 rotates to the unloading unit 8, where it is processed as a defective product. S5. Turntable 1 rotates with coil assembly 200 to the position of the second detection unit 6. The second vision camera checks whether there is an overlap of the pole claws 201 inside the coil assembly 200. If there is no overlap, proceed to the next step. If there is overlap, an alarm is issued and image information is uploaded to the second display screen 20. The operator makes a second judgment based on the image information on the second display screen 20. If it is determined that there is no overlap of the pole claws 201, press the second OK button 50 and proceed to the next step. If it is determined that there is an overlap of the pole claws 201, press the second NG button 60 and rotate with turntable 1 to the unloading unit 8. The unloading unit 8 processes the product as a defective product. S6. Turntable 1 rotates with coil assembly 200 to insulating cover assembly and welding unit 7. Insulating cover feeding module 71 automatically and continuously supplies insulating cover 400. Third conveying mechanism 73 conveys and assembles insulating cover 400 onto coil assembly 200 in first carrier 2. Ultrasonic welding mechanism 74 welds insulating cover 400 and coil assembly 200 together, completing the welding assembly of insulating cover 400 and obtaining coil module. S7. Turntable 1 rotates with coil assembly 200 to unloading unit 8. According to the detection results of steps S4 and S5, unloading unit 8 transports qualified coil modules to unloading conveyor line 9 for output, and unqualified coil assemblies to NG material box 70.

[0049] For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this invention, and these all fall within the protection scope of this invention.

Claims

1. An automatic assembly and welding equipment for coil harnesses, characterized in that, This is used to weld a wire harness assembly and an insulating cover onto a coil assembly to obtain a coil module. The wire harness assembly includes a wire body, a circuit board located at one end of the wire body, and a connector located at the other end of the wire body. The automatic coil harness assembly and welding equipment includes: A turntable, on which a plurality of first carriers are arranged at equal angles, the first carriers including a positioning seat for carrying the coil assembly, a first socket for the connector to be inserted into, and a second socket electrically connected to the first socket; The coil feeding unit includes a coil feeding conveyor line for conveying coil assemblies along the X direction, a card pressing mechanism located above the coil feeding conveyor line, a first conveying mechanism disposed at one end of the coil feeding conveyor line, a receiving and transferring mechanism for receiving coil assemblies from the first conveying mechanism and transferring them along the Y direction, a laser welding mechanism disposed on the conveying path of the receiving and transferring mechanism for welding and fixing cards to the coil assemblies, and a second conveying mechanism for removing coil assemblies from the receiving and transferring mechanism and transferring them to the first carrier; the second carrier is conveyed on the coil feeding conveyor line. Wire harness loading station; Several soldering mechanisms, each soldering mechanism is used to complete the soldering of at least two non-adjacent PIN pins on the coil assembly to the circuit board; The first detection unit includes a first vision camera that detects whether the soldering of the coil assembly and the circuit board is qualified, and a power-on module that is plugged into the second socket. The second detection unit includes a second vision camera that detects whether there is an overlap of the pole claws inside the detection coil assembly; The insulating cover assembly and welding unit includes an insulating cover feeding module for supplying insulating covers, a dispensing module that connects to the output end of the insulating cover feeding module and separates the insulating covers one by one, a third conveying mechanism that transports the insulating covers on the dispensing module to the first carrier and assembles them together with the coil assembly, and an ultrasonic welding mechanism that welds the insulating covers together with the coil assembly. The unloading unit; the coil feeding and loading unit, the wire harness loading station, the plurality of soldering mechanisms, the first detection unit, the second detection unit, the insulating cover assembly and welding unit, and the unloading unit are arranged sequentially around the turntable.

2. The automatic coil harness assembly and welding equipment as described in claim 1, characterized in that, The first carrier further includes a fifth support plate fixed on the turntable for supporting the positioning seat, a pair of first clamping assemblies disposed on the positioning seat for pressing the two sides of the circuit board, a second clamping assembly for horizontally clamping the coil assembly, and a mounting plate fixed on the fifth support plate and located beside the positioning seat; the first socket is mounted on the front surface of the mounting plate, and the second socket is mounted on the rear surface of the mounting plate; a basket for supporting the wire body is provided at the lower end of the fifth support plate.

3. The automatic coil harness assembly and welding equipment as described in claim 2, characterized in that, The positioning seat is provided with a second bearing groove for carrying the coil assembly. The second bearing groove extends horizontally backward from the front surface of the positioning seat, and an inlet and outlet for the coil assembly is formed on the front surface of the positioning seat. A limiting plate is formed on the rear side of the second bearing groove to limit one end of the coil assembly in the axial direction. The second pressing component presses the coil assembly axially backward from the front side of the coil assembly onto the limiting plate. An operation opening is provided above the second bearing groove to facilitate the installation and soldering of the circuit board.

4. The automatic coil harness assembly and welding equipment as described in claim 2, characterized in that, The first carrier also includes an opening clamping mechanism that drives the second clamping component to switch to the open state; the opening clamping mechanism is provided below the turntable at the positions corresponding to the coil feeding unit and the unloading unit.

5. The automatic coil harness assembly and welding equipment as described in claim 1, characterized in that, The card pressing mechanism includes a first cylinder, a pressure plate that moves up and down driven by the first cylinder, and a sensor that detects whether there is a second carrier under the pressure plate; The first conveying mechanism includes a second cylinder, a first support plate that moves along the Y direction driven by the second cylinder, a third cylinder fixed on the first support plate, and a first gripper assembly that moves up and down driven by the third cylinder. The material receiving and transfer mechanism includes a first driving member, a second support plate driven by the first driving member to move along the Y direction, a first receiving plate rotatably disposed on the second support plate about the X axis, and a fifteenth cylinder fixed on the second support plate and driving the first receiving plate to reciprocate between a horizontal state and a standing state; the first receiving plate is provided with a first bearing groove for bearing and positioning the coil assembly.

6. The automatic coil harness assembly and welding equipment as described in claim 1, characterized in that, The second conveying mechanism includes a fourth cylinder, a third support plate driven by the fourth cylinder around the Z-axis, a fifth cylinder fixed on the third support plate, a fourth support plate driven by the fifth cylinder to move horizontally, and a second gripper assembly fixed on the fourth support plate.

7. The automatic coil harness assembly and welding equipment as described in claim 1, characterized in that, The wire harness loading station is equipped with a first display screen for displaying image information acquired by the first vision camera and a second display screen for displaying image information acquired by the second vision camera, a first OK button configured to send a signal indicating that the welding quality of the coil assembly and the circuit board is acceptable, a first NG button configured to send a signal indicating that the welding quality of the coil assembly and the circuit board is unacceptable, a second OK button configured to send a signal indicating that there is no overlap of the internal pole claws of the coil assembly, and a second NG button configured to send a signal indicating that there is overlap of the internal pole claws of the coil assembly.

8. The automatic coil harness assembly and welding equipment as described in claim 1, characterized in that, The material distribution module includes a ninth cylinder and a second receiving plate driven by the ninth cylinder and perpendicular to the material feeding direction of the insulating cover feeding module. The second receiving plate is provided with a receiving groove for supporting the insulating cover. The third conveying mechanism includes a second driving member, a seventh support plate driven by the second driving member to move horizontally, a tenth cylinder fixed on the seventh support plate, an eighth support plate driven by the tenth cylinder to move up and down, and an adsorption block provided on the eighth support plate for adsorbing the insulating cover. The adsorption block has a suction nozzle embedded inside, and the lower surface of the adsorption block is provided with a limiting stop around the suction nozzle for limiting the position of the insulating cover.

9. The automatic coil harness assembly and welding equipment as described in claim 1, characterized in that, The unloading unit includes a third driving member, a ninth support plate driven by the third driving member to move horizontally, a first clamping module fixed on the ninth support plate for clamping the coil module, a second clamping module fixed on the ninth support plate for clamping the connector inserted into the first socket, and an ejection unloading module that pushes the coil module radially outward from the rear of the first carrier; the ejection unloading module includes a thirteenth cylinder located behind the first carrier and a push rod driven by the thirteenth cylinder to move radially along the turntable.

10. A process method based on the automatic coil harness assembly and welding equipment according to claim 1, comprising the following steps: S1. Coil assembly feeding and loading: S11. Insert the card into the coil assembly, place the coil assembly in a horizontal position in the second carrier, and transport it to the card pressing mechanism below the coil feeding conveyor. The card pressing mechanism presses the card on the coil assembly into place, and then transports it to the designated position through the coil feeding conveyor. S12. The first conveying mechanism takes out the coil assembly from the second carrier on the coil feeding conveyor line and places it in a lying position into the receiving and transferring mechanism. The receiving and transferring mechanism receives the coil assembly and moves it to below the laser welding mechanism. S13. The laser welding mechanism welds and fixes the card onto the coil assembly, and then moves it to the designated position through the material receiving and transfer mechanism; S14. The receiving and transferring mechanism drives the coil assembly to a standing position, and the second conveying mechanism takes out the standing coil assembly from the receiving and transferring mechanism and places it into the first carrier on the turntable. S2. The turntable rotates with the coil assembly to the wire harness loading station. The operator assembles the wire harness assembly onto the coil assembly. Specifically, the connector of the wire harness assembly is inserted into the first socket, the circuit board is assembled into the designated position on the coil assembly, and the wire body is placed in the basket on the first carrier to complete the loading of the wire harness assembly. S3. The turntable rotates together with the coil assembly and the wire harness assembly to the first soldering mechanism position, and solders at least two non-adjacent PINs on the coil assembly to the circuit board through the first soldering mechanism; then rotates to the second soldering mechanism position, and completes the soldering of at least two other non-adjacent PINs to the circuit board through the second soldering mechanism position, and so on, until all PINs on the coil assembly are soldered to the circuit board. S4. The turntable rotates with the coil assembly to the first detection unit. The first vision camera checks whether the coil assembly and the circuit board are properly soldered. At the same time, the power module is plugged into the second socket to perform electrical performance testing. If all tests are OK, proceed to the next step. If the first vision camera fails the test, an alarm is issued and image information is simultaneously uploaded to the first display screen. The operator makes a secondary judgment based on the image information on the first display screen. If the coil assembly and the circuit board are deemed to be properly soldered, the first OK button is pressed and the next step is executed. If they are deemed to be unqualified, the first NG button is pressed, and the turntable rotates to the unloading unit, where it is processed as a defective product. S5. The turntable rotates with the coil assembly to the position of the second detection unit. The second vision camera checks whether there is any overlap between the pole claws inside the coil assembly. If there is no overlap, proceed to the next step. If there is overlap, an alarm is issued and image information is uploaded to the second display screen. The operator makes a second judgment based on the image information on the second display screen. If it is determined that there is no overlap between the pole claws, the second OK button is pressed and the next step is executed. If it is determined that there is overlap between the pole claws, the second NG button is pressed and the turntable rotates to the unloading unit, where it is processed as a defective product. S6. The turntable rotates the coil assembly to the insulation cover assembly and welding unit. The insulation cover feeding module automatically and continuously supplies the insulation cover in an orderly manner. The third conveying mechanism transports the insulation cover onto the coil assembly in the first carrier. The ultrasonic welding mechanism welds the insulation cover and the coil assembly together, completing the welding assembly of the insulation cover and obtaining the coil module. S7. The turntable rotates with the coil assembly to the unloading unit, and the unloading unit performs the product unloading operation according to the detection results of steps S4 and S5.

Images