Quick remodeling method for mixed wire production of multi-specification copper wire lamps
By introducing a rapid changeover method into the copper wire lamp production equipment, the problem of slow changeover speed has been solved, achieving seamless integration and efficient production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-12
- Publication Date
- 2026-03-13
AI Technical Summary
The slow changeover speed of existing copper wire lamp production equipment has greatly hampered production efficiency.
By introducing a rapid changeover method into copper wire lamp production equipment, which involves waiting for the wire feeding reel to pause feeding and cutting off the copper wire of the previous specification, connecting the copper wire of the current specification, simultaneously changing and winding the LED device, and finally stopping feeding when the connection point reaches the take-up reel, a seamless connection is achieved, reducing changeover time.
It enables rapid changeover of copper wire lamp production equipment, minimizing changeover time and eliminating the need for downtime, thereby improving production efficiency.
Smart Images
Figure CN121654907A_ABST
Abstract
Description
Technical Field
[0001] This application belongs to the field of copper wire lamp production technology, and in particular relates to a rapid changeover method for mixed-wire production of multi-specification copper wire lamps. Background Technology
[0002] Copper wire lamps are a simple type of light string that, when used with an IC controller, can achieve various lighting modes such as constant light, wave-like patterns, and flashing. Manufacturing copper wire lamps typically involves three steps: winding, soldering, and sealing. Winding refers to winding copper wire around a mold core to precisely control the spacing between the LED beads. Soldering refers to soldering the LED beads onto the copper wire. Sealing refers to sealing the copper wire with adhesive to achieve waterproof and corrosion-resistant properties.
[0003] Changeover refers to replacing molds or other components to allow production equipment to produce products of different specifications. For copper wire lamp production equipment, changeover mainly involves changing the wire feeding and take-up reels, as well as changing the LEDs during the welding process. Currently, changeover for copper wire lamp production equipment mainly relies on manual changeover after the production equipment has been completely shut down, which has the problems of slow changeover speed and greatly dragging down production efficiency. Summary of the Invention
[0004] This application provides a rapid changeover method for the production of mixed copper wire lamps of multiple specifications, which can solve the problem of slow changeover speed, which greatly hinders production efficiency.
[0005] In a first aspect, embodiments of this application provide a rapid changeover method for the mixed-wire production of multi-specification copper wire lamps, applied to rapid changeover equipment, used for rapid changeover of copper wire lamp production equipment. The copper wire lamp production equipment includes, in sequence, a wire feeding reel, a winding device, an LED welding device, a sealing device, and a wire take-up reel. The method includes: In response to the changeover information, the wire feeding reel is allowed to pause feeding. Then, the copper wire of the previous specification is cut at the outlet of the wire feeding reel, and the wire feeding reel is changed again. The changeover information is used to instruct the copper wire lamp production equipment to change the type. Connect the cut end of the copper wire of the previous specification to the beginning end of the copper wire of this specification, and mark it as the connection point; After waiting for the previous specification of copper wire to complete all LED welding and determine the connection point, the LED inventory of the LED welding device is changed according to the changeover information. At the same time, the wire feeding wheel feeds the copper wire of this specification, and the winding device winds the copper wire of this specification. Then, the wire feeding stops when the connection point reaches the inlet of the sealing device. After the LED welding is completed on the winding section of the copper wire of this specification and the sealing of the copper wire of the previous specification is completed, continue to release the wire. Then, stop releasing the wire when the connection point just reaches the take-up reel. Then disconnect the connection point and change the take-up reel. The take-up reel gathers the copper wire lamp produced by the copper wire of this specification.
[0006] The technical solutions described in this application embodiment have at least the following technical effects: In the rapid changeover method for mixed-wire production of multi-specification copper wire lamps provided in this application, firstly, in response to changeover information, the system waits for the feed reel to pause feeding and cuts the copper wire of the previous specification at the feed reel outlet, then changes the feed reel. In this step, after receiving the changeover information, the system waits for the feed reel to pause feeding, and during this pause, the copper wire of the previous specification is cut and changed to the current specification. This maximizes the overlap between the changeover time and the pause phase of the feed reel, thereby minimizing disruption to production efficiency. Secondly, the cut end of the copper wire of the previous specification is connected to the beginning end of the copper wire of the current specification, and marked as the connection point. This step connects the cut copper wire of the previous specification to the copper wire of the current specification, allowing the copper wire lamp production equipment to maintain uninterrupted production even during changeover. Subsequently, after waiting for the previous specification of copper wire to complete all LED soldering and determine the connection point, the LED inventory of the LED soldering device is changed according to the changeover information. At the same time, the wire feeding wheel feeds the current specification of copper wire, and the winding device winds the current specification of copper wire. The feeding stops when the connection point reaches the entrance of the sealing device. In this step, after the first two steps are completed, the LED inventory of the LED soldering device is prepared for the soldering of the current specification of copper wire. At the same time, the wire feeding wheel is operated to continue feeding the current specification of copper wire, and the winding device winds the current specification of copper wire. That is, the LED inventory change, the feeding of the current specification of copper wire, and the winding of the current specification of copper wire start simultaneously, and the feeding of the current specification of copper wire stops when the connection point reaches the entrance of the sealing device. Finally, after the LED welding of the winding section of the copper wire of this specification is completed and the sealing of the copper wire of the previous specification is completed, continue to feed the wire. Stop feeding the wire when the connection point just reaches the take-up reel. Then disconnect the connection point and change the take-up reel. The take-up reel gathers the copper wire lamp produced by the copper wire of this specification. In this step, after the previous step is completed, continue to feed the copper wire of this specification until the connection point just reaches the take-up reel. Stop feeding the wire when the connection point is stopped. During this feeding stop, disconnect the connection point and change the take-up reel. The take-up reel is connected to the beginning of the copper wire of this specification. This can maximize the overlap between the take-up reel changing time and the feeding stop time, thereby minimizing the impact on production efficiency. In this method, the copper wire lamp production equipment is a step-by-step production equipment with a stop-start mechanism. Therefore, the wire feeding rotation, wire take-up rotation, and LED inventory replacement are all embedded in the stop phase of the copper wire lamp production equipment, allowing for seamless connection between the previous specification of copper wire and the current specification of copper wire. This minimizes the changeover time and eliminates the need for machine downtime, thus solving the problem of slow changeover speed in existing copper wire lamp production equipment, which greatly hinders production efficiency.
[0007] Secondly, this application provides a quick changeover device applied to quick changeover equipment for quickly changing copper wire lamp production equipment. The copper wire lamp production equipment includes, in sequence, a wire feeding reel, a winding device, an LED welding device, a sealing device, and a wire take-up reel. The quick changeover device includes: The first type-changing unit is used to respond to type-changing information, wait for the wire feeding reel to stop feeding, then cut the copper wire of the previous specification at the outlet of the wire feeding reel, and then change the type of the wire feeding reel; wherein, the type-changing information is used to instruct the copper wire lamp production equipment to perform type-changing; The connection point unit is used to connect the cut end of the copper wire of the previous specification to the start end of the copper wire of the current specification, and marks it as the connection point; The second type-changing unit is used to change the LED inventory of the LED welding device according to the type-changing information after waiting for the previous specification of copper wire to complete all LED welding and determine the connection point. At the same time, the wire feeding wheel feeds the copper wire of this specification, and the wire winding device winds the copper wire of this specification. Then, the wire feeding stops when the connection point reaches the inlet of the sealing device. The third conversion unit is used to continue feeding wire after the LED welding of the winding part of the copper wire of this specification is completed and the sealing of the copper wire of the previous specification is completed. Then, the feeding is stopped when the connection point just reaches the take-up reel. The connection point is then disconnected and the take-up reel is converted. The take-up reel gathers the copper wire lamp produced by the copper wire of this specification.
[0008] Thirdly, embodiments of this application provide a quick changeover device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that the processor executes the computer program to implement the method described in any of the first aspects above.
[0009] Fourthly, embodiments of this application provide a computer-readable storage medium storing a computer program that, when executed by a processor, implements the method described in any of the first aspects above.
[0010] Fifthly, embodiments of this application provide a computer program product that, when run on a quick changeover device, causes the quick changeover device to execute the quick changeover method for producing mixed-wire multi-specification copper wire lamps as described in any of the first aspects above.
[0011] It is understood that the beneficial effects of the second to fifth aspects mentioned above can be found in the relevant descriptions in the first aspect mentioned above, and will not be repeated here. Attached Figure Description
[0012] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0013] Figure 1 This is a flowchart illustrating a rapid changeover method for producing mixed-wire lamps of multiple specifications provided in an embodiment of this application. Figure 2 This is a schematic diagram of the structure of a copper wire lamp production equipment provided in one embodiment of this application; Figure 3 This is a schematic diagram of the quick changeover equipment provided in this application embodiment applied to a copper wire lamp production equipment; Figure 4 This is a schematic diagram of the quick changeover device provided in the embodiments of this application; Figure 5 This is a schematic diagram of the structure of the quick changeover device provided in the embodiments of this application. Detailed Implementation
[0014] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.
[0015] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.
[0016] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.
[0017] As used in this application specification and the appended claims, the term "if" may be interpreted, depending on the context, as "when," "once," "in response to determination," or "in response to detection." Similarly, the phrase "if determined" or "if detected [the described condition or event]" may be interpreted, depending on the context, as meaning "once determined," "in response to determination," "once detected [the described condition or event]," or "in response to detection [the described condition or event]."
[0018] Furthermore, in the description of this application and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.
[0019] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.
[0020] In related technologies, copper wire lamps are simple light strings that, when used with an IC controller, can achieve various lighting modes such as constant light, wave-like patterns, and flashing. Manufacturing copper wire lamps typically involves three steps: winding, soldering, and sealing. Winding refers to winding copper wire around a mold core to precisely control the spacing between the LED beads. Soldering involves soldering the LED beads onto the copper wire. Sealing involves sealing the soldered copper wire with adhesive to achieve waterproofing and corrosion resistance. Changeover refers to replacing molds or other components to allow production equipment to produce products of different specifications. In copper wire lamp production equipment, changeover mainly involves changing the wire feeding and take-up reels, as well as changing the LEDs during the soldering process. Currently, changeover in copper wire lamp production equipment relies primarily on manual changeover after the equipment has completely stopped operating, resulting in slow changeover speeds and significantly hindering production efficiency.
[0021] To address the aforementioned problems, this application provides a rapid changeover method for mixed-wire production of multi-specification copper wire lamps. In this method, firstly, in response to changeover information, the system waits for the feed reel to pause feeding and cuts the copper wire of the previous specification at the feed reel outlet. Then, the feed reel is changed. In this step, upon receiving the changeover information, the system waits for the feed reel to pause feeding, and during this pause, the copper wire of the previous specification is cut and changed to the current specification. This maximizes the overlap between the changeover time and the pause phase of the feed reel, thereby minimizing disruption to production efficiency. Secondly, the cut end of the previous specification copper wire is connected to the beginning end of the current specification copper wire, and marked as the connection point. This step connects the cut end of the previous specification copper wire to the current specification copper wire, enabling the copper wire lamp production equipment to maintain uninterrupted production even during changeover. Subsequently, after waiting for the previous specification of copper wire to complete all LED soldering and determine the connection point, the LED inventory of the LED soldering device is changed according to the changeover information. At the same time, the wire feeding wheel feeds the current specification of copper wire, and the winding device winds the current specification of copper wire. The feeding stops when the connection point reaches the entrance of the sealing device. In this step, after the first two steps are completed, the LED inventory of the LED soldering device is prepared for the soldering of the current specification of copper wire. At the same time, the wire feeding wheel is operated to continue feeding the current specification of copper wire, and the winding device winds the current specification of copper wire. That is, the LED inventory change, the feeding of the current specification of copper wire, and the winding of the current specification of copper wire start simultaneously, and the feeding of the current specification of copper wire stops when the connection point reaches the entrance of the sealing device. Finally, after the LED welding of the winding section of the copper wire of this specification is completed and the sealing of the copper wire of the previous specification is completed, continue to feed the wire. Stop feeding the wire when the connection point just reaches the take-up reel. Then disconnect the connection point and change the take-up reel. The take-up reel gathers the copper wire lamp produced by the copper wire of this specification. In this step, after the previous step is completed, continue to feed the copper wire of this specification until the connection point just reaches the take-up reel. Stop feeding the wire when the connection point is stopped. During this feeding stop, disconnect the connection point and change the take-up reel. The take-up reel is connected to the beginning of the copper wire of this specification. This can maximize the overlap between the take-up reel changing time and the feeding stop time, thereby minimizing the impact on production efficiency. In this method, the copper wire lamp production equipment is a step-by-step production equipment with a stop-start mechanism. Therefore, the wire feeding rotation, wire take-up rotation, and LED inventory replacement are all embedded in the stop phase of the copper wire lamp production equipment, allowing for seamless connection between the previous specification of copper wire and the current specification of copper wire. This minimizes the changeover time and eliminates the need for machine downtime, thus solving the problem of slow changeover speed in existing copper wire lamp production equipment, which greatly hinders production efficiency.
[0022] The rapid changeover method for producing mixed copper wire lamps of various specifications provided in this application embodiment can be applied to rapid changeover equipment. In this case, the rapid changeover equipment is the executing entity of the rapid changeover method for producing mixed copper wire lamps of various specifications provided in this application embodiment. This application embodiment does not impose any restrictions on the specific type of rapid changeover equipment.
[0023] For example, a quick changeover device may include a first cutting device, a wire feeding reel changing device, a connection point setting device, an LED inventory changing device, a second cutting device, a take-up reel changing device, and a control device. The control device is communicatively connected to the first cutting device, the wire feeding reel changing device, the connection point setting device, the LED inventory changing device, the second cutting device, and the take-up reel changing device. The control device is also communicatively connected to the copper wire lamp production equipment. The first cutting device may be an electric cutting device, such as electric shears, located at the outlet of the wire feeding reel, used to cut the copper wire released from the reel. The wire feeding reel changing device may be a robotic arm or a reel changing device, located beside the wire feeding reel and used to change the type of the wire feeding reel. The connection point setting device may be an electric twisting clamp, located beside the first cutting device, used to twist two separated copper wires together (like an electric vise twisting two sections of copper wire), or a connection clamp mounting device including an electric twisting device and a detachable clamp, for connecting two separated copper wires... When the wires converge at a single point, a detachable clamp is installed at the convergence point. An electric twisting device then twists the clamp to further reinforce the connection and separate it. The LED inventory changing device can be a robotic arm or a rotating wheel-type device, located at the LED inventory of the LED welding device, used to change the LED inventory of the LED welding device. The second cutting device can be the same as the first cutting device, located at the inlet of the take-up reel, used to cut off the connection point. The take-up reel changing device can be a robotic arm or a rotating wheel-type device, located beside the take-up reel and used to change the take-up reel. The control device can control the first cutting device to cut the copper wire, control the pay-off reel changing device to change the pay-off reel, control the connection point setting device to establish a connection point between the two separated copper wires, control the LED inventory changing device to change the LED inventory of the LED welding device, control the second cutting device to cut off the connection point, and control the pay-off reel changing device to change the take-up reel. The control device can also communicate with the copper wire lamp production equipment to obtain the feeding time and stop feeding time of the feeding wheel, whether the LED welding device has completed welding, and whether the sealing device has completed sealing. It can also take over the feeding and stopping of the feeding wheel during the changeover period. For example, it can control the feeding wheel to feed after waiting for the previous specification of copper wire to complete all LED welding and determine the connection point; it can also control the feeding wheel to feed after waiting for the winding part of the current specification of copper wire to complete LED welding and the previous specification of copper wire to complete sealing.
[0024] The control device can be a microcontroller, microprocessor, mobile phone, tablet computer, laptop computer, desktop computer, computer, or laptop computer.
[0025] To better understand the rapid changeover method for producing mixed-wire lamps with multiple specifications of copper wire provided in this application, the specific implementation process of the rapid changeover method for producing mixed-wire lamps with multiple specifications of copper wire provided in this application will be described below by way of example.
[0026] Figure 1 This illustration shows a schematic flowchart of a rapid changeover method for producing mixed-spec copper wire lamps according to an embodiment of this application. Applied to rapid changeover equipment, it is used to quickly change over copper wire lamp production equipment. The copper wire lamp production equipment includes, in sequence, a wire feeding reel, a winding device, an LED welding device, a sealing device, and a wire take-up reel. The rapid changeover method for producing mixed-spec copper wire lamps includes: S100, in response to the changeover information, waits for the feed reel to pause feeding, then cuts the previous specification copper wire at the feed reel outlet, and then changes the feed reel again. The changeover information is used to instruct the copper wire lamp production equipment to perform a changeover.
[0027] Understandable. Figure 2 The diagram shows the structure of a copper wire lamp production equipment. The equipment, in sequence, includes a wire feeding reel, a winding device, an LED welding device, a sealing device, and a take-up reel. The wire feeding reel feeds out copper wire of the corresponding specifications. The winding device can be a winding table, which evenly winds the copper wire around the table. The LED welding device can be a copper wire lamp chip mounter with welding capabilities, used to attach LEDs to the wound copper wire and weld them. The sealing device can be a glue sprayer, used to seal the semi-finished copper wire lamp with welded LEDs. The take-up reel collects the finished copper wire lamps.
[0028] The changeover information specifies the changeover steps in the rapid changeover process, instructing the copper wire lamp production equipment to perform the changeover. After the execution entity of this method detects the changeover information, it first waits for the feed reel to pause feeding (the feed reel feeds periodically). During the pause, the first cutting device cuts the copper wire of the previous specification from the feed reel outlet. Immediately after cutting, the feed reel is changed using the feed reel changeover device, and the changeover target is determined from the changeover information.
[0029] This setup, which cuts off the previous specification of copper wire and replaces it with the current specification during the pause in the wire feeding phase, maximizes the overlap between the wire feeding reel replacement time and the pause phase, thus minimizing the impact on production efficiency during the wire feeding reel replacement process.
[0030] S200: Connect the cut end of the copper wire of the previous specification to the beginning end of the copper wire of this specification, and mark it as the connection point.
[0031] It can be understood that the previous specification copper wire refers to the copper wire left in the copper wire lamp production equipment by the wire feeding reel before the conversion, while the current specification copper wire refers to the copper wire fed out by the wire feeding reel after the conversion. After the wire feeding reel is converted, the cut end of the previous specification copper wire is connected to the beginning end of the current specification copper wire. The two copper wires can be connected by a connection point device. This connection point device can be a twist clamp, located next to the first cutting device, used to twist the two separated copper wires together; the twist point is the connection point. Alternatively, it can be a connection clamp installation device used to install the clamp connecting the two separated copper wires. The movement distance of the connection point can be determined by the wire feeding length, and the location of the connection point can be calculated based on the fixed dimensions of each device in the copper wire lamp production equipment.
[0032] Optionally, the connection point is a node formed by connecting the cut end of a copper wire of a previous specification to the beginning end of a copper wire of the current specification using a magnetic clamp. The copper wire lamp production equipment includes a magnetic measuring device at the critical node. This device is used to detect whether the distance between the magnetic measuring device and the connection point is less than a threshold distance. The critical node includes at least the inlet of the sealing device and the inlet of the take-up reel. The method includes: S210, when the magnetic measuring device detects that its distance from the connection point is less than a threshold distance, it sends a first signal to the quick changeover device. The first signal reflects which critical node the connection point has reached.
[0033] It is understandable that a clamp made of magnetic material connects the cut end of a copper wire of the previous specification to the beginning end of a copper wire of the current specification. The magnetic material clamp can be of various connection structures, and its function is to connect the two copper wires and make them magnetic. At the key node of the copper wire lamp production equipment, there is a magnetic measuring device, which can be of various magnetometers, used to detect the magnetic material clamp within a threshold distance (the closer the distance, the higher the measured magnetic field strength; when the magnetic field strength is higher than the preset threshold, it means that the magnetic material clamp is within the threshold distance). When a magnetic measuring device detects the magnetic material clamp within the threshold distance, it sends a first signal to the quick changeover equipment. The first signal reflects the key node where the magnetic measuring device is located, that is, the key node reached by the connection point.
[0034] This setting can improve the accuracy of the obtained connection point positions.
[0035] Optionally, both the copper wire lamp production equipment and the quick changeover equipment are made of non-ferromagnetic materials.
[0036] It is understandable that copper wire lamp production equipment and quick changeover equipment can use aluminum parts or other non-ferromagnetic materials.
[0037] This design prevents ferromagnetic materials from affecting the measurement accuracy of the magnetic measuring device.
[0038] S300: After waiting for the previous specification of copper wire to complete all LED welding and determine the connection point, the LED inventory of the LED welding device is changed according to the changeover information. At the same time, the wire feeding wheel feeds the copper wire of this specification, and the winding device winds the copper wire of this specification. Then, the wire feeding stops when the connection point reaches the entrance of the sealing device.
[0039] It is understandable that after receiving the changeover information, the control device communicates with the copper wire lamp production equipment and takes over the feeding and stopping of the feeding reel. The control device obtains the welding progress of the LED welding device from the copper wire lamp production equipment. When all LED welding of the previous specification of copper wire is completed and the connection point is determined, the following operations are performed simultaneously: the feeding reel is controlled to perform the next round of feeding, stopping feeding when the connection point reaches the entrance of the sealing device; the copper wire fed in this round is all of the same specification, and the winding device is controlled to wind the fed copper wire of the same specification; in response to the changeover information, the LED inventory changeover device is controlled to change the LED inventory of the LED welding device. The above three steps are not sequential and start simultaneously. Furthermore, the size of the LEDs in each specification of copper wire lamp is kept as similar as possible to avoid the need to change the surface mount head of the LED welding device.
[0040] S400: After the LED welding of the winding part of the copper wire of this specification is completed and the sealing of the copper wire of the previous specification is completed, continue to release the wire. Then, stop releasing the wire when the connection point just reaches the take-up reel. Then disconnect the connection point and change the take-up reel. The take-up reel gathers the copper wire lamp produced by the copper wire of this specification.
[0041] It is understandable that in step S300, the copper wire of this specification released by the pay-off reel is simultaneously wound. After the winding is completed, the LED welding device automatically welds LED beads onto the wound copper wire. Therefore, we first wait for the winding portion of the copper wire of this specification to complete the LED welding. Simultaneously, the connection point has reached the entrance of the sealing device following the pay-off stage of the pay-off reel (i.e., the previous specification of copper wire is entirely in the sealing device). Therefore, the sealing device also simultaneously seals the previous specification of copper wire. After waiting for the winding portion of the copper wire of this specification to complete the LED welding and the previous specification of copper wire to complete the sealing, the pay-off reel continues the next pay-off cycle. Pay-off stops when the connection point just reaches the take-up reel. After pay-off stops, the second cutting device is controlled to cut at the connection point, and then the take-up reel changing device is controlled to change the take-up reel (using a new take-up reel to gather the copper wire lamp of this specification). The take-up reel can gather the copper wire lamp produced by the copper wire of this specification.
[0042] This design takes into account that the copper wire lamp production equipment is a step-by-step production equipment with a stop-start mechanism. Therefore, the wire feeding rotation, wire take-up rotation, and LED inventory changeover are all embedded within the stop phase of the copper wire lamp production equipment, allowing for a seamless connection between the previous specification of copper wire and the current specification of copper wire. This minimizes changeover time and eliminates the need for machine downtime, solving the problem of slow changeover speed in existing copper wire lamp production equipment, which greatly hinders production efficiency.
[0043] Optionally, the take-up reel has magnetic adsorption points on its surface; disconnecting the connection point and replacing the take-up reel includes: S410 involves cutting the wire from the previous specification copper wire, ensuring the magnetic material clip remains intact on the beginning of the current specification copper wire, and then changing the take-up reel. The magnetic material clip automatically attaches to the magnetic adsorption point on the changed take-up reel.
[0044] Under normal circumstances, when the take-up reel starts taking up the wire, the copper wire needs to be manually wound around the reel several times beforehand, and then the remaining copper wire is taken up using the friction between the copper wire and the surface of the take-up reel. This process can hinder the automation of take-up reel switching. Therefore, magnetic adsorption points can be provided on the surface of the take-up reel. The magnetic adsorption points can be permanent magnets or electromagnets, used to automatically adsorb the magnetic material clips on the beginning of the copper wire of this specification. The take-up reel can be slowly rotated before adsorption, and the slow rotation can be stopped after successful adsorption (the success of adsorption can be detected by a magnetic measuring device).
[0045] This setup facilitates automation of the take-up rotation type.
[0046] Optionally, the various devices in the copper wire lamp production equipment operate asynchronously, with the outlet of the LED welding device being one of the key nodes. After changing the LED inventory of the LED welding device based on the changeover information, the method further includes the following steps before the connection point reaches the inlet of the encapsulation device: S510: Wait for the connection point to reach the outlet of the LED welding device, then let the pay-off reel idle, and stop the winding device and LED welding device. Let the take-up reel and sealing device run synchronously until the connection point reaches the inlet of the sealing device, and then restart the pay-off reel, winding device and LED welding device. During the pay-off reel idle period, the take-up reel pulls the copper wire.
[0047] It is understandable that in all the methods described above, the various devices in the copper wire lamp production equipment operate synchronously, meaning that the semi-finished products processed by the previous device are immediately sent to the next device for further processing, with no surplus semi-finished products between devices. However, the various devices in the copper wire lamp production equipment can also operate asynchronously. In this case, there can be a large number of semi-finished products with soldered LEDs but not yet sealed between the LED soldering device and the sealing device, making it impossible to directly apply the above-mentioned quick changeover method. Therefore, it is necessary to add the following steps after changing the LED inventory of the LED soldering device according to the changeover information and before the connection point reaches the inlet of the sealing device, so that the quick changeover method can be applied to asynchronously operating copper wire lamp production equipment. The added steps include: waiting for the connection point to reach the outlet of the LED soldering device, then idling the wire feeding reel, stopping the winding device and the LED soldering device, allowing the take-up reel and the sealing device to run synchronously until the connection point reaches the inlet of the sealing device, and then restarting the wire feeding reel, the winding device, and the LED soldering device. After the connection point reaches the outlet of the LED welding device, immediately let the wire feeding reel idle (idle means without generating power or resistance), and stop the winding device and the LED welding device. This ensures that the remaining semi-finished products between the LED welding device and the sealing device belong to the previous specification of copper wire. Then, let the take-up reel and the sealing device run synchronously until the connection point reaches the inlet of the sealing device. Then, restart the wire feeding reel, the winding device, and the LED welding device to complete the welding of the remaining semi-finished products between the LED welding device and the sealing device. This allows the asynchronously running copper wire lamp production equipment to be the same as the synchronously running copper wire lamp production equipment, making it suitable for the above-mentioned quick changeover method.
[0048] This configuration allows the quick changeover method in this application to also be applied to asynchronous copper wire lamp production equipment.
[0049] Optionally, when the quick changeover equipment or copper wire lamp production equipment is not properly shut down and restarted, the method also includes: S520, during the first cycle, uses a magnetic measuring device to detect connection points in real time. When a connection point is detected, based on the critical node where the connection point is located, the corresponding step in the rapid changeover method is executed. Here, the first cycle refers to the time required to complete one rapid changeover.
[0050] It is understandable that various unforeseen circumstances may occur that cause the quick changeover equipment or copper wire lamp production equipment to fail to shut down properly (such as power outages or emergency braking). In such cases, the quick changeover equipment may be performing a quick changeover process on the copper wire lamp production equipment. This can result in some parts of the equipment completing the changeover while others fail, leading to unsatisfactory product output. Therefore, it is necessary to perform a check before restarting the quick changeover equipment or copper wire lamp production equipment if it fails to shut down properly, to determine whether a quick changeover process was in progress at the time of the failure. If confirmed, the remaining parts of the quick changeover process should be completed. It should be noted that determining whether the equipment has shut down properly is a common existing technology and will not be elaborated upon here.
[0051] The quick changeover equipment uses all magnetic measuring devices to detect connection points in real time during the first cycle. The first cycle refers to the time required to complete one quick changeover process, which is also the complete time for detecting connection points (i.e., it can be determined whether the quick changeover process is being executed when the machine is not properly shut down). If a connection point is detected at any time during the first cycle, it means that the quick changeover equipment or the copper wire lamp production equipment is executing the quick changeover process when it is not properly shut down. Based on the critical node where the connection point is located, the execution progress of the incomplete quick changeover process is determined, and the quick changeover process continues to be executed from the corresponding step in the quick changeover process. That is, the quick changeover process continues to be completed from the corresponding execution progress, allowing the copper wire lamp production equipment to perform a complete changeover.
[0052] This setup allows the quick changeover equipment or copper wire lamp production equipment to continue executing the incomplete quick changeover process on the next startup if it fails to shut down properly.
[0053] Optionally, the method also includes: S530, if the second type change information is received during the execution of the fast type change method, then determine whether the connection point has been determined during the execution of the fast type change method.
[0054] It is understood that the quick changeover method in this application begins from the moment the quick changeover device receives the changeover information. Operators may enter unintended changeover information due to operational errors. In this case, the operator will re-enter the correct changeover information. Since the changeover process takes a considerable amount of time, it is necessary to consider a solution for detecting the changeover information again during the execution of the quick changeover method. In the quick changeover method, the connection point can be used as a dividing point to define an undetermined connection point stage and a determined connection point stage. In the undetermined connection point stage, no changeover has been performed, so the changeover information can be directly replaced. However, in the determined connection point stage, at least the feed reel has been changed, making the situation more complex, and the changeover information cannot be directly replaced.
[0055] S540, if the connection point is not determined, the second change information is used to replace the change information; if the connection point is determined, a new fast change method is executed based on the second change information to obtain the second connection point; wherein, the copper wire lamp production equipment does not process the copper wire between the connection point and the second connection point.
[0056] It is understandable that in the stage where the connection point is not determined, no changeover has been performed, so the second changeover information can be directly used to replace the original changeover information. In the stage where the connection point is determined, some equipment has already completed the changeover and produced some semi-finished copper wire lamps. First, the rapid changeover method is re-executed based on the second changeover information, and then the second connection point is obtained. At this point, the copper wire includes both the connection point and the second connection point. The semi-finished copper wire lamps between the connection point and the second connection point are unwanted erroneous products produced due to operator error. Therefore, after receiving the second changeover information during the rapid changeover process, the copper wire lamp production equipment will not process the copper wire between the connection point and the second connection point to save materials. When the rapid changeover method is re-executed, this portion of semi-finished copper wire lamps will be cut off at both ends and will not be collected by any take-up reel.
[0057] This setup effectively addresses situations where operators repeatedly input changeover signals and saves production materials.
[0058] Optionally, when LEDs of different specifications have different sizes, the method further includes: S550, while maintaining the LED inventory of the LED welding device, also performs a corresponding upgrade of the LED welding device, so that the upgraded LED welding device can be adapted to the upgraded LED.
[0059] It is understandable that when soldering LEDs onto copper wire, a dedicated copper wire lamp chip mounter is typically used to mount the LEDs before soldering. However, chip mounters have different sizes of mounting heads to accommodate LEDs of varying sizes. When LEDs of different sizes are used, it is necessary to change the mounting head in the LED soldering device. A copper wire lamp chip mounter capable of automatically changing mounting heads can be used, along with a pre-prepared table of copper wire lamp specifications and mounting head types. This allows for the replacement of the mounting head while maintaining the LED inventory in the LED soldering device, ensuring that the soldering device can adapt to the changed LEDs.
[0060] This setup allows the method to be applied even when LEDs of different specifications have different sizes.
[0061] Optionally, when using magnetic material clips as the device for forming connection points, both the copper wire lamp production equipment and the quick changeover equipment are made of non-ferromagnetic materials.
[0062] It is understandable that when a magnetic material clip is used as a device to form a connection point, the magnetic field emitted by the magnetic material clip can indicate the position of the connection point. Therefore, it is advisable to use non-ferromagnetic materials, such as aluminum, for both copper wire lamp production equipment and quick changeover equipment, so that the magnetic field emitted by the magnetic material clip is not disturbed.
[0063] This design reduces the impact on the function of the magnetic material clamp.
[0064] Figure 3 The diagram shows a quick changeover device applied to a copper wire lamp production equipment. The quick changeover device includes a first cutting device, a wire feeding and changing device, a connection point setting device, an LED inventory changing device, a second cutting device, a take-up changing device, and a control device. The control device is communicatively connected to the first cutting device, the wire feeding and changing device, the connection point setting device, the LED inventory changing device, the second cutting device, and the take-up changing device. The control device is also communicatively connected to the copper wire lamp production equipment. The first cutting device can be an electrically powered cutting device, such as an electric shear, located at the outlet of the pay-off reel to cut the copper wire released from the pay-off reel; the pay-off reel changing device can be a robotic arm or a changing reel device, located next to the pay-off reel and used to change the type of the pay-off reel; the connection point setting device can be a twisting clamp, located next to the first cutting device, used to twist the two separated copper wires together, or a connecting clamp mounting device, used to install clamps connecting the two separated copper wires; the LED inventory changing device can be a robotic arm or a changing reel device, located at the LED inventory of the LED welding device, used to change the type of the LED inventory of the LED welding device; the second cutting device can be the same as the first cutting device, located at the inlet of the take-up reel, used to cut the connection point; the take-up reel changing device can be a robotic arm or a changing reel device, located next to the take-up reel and used to change the type of the take-up reel.
[0065] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.
[0066] Corresponding to the rapid changeover method for producing mixed-wire lamps of multiple specifications described in the above embodiments, this application also provides a rapid changeover device, the various units of which can realize the various steps of the rapid changeover method for producing mixed-wire lamps of multiple specifications. Figure 4 A structural block diagram of the quick changeover device provided in the embodiments of this application is shown. For ease of explanation, only the parts related to the embodiments of this application are shown.
[0067] Reference Figure 4 The device includes: The first type-changing unit is used to respond to type-changing information, wait for the wire feeding reel to stop feeding, then cut the copper wire of the previous specification at the outlet of the wire feeding reel, and then change the type of the wire feeding reel; wherein, the type-changing information is used to instruct the copper wire lamp production equipment to perform type-changing; The connection point unit is used to connect the cut end of the copper wire of the previous specification to the start end of the copper wire of the current specification, and marks it as the connection point; The second type-changing unit is used to change the LED inventory of the LED welding device according to the type-changing information after waiting for the previous specification of copper wire to complete all LED welding and determine the connection point. At the same time, the wire feeding wheel feeds the copper wire of this specification, and the wire winding device winds the copper wire of this specification. Then, the wire feeding stops when the connection point reaches the inlet of the sealing device. The third conversion unit is used to continue feeding wire after the LED welding of the winding part of the copper wire of this specification is completed and the sealing of the copper wire of the previous specification is completed. Then, the feeding is stopped when the connection point just reaches the take-up reel. The connection point is then disconnected and the take-up reel is converted. The take-up reel gathers the copper wire lamp produced by the copper wire of this specification.
[0068] It should be noted that the information interaction and execution process between the above-mentioned units are based on the same concept as the method embodiments of this application. For details on their specific functions and technical effects, please refer to the method embodiments section, which will not be repeated here.
[0069] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units is used as an example. In practical applications, the above functions can be assigned to different functional units as needed, that is, the internal structure of the device can be divided into different functional units to complete all or part of the functions described above. The functional units in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units are only for easy differentiation and are not intended to limit the scope of protection of this application. The specific working process of the units in the above system can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.
[0070] This application also provides a quick changeover device. Figure 5 This is a schematic diagram of the structure of a quick changeover device provided in one embodiment of this application. Figure 5As shown, the quick changeover device of this embodiment includes a first cutting device, a pay-off changing device, a connection point setting device, an LED inventory changing device, a second cutting device, a take-up changing device, and a control device 5. The control device is communicatively connected to the first cutting device, the pay-off changing device, the connection point setting device, the LED inventory changing device, the second cutting device, and the take-up changing device. The control device 5 of the quick changeover device in this embodiment includes at least one processor 50. Figure 5 Only one is shown in the image), at least one memory 51 ( Figure 5 (Only one is shown in the image) and a computer program 52 stored in the at least one memory 51 and executable on the at least one processor 50. When the processor 50 executes the computer program 52, it causes the control device 5 of the quick changeover device to perform the steps in any of the above embodiments of the quick changeover method for producing mixed multi-specification copper wire lamps, or causes the control device 5 of the quick changeover device to perform the functions of each unit in the above embodiments of the device.
[0071] For example, the computer program 52 may be divided into one or more units, which are stored in the memory 51 and executed by the processor 50 to complete this application. The one or more units may be a series of computer program instruction segments capable of performing a specific function, which describe the execution process of the computer program 52 in the control device 5 of the quick changeover equipment.
[0072] The control device 5 of the quick-change device can be a microcontroller, microprocessor, mobile phone, tablet computer, wearable device, vehicle-mounted device, laptop computer, ultra-mobile personal computer (UMPC), netbook, personal digital assistant (PDA), desktop computer, smart screen, smart TV, or handheld device with wireless communication capabilities. The control device 5 of the quick-change device may include, but is not limited to, a processor 50 and a memory 51. Those skilled in the art will understand that... Figure 5 This is merely an example of the control device 5 for a quick changeover device and does not constitute a limitation on the control device 5 for a quick changeover device. It may include more or fewer components than shown, or combine certain components, or different components, such as input / output devices, network access devices, buses, etc.
[0073] The processor 50 can be a Central Processing Unit (CPU), or it can be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor.
[0074] In some embodiments, the memory 51 may be an internal storage unit of the control device 5 of the quick-change device, such as a hard disk or memory of the control device 5. In other embodiments, the memory 51 may be an external storage device of the control device 5, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc., equipped on the control device 5. Further, the memory 51 may include both internal and external storage units of the control device 5. The memory 51 is used to store the operating system, applications, bootloader, data, and other programs, such as the program code of the computer program. The memory 51 can also be used to temporarily store data that has been output or will be output.
[0075] This application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the steps in any of the above method embodiments.
[0076] This application provides a computer program product that, when run on a quick changeover device, enables the quick changeover device to implement the steps in any of the above method embodiments.
[0077] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the methods of the above embodiments of this application can be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include at least: any entity or device capable of carrying computer program code to a quick-change device, a recording medium, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium. Examples include USB flash drives, portable hard drives, magnetic disks, or optical disks.
[0078] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.
[0079] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.
[0080] In the embodiments provided in this application, it should be understood that the disclosed rapid changeover method, rapid changeover device, and rapid changeover equipment for producing multi-specification copper wire lamps can be implemented in other ways. For example, the embodiments of the rapid changeover method, rapid changeover device, and rapid changeover equipment for producing multi-specification copper wire lamps described above are merely illustrative. For instance, the division of units is merely a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the displayed or discussed mutual coupling or direct coupling or communication connection may be an indirect coupling or communication connection through some interfaces, devices, or units, and may be electrical, mechanical, or other forms.
[0081] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.
[0082] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.
Claims
1. A rapid changeover method for producing mixed-wire lamps with multiple specifications of copper wire, characterized in that, This method is applied to quick changeover equipment for rapidly changing copper wire lamp production equipment. The copper wire lamp production equipment includes, in sequence, a wire feeding reel, a winding device, an LED welding device, a sealing device, and a wire take-up reel. The method includes: In response to the changeover information, the wire feeding reel is allowed to pause feeding. Then, the copper wire of the previous specification is cut at the outlet of the wire feeding reel, and the wire feeding reel is changed again. The changeover information is used to instruct the copper wire lamp production equipment to change the type. Connect the cut end of the copper wire of the previous specification to the beginning end of the copper wire of this specification, and mark it as the connection point; After waiting for the previous specification of copper wire to complete all LED welding and determine the connection point, the LED inventory of the LED welding device is changed according to the changeover information. At the same time, the wire feeding wheel feeds the copper wire of this specification, and the winding device winds the copper wire of this specification. Then, the wire feeding stops when the connection point reaches the inlet of the sealing device. After the LED welding is completed on the winding section of the copper wire of this specification and the sealing of the copper wire of the previous specification is completed, continue to release the wire. Then, stop releasing the wire when the connection point just reaches the take-up reel. Then disconnect the connection point and change the take-up reel. The take-up reel gathers the copper wire lamp produced by the copper wire of this specification.
2. The rapid changeover method for producing mixed-wire lamps of multiple specifications as described in claim 1, characterized in that, The connection point is a node formed by connecting the cut end of a copper wire of a previous specification to the beginning end of a copper wire of the current specification using a magnetic clamp. The copper wire lamp production equipment includes a magnetic measuring device at a key node. This magnetic measuring device is used to detect whether the distance between itself and the connection point is less than a threshold distance. The key node includes at least the inlet of the sealing device and the inlet of the take-up reel. The method includes: When the magnetic measuring device detects that its distance from the connection point is less than a threshold distance, it sends a first signal to the quick changeover device; wherein the first signal is used to reflect which key node the connection point has reached.
3. The rapid changeover method for producing mixed-wire lamps of multiple specifications as described in claim 2, characterized in that, The take-up reel has magnetic adsorption points on its surface; disconnecting the connection point and replacing the take-up reel includes: Cut the copper wire of the previous specification, leaving the magnetic material clip intact on the beginning of the current specification copper wire, and then change the take-up reel; wherein, the magnetic material clip and the magnetic adsorption point on the changed take-up reel automatically adsorb together.
4. The rapid changeover method for producing mixed-wire lamps of multiple specifications as described in claim 2, characterized in that, The various devices in the copper wire lamp production equipment operate asynchronously, and the outlet of the LED welding device is one of the key nodes. After the LED inventory of the welding LED device is changed according to the changeover information, and before the connection point reaches the inlet of the sealing device, the method further includes: Wait for the connection point to reach the outlet of the LED welding device, then let the wire feeding reel idle, the winding device and the LED welding device stop, and let the wire take-up reel and the sealing device run synchronously until the connection point reaches the inlet of the sealing device. Then let the wire feeding reel, the winding device and the LED welding device restart. In this case, after the wire feeding reel is idle, the wire take-up reel pulls the copper wire.
5. The rapid changeover method for producing mixed-wire lamps of multiple specifications as described in claim 2, characterized in that, When the quick changeover equipment or the copper wire lamp production equipment fails to shut down properly and restarts, the method further includes: During the first cycle, the connection point is detected in real time by the magnetic measuring device. When the connection point is detected, the rapid changeover method continues to be executed from the corresponding step in the rapid changeover method according to the key node where the connection point is located. Herein, the first cycle refers to the time required to complete one rapid changeover method.
6. The rapid changeover method for producing mixed-wire lamps of multiple specifications as described in claim 2, characterized in that, Both the copper wire lamp production equipment and the quick changeover equipment are made of non-ferromagnetic materials.
7. The rapid changeover method for producing mixed-wire lamps of multiple specifications as described in claim 1, characterized in that, The method further includes: If a second type change information is received during the execution of the fast type change method, it is determined whether the connection point has been determined during the execution of the fast type change method. If the connection point is not determined, the second type change information is used to replace the type change information; if the connection point is determined, a new rapid type change method is executed based on the second type change information to obtain the second connection point; wherein, the copper wire lamp production equipment does not process the copper wire located between the connection point and the second connection point.
8. The rapid changeover method for mixed-wire production of multi-specification copper wire lamps as described in claim 1, characterized in that, When LEDs of different specifications have different sizes, the method further includes: While replacing the LED inventory of the welding LED device, the welding LED device itself is also replaced accordingly, so that the welding LED device can be adapted to the replaced LED.
9. A quick changeover device, characterized in that, This device is used in quick changeover equipment for rapidly changing the configuration of copper wire lamp production equipment. The copper wire lamp production equipment includes, in sequence, a wire feeding reel, a winding device, an LED welding device, a sealing device, and a wire take-up reel. The quick changeover device includes: The first type-changing unit is used to respond to type-changing information, wait for the wire feeding reel to stop feeding, then cut the copper wire of the previous specification at the outlet of the wire feeding reel, and then change the type of the wire feeding reel; wherein, the type-changing information is used to instruct the copper wire lamp production equipment to perform type-changing; The connection point unit is used to connect the cut end of the copper wire of the previous specification to the start end of the copper wire of the current specification, and marks it as the connection point; The second type-changing unit is used to change the LED inventory of the LED welding device according to the type-changing information after waiting for the previous specification of copper wire to complete all LED welding and determine the connection point. At the same time, the wire feeding wheel feeds the copper wire of this specification, and the wire winding device winds the copper wire of this specification. Then, the wire feeding stops when the connection point reaches the inlet of the sealing device. The third conversion unit is used to continue feeding wire after the LED welding of the winding part of the copper wire of this specification is completed and the sealing of the copper wire of the previous specification is completed. Then, the feeding is stopped when the connection point just reaches the take-up reel. The connection point is then disconnected and the take-up reel is converted. The take-up reel gathers the copper wire lamp produced by the copper wire of this specification.
10. A quick changeover device, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the method as described in any one of claims 1 to 8.