Keyboard automatic assembly and detection integrated process

Abstract

The invention provides an automatic keyboard assembling and detecting integrated process, and relates to the technical field of keyboard production. The keyboard keycap detection machine, the bottom plate feeding machine, the keycap assembly all-in-one machine and the multi-station detection equipment are integrated, a full-process automatic production line from keycap detection feeding, bottom plate feeding labeling, keycap and bottom plate assembly to finished product multi-dimensional detection is constructed, all procedures are connected, traditional manual operation is replaced, the production efficiency is improved, and the production efficiency is improved. The problems of low efficiency, large errors and the like caused by manual operation are reduced, continuity and high efficiency of the production process are achieved, automatic equipment has high continuous operation capacity, the operation speed is stable and efficient, the production yield in unit time can be increased, the production cycle can be shortened, and the large-scale keyboard production requirement can be met.

Description

Technical Field

[0001] This invention relates to the field of keyboard manufacturing technology, and more specifically, to an integrated process for automated keyboard assembly and testing. Background Technology

[0002] In the keyboard manufacturing industry, keycap assembly is a core and critical step. In the traditional keyboard production process, the assembly process mainly relies on manual visual inspection and manual operation. This production mode has many significant drawbacks. On the one hand, manual operation is inefficient. With the continuous expansion of the keyboard market demand and the continuous growth of production scale, manual operation can no longer meet the needs of high-efficiency production. It has gradually become a bottleneck restricting the efficiency improvement of the entire production process, resulting in extended production cycles and failing to meet the actual needs of large-scale mass production. On the other hand, the accuracy of manual inspection is easily affected by subjective factors such as the operator's fatigue and concentration. The inspection results are unstable and prone to problems such as missed inspections and false inspections, which in turn affect the consistency of product quality. Summary of the Invention

[0003] This invention provides an integrated automated keyboard assembly and testing process. The automated production line achieves keyboard assembly and testing, including a keycap testing machine, a base plate loading machine, a labeling machine, a keycap assembly machine, and testing equipment. The process includes the following steps: S1. Keycap inspection and loading: The keycap tray A, which carries the keycaps, is placed on the tray one of the keyboard keycap testing machine. The keycap tray A is positioned by the positioning rod of the positioning structure. The drive motor drives the lifting screw to rotate, and the height of the tray one is adjusted to a suitable picking position through the transmission block. The linear modules 1, 2, and 3 of the picking robot work together to drive the vacuum suction cup of the tray to move above the keycap tray A. After adsorbing the keycap tray A, it is transferred to the transfer tray at one point of the lifting structure. The limiting frame at the top of the transfer tray fixes the keycap tray A. The lifting structure transports the transfer pallet containing the keycap tray A to the upper conveyor of the double-layer conveyor. During the transfer, the detection camera on the gantry, together with the lighting, captures images of the keycap tray A. The vision detection system determines whether keycaps are missing. If a keycap is detected as missing, an alarm is triggered, and the defective tray is manually removed. If the inspection is successful, the transfer pallet continues to be transported to the feeding end of the keycap assembly machine. S2. Base plate loading and labeling: The loading tray carrying the keyboard base plate is stacked on the second tray of the base plate loading machine. The positioning area is formed by the positioning column of the positioning component to position the loading tray. The drive motor drives the adjusting screw to rotate and the height of the second tray is adjusted to a suitable material picking position through the transmission seat. Linear modules four, five, and six of the feeding mechanism work together to drive the vacuum chamber to move above the feeding tray. The small suction cups at the bottom of the vacuum chamber contact and adhere to the base plate, while the FPC vacuum suction cups adhere to the FPC on the base plate. The feeding mechanism moves the adsorbed base plate to the detection structure, the supplementary light provides supplementary light, the detection camera two collects images of the base plate, and determines whether the position of the base plate is deviated. If there is a deviation, the rotary motor drives the connecting plate three to rotate, thereby adjusting the base plate to the correct position. After positioning, the base plate is conveyed to the labeling machine, which affixes a QR code and waterproof label to the base plate. After labeling, the base plate is conveyed to the feeding end of the keycap assembly machine. S3 assembly operation: The keycap assembly machine receives the qualified keycaps from step S1 and the labeled base plate from step S2, and completes the automated assembly of the keycaps and base plate. The assembled semi-finished products are then transported to the manual assembly station for irregularly shaped keys, where manual assembly of the irregularly shaped keys is completed.

[0004] Compared with the prior art, the beneficial effects of the present invention are as follows: In the scheme of this application: This application integrates a keyboard keycap testing machine, a base plate loading machine, a keycap assembly machine, and multi-station testing equipment to construct a fully automated production line that spans from keycap testing and loading, base plate loading and labeling, keycap and base plate assembly to multi-dimensional testing of finished products. The seamless integration of each process replaces traditional manual operation, reducing the inefficiencies and errors associated with manual operation. This achieves continuous and efficient production. The automated equipment possesses strong continuous operation capabilities, with stable and efficient operating speeds, increasing production output per unit time, shortening the production cycle, and adapting to the needs of large-scale keyboard production. Attached Figure Description

[0005] Figure 1 A schematic diagram of the automated production line provided in this application; Figure 2 A top view of the automated production line provided in this application; Figure 3 This is a schematic diagram of the keyboard keycap testing machine provided in this application; Figure 4 A schematic diagram of the feeding structure provided in this application; Figure 5 This is a schematic diagram of the material handling robot provided in this application; Figure 6 This is a schematic diagram of the structure of the tray vacuum suction cup provided in this application; Figure 7 This is a schematic diagram of the structure of the pallet and the material detection sensor provided in this application; Figure 8 A schematic diagram of the positioning structure provided in this application; Figure 9 A partial structural schematic diagram of the second lifting structure provided in this application; Figure 10This is a structural schematic diagram of the short-range belt conveyor provided in this application; Figure 11 A schematic diagram illustrating the structure of the transfer pallet provided in this application when it is transported in the upper conveyor of a double-layer conveyor; Figure 12 This is a structural schematic diagram of the base plate loading machine provided in this application; Figure 13 This is a structural diagram of the top of the loading cabinet provided in this application; Figure 14 This is a structural diagram of the bottom of the loading cabinet and pallet recycling vehicle provided in this application; Figure 15 A schematic diagram of the positioning component provided in this application; Figure 16 A bottom view of the structure of the second pallet provided in this application; Figure 17 A schematic diagram of the structure of the fixing frame provided in this application; Figure 18 This is a schematic diagram of the detection structure provided in this application; Figure 19 A schematic diagram of the lifting structure provided in this application; Figure 20 A bottom view of the lifting platform provided in this application; Figure 21 A schematic diagram of the structure of the transfer tray provided in this application; Figure 22 A schematic diagram of the structure when the base plate provided in this application is placed between the transfer tray and the base plate positioning frame; Figure 23 A schematic diagram of the feeding structure provided in this application; Figure 24 This is a structural schematic diagram of the linear module six provided in this application; Figure 25 A schematic diagram of the structure of the vacuum connection tube provided in this application. Detailed Implementation

[0006] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0007] It should be noted that, unless otherwise specified, the embodiments and features and technical solutions in the embodiments of the present invention can be combined with each other.

[0008] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0009] Example 1, as Figures 1-2As shown, an integrated automated keyboard assembly and testing process is implemented using an automated production line. The automated production line includes a keycap testing machine 1, a base plate loading machine 2, a labeling machine 3, a keycap assembly machine 4, and testing equipment. The process includes the following steps: S1. Keycap inspection and loading: The keycap tray A, which carries the keycaps, is stacked on the tray 104 of the keyboard keycap testing machine 1. The keycap tray A is positioned by the positioning rod 1066 of the positioning structure 106. The drive motor drives the lifting screw 1062 to rotate. The height of the tray 104 is adjusted to a suitable picking position by the transmission block 1063. The linear modules 1031, 1036, and 1038 of the picking robot 103 work together with the drive tray vacuum suction cup 1035 to move above the keycap tray A, and after adsorbing the keycap tray A, transfer it to the transfer tray 112 at the lifting structure 107. The limiting frame 1121 at the top of the transfer tray 112 fixes the keycap tray A. The lifting structure 107 transports the transfer tray 112 containing the keycap tray A to the upper conveyor of the double-layer conveyor 109. During the transfer, the detection camera 111 on the gantry 110, in conjunction with the lighting, captures images of the keycap tray A. The visual inspection system determines whether keycaps are missing. If a keycap is detected as missing, an alarm is triggered, and the defective tray is manually removed. If the inspection is successful, the transfer tray 112 continues to be transported to the feeding end of the keycap assembly machine 4. After the keycaps are removed, the empty keycap tray A moves with the transfer tray 112 to the lifting structure 108. The short-range belt conveyor 1087 of the lifting structure 108 connects to the upper conveyor to receive the transfer tray 112. After the empty keycap tray A is removed, the belt-type linear module 1089 drives the short-range belt conveyor 1087 to descend and connect to the lower conveyor, transporting the empty transfer tray 112 back to the lifting structure 107, completing the cycle. S2. Base plate loading and labeling: The loading tray 207 carrying the keyboard base plate is stacked on the second tray 2084 of the base plate loading machine 2. The positioning area is formed by the positioning post 20812 of the positioning component 208 to position the loading tray 207. The drive motor drives the adjusting screw 2082 to rotate, and the height of the second tray 2084 is adjusted to a suitable material picking position through the transmission seat 2083. The linear modules 4 2031, 5 2033, and 6 2034 of the feeding mechanism 203 work together to drive the vacuum chamber 2037 to move above the feeding tray 207. The small suction cup 20371 at the bottom of the vacuum chamber 2037 contacts and adsorbs the base plate, while the FPC vacuum suction cup 2038 adsorbs the FPC on the base plate. The feeding mechanism 203 moves the adsorbed base plate to the detection structure 204, the supplementary light 2042 provides supplementary light, the detection camera 2043 collects the image of the base plate, and determines whether the position of the base plate is deviated. If there is a deviation, the rotary motor 2036 drives the connecting plate 3 2039 to rotate, thereby adjusting the base plate to the correct position. After positioning, the base plate is conveyed to the labeling machine 3, where the labeling machine 3 affixes a QR code and a waterproof label to the base plate. After labeling, the base plate is conveyed to the feeding end of the keycap assembly machine 4. After labeling, the base plate is placed in the base plate positioning frame 2061 of the transfer tray 206. The short-range belt conveyor 2055 of the lifting structure 3 205 transports the transfer tray 206 to the upper layer of the double-layer belt conveyor. The empty transfer tray 206 is transported back to the short-range belt conveyor 2055 through the lower layer of the double-layer belt conveyor, completing the cycle. The empty loading pallet 207 is picked up by the loading mechanism 203 and placed into the pallet recycling cart 209 for recycling. S3 assembly operation: The keycap assembly machine 4 receives the qualified keycaps from step S1 and the labeled base plate from step S2, and completes the automated assembly of the keycaps and base plate. The assembled semi-finished products are then transported to the irregular key manual assembly station 6, where manual assembly of the irregular keys is completed.

[0010] The testing equipment includes, in sequence: a key core appearance inspection machine 8, a key core crack inspection machine 9, a key core noise detection machine 10, a key core pull-out and key height testing machine 12, an ATE testing machine 13, a key core backlight plate attaching and pressure holding machine 14, a key core backlight uniformity testing machine 15, a key core front and back light leakage detection and indicator light detection machine 16, a multi-functional testing machine 17, and a second lifting machine 18; the output direction of the keycap assembly machine 4 is equipped with a manual assembly station 6 for irregularly shaped keys; a manual repair point 1 7 is set at the key core appearance inspection machine 8, a manual repair point 2 11 is set at the key core pull-out and key height testing machine 12, and a manual repair point 3 19 is set at the ATE testing machine 13.

[0011] Furthermore, it also includes S4 multi-station inspection, specifically including: Key core appearance inspection: The semi-finished products after the irregular key assembly are sent to the key core appearance full inspection machine 8 for a comprehensive inspection of the key core appearance. Products that fail the inspection are transferred to the manual repair point 7 for repair. Key core crack detection: Products that pass the appearance inspection are sent to the key core crack full inspection machine 9 to detect whether there are cracks in the key core; Key core noise detection: Products that pass the crack detection are sent to the key core noise detection machine 10 to detect whether there is any noise when the key core is pressed; Key core pulling and key height testing: Products that pass the noise test are sent to the key core pulling and key height testing machine 12 for key core pulling and key height dimension testing. Products that fail the test are transferred to manual repair point 2 11 for repair.

[0012] Furthermore, multi-station inspection also includes: ATE Testing: Products that pass the pull-out and key height tests are sent to ATE testing machine 13 for electrical performance testing. Products that fail the tests are sent to manual repair point 3 19 for repair. Backlight panel mounting and pressure holding: Products that pass ATE testing are transported to the backlight panel mounting and pressure holding machine 14 to complete the backlight panel mounting and pressure holding process; Backlight uniformity test: After pressure holding, the product is transported to the key core backlight uniformity tester 15 to test the backlight uniformity of the key core. Light leakage and indicator light detection: Products that pass the backlight uniformity test are sent to the key core front and back light leakage detection and indicator light detection machine 16 to detect whether there is light leakage on the key core front and back and whether the indicator lights are working properly.

[0013] Furthermore, multi-station inspection also includes: Multifunctional testing: Products that pass the light leakage and indicator light tests are sent to the multifunctional testing machine 17 for AIO character, conductive film PIN and GAP testing; Finished product output: Products that pass the multi-functional inspection are transported to the finished product area by the No. 2 elevator 18 to complete the entire assembly and inspection process.

[0014] The multi-functional inspection machine 17 integrates an optical character recognition module, a conductive film PIN inspection module, and a GAP inspection module. The optical character recognition module is used to read AIO characters and compare them with a standard character library. The conductive film PIN inspection module uses probes to detect the conductivity and contact resistance of the conductive film PIN pins. The GAP inspection module uses a laser rangefinder to detect the gap between the key core and the base plate.

[0015] The keyboard core appearance inspection machine 8 uses machine vision inspection technology. It uses a high-definition camera to capture images of the keyboard core appearance and compares them with preset standard appearance images to detect whether there are scratches, stains, deformations and defects on the surface of the keyboard core.

[0016] The keycap assembly machine 4 is set in the output direction of the keyboard keycap inspection machine 1 and the base plate loading machine 2. The keyboard keycap inspection machine 1 and the base plate loading machine 2 are used for keycap inspection and loading and base plate loading, respectively. The labeling machine 3 is used to affix QR codes and waterproof labels to the base plate. The keycap assembly machine 4 is used for assembling the keycaps and the base plate. The testing equipment is used for testing the keycaps and the base plate after assembly.

[0017] Example 2, please refer to Figures 3-11 The keyboard keycap testing machine 1 includes a double-layer conveyor 109, which has upper and lower layers. Lifting structure 2 108 and lifting structure 1 107 are respectively installed at both ends of the double-layer conveyor 109. A feeding structure is installed at lifting structure 1 107. A gantry frame 110 is also installed on the double-layer conveyor 109, and a detection camera 111 is installed on the gantry frame 110. The detection camera 111 is equipped with a light. Several transfer stations are circulated between lifting structure 1 107, lifting structure 2 108, and the upper and lower layers of the double-layer conveyor 109. The top of the transfer tray 112 is equipped with a limiting frame 1121. The transfer tray 112 and the limiting frame 1121 work together to position the keycap tray A. The keycap tray A is used to carry and position the keycaps. The detection camera 111 can capture images of the keycap tray A in the transfer tray 112 after passing through the upper conveyor of the double-layer conveyor 109. In conjunction with the existing vision inspection system, it can determine whether there are any missing keycaps in the keycap tray A, so as to realize automated detection. The limiting frame 1121 is bolted to the transfer tray 112, and its shape and size correspond to the keycap tray A.

[0018] Furthermore, guide wheels 1122 are provided at each of the four corners of the transfer pallet 112. The guide wheels 1122 can reduce the friction and collision between the transfer pallet 112 and other components during the transportation process, thereby improving the transportation stability. The lifting structure 107 has the same structure as the lifting structure 2 108. The lifting structure 2 108 includes a cabinet 2 1081, in which a lifting plate 1084 is provided. A slide rail 4 1082 is installed in the cabinet 2 1081. A slider 4 1083 is slidably connected to the outer surface of the slide rail 4 1082, and the slider 4 1083 is connected to the lifting plate 1084. The slider 4 1083 and the slide rail 4 1082 cooperate to limit the lifting plate 1084, thereby improving the stability of the lifting plate 1084 during lifting. A belt-type linear module 1089 is provided in the cabinet 2 1081. The movable end of 89 is connected to the lifting plate 1084. The bottom of the lifting plate 1084 is equipped with a cylinder 3 1085. The piston rod of the cylinder 3 1085 extends above the lifting plate 1084 and is connected to the lifting plate 2 1086. The top of the lifting plate 2 1086 is connected to the short-distance belt conveyor 1087. The cylinder 3 1085 can drive the lifting plate 2 1086 to rise and fall, thereby driving the short-distance belt conveyor 1087 to rise and fall. The bottom of the lifting plate 2 1086 is equipped with a limit rod 1088, and the bottom end of the limit rod 1088 passes through the lifting plate 1084. The belt-type linear module 1089 is used to drive the lifting plate 1084 to rise and fall, so as to realize the switching of the short-distance belt conveyor 1087 between the upper and lower layers of the double-layer conveyor 109. The transfer tray 112 can move between the short-distance belt conveyor 1087 and the double-layer conveyor 109.

[0019] Furthermore, the feeding structure includes a cabinet 101, a lifting structure 107 located at the end away from the double-layer conveyor 109 inside the cabinet 101, a detection cover 102 installed on the top of the cabinet 101, a material handling robot 103 installed inside the detection cover 102, a pallet 104 located inside the detection cover 102 and a support plate 105 located below the pallet 104 installed on the top of the cabinet 101, a positioning structure 106 provided between the support plate 105 and the pallet 104, a keycap tray A can be stacked on the pallet 104, and the positioning structure 106 is used to position the keycap tray A stacked on the pallet 104.

[0020] Furthermore, the material handling robot 103 includes a linear module three 1038 installed inside the inspection cover 102. The moving end of the linear module three 1038 is connected to a connecting frame three 1037. The connecting frame three 1037 is connected to a linear module two 1036. The moving end of the linear module two 1036 is connected to a linear module one 1031. The moving end of the linear module one 1031 is connected to a connecting frame one 1032. The bottom of the connecting frame one 1032 is connected to a support rod 1033. Several support plates 1034 are connected to the support rod 1033. The support plates 1034 are connected to a tray vacuum suction cup 1035. The tray vacuum suction cup 1035 is used to adsorb the keycap tray A. The linear module three 1038, the connecting frame three 1037, the linear module two 1036, and the linear module one 1031 cooperate with each other to drive the connecting frame one 1032 to move in three axes.

[0021] Furthermore, the positioning structure 106 includes a support frame 1061 installed on the cabinet 101. A lifting screw 1062 is rotatably connected to the support frame 1061 via bearings. A drive motor is provided between the lifting screw 1062 and the support frame 1061. A screw nut is provided on the outer surface of the lifting screw 1062, and a transmission block 1063 is connected to the screw nut. The transmission block 1063 is connected to the side of the tray 104. When the drive motor drives the lifting screw 1062 to rotate, it can drive the tray 104 to rise and fall through the screw nut and the transmission block 1063. That is, the height of the tray 104 can be adjusted according to the number of keycap trays A stacked on the top of the tray 104. A connecting plate 1064 is installed on the side of the tray 104. A slider 1067 is connected to the connecting plate 1064. The slider 1067 is connected to a slide rail 1065, and the slide rail 1065 is installed on the inner wall of the cabinet 101.

[0022] Furthermore, a movable frame 1069 and several fixed plates 1068 are installed on the top of the support plate 105. Multiple positioning rods 1066 are installed on the top of both the movable frame 1069 and the fixed plates 1068. The top ends of the positioning rods 1066 pass through the support plate 104. A slide rail 10610 is provided below the movable frame 1069. A second slider is slidably connected to the slide rail 10610, and the second slider is connected to the bottom of the movable frame 1069. A cylinder 10611 is installed on the frame 1069. The piston rod of the cylinder 10611 is connected to a limit block. When the piston rod of the cylinder 10611 extends, the limit block contacts the top of the support plate 105. After the cylinder 10611 drives the corresponding limit block to separate from the support plate 105, the movable frame 1069 can be moved, thereby adjusting the distance between the positioning rod 1066 on the movable frame 1069 and the positioning rod 1066 on the fixed plate 1068.

[0023] Furthermore, a fixed plate 10612 and a movable frame 10613 parallel to the fixed plate 10612 are also installed on the top of the support plate 105. Multiple positioning rods 1066 with their tips passing through the support plate 104 are also installed on the top of both the fixed plate 10612 and the movable frame 10613. A slide rail 10614 is provided below the movable frame 10613, and a third slider is slidably connected to the slide rail 10614, and the third slider is connected to the bottom of the movable frame 10613. A cylinder 10615 is installed on the movable frame 10613. The piston rod of the cylinder 10615 is also connected to a limit block. When the piston rod of the cylinder 10615 extends, the limit block contacts the top of the support plate 105. After the cylinder 10615 drives the corresponding limit block to separate from the support plate 105, the movable frame 10613 can be moved, thereby adjusting the distance between the positioning rod 1066 on the movable frame 10613 and the positioning rod 1066 on the fixed plate 10612.

[0024] Furthermore, the moving direction of the second movable frame 10613 is perpendicular to the moving direction of the first movable frame 1069. Multiple positioning rods 1066 form several positioning areas on the first tray 104 for positioning the keycap tray A. The first tray 104 has notches for the positioning rods 1066 to pass through and move.

[0025] Furthermore, a material detection sensor 1041 is installed at the bottom of the pallet 104. The number and position of the material detection sensors 1041 correspond to the number and position of the positioning areas. The pallet 104 is provided with detection holes for the material detection sensors 1041 to detect. When the keycap tray A in the corresponding positioning area at the top of the pallet 104 is completely removed, the material detection sensor 1041 can detect the corresponding signal. By configuring an alarm, the staff can be reminded to load material onto the top of the pallet 104. The control of cylinder 10611 and cylinder 20615 is manual.

[0026] For ease of understanding, this application uses B to represent keycaps and marks them in the figure. In use, after the tray 104 descends, the operator stacks multiple keycap trays A containing keycaps in the positioning area on top of the tray 104. The keycap trays A are positioned by the positioning rod 1066. The linear module 3 1038, the connecting bracket 3 1037, the linear module 2 1036, and the linear module 1 1031 cooperate to drive the connecting bracket 1032 to move in three axes, so that the tray vacuum suction cup 1035 can pick up the keycap trays A and move them to the desired position. At lifting structure 107, a transfer tray 112 is located at its top. A tray vacuum suction cup 1035 moves the keycap tray A between the transfer tray 112 and the limiting frame 1121 at the top of lifting structure 107. Then, the tray vacuum suction cup 1035 releases the keycap tray A and returns to the tray 104. Lifting structure 107 then transports the transfer tray 112 containing the keycap tray A and the keycaps to the upper conveyor of the double-layer conveyor 109. The upper conveyor drives the transfer tray 112 towards lifting structure 2 10. The device moves in eight directions. During this process, information is collected by detection camera 111 for visual inspection. If it fails, an alarm is triggered, and the keycap is manually removed. If it passes, the keyboard in keycap tray A is removed by keycap assembly machine 4, and the empty keycap tray A moves to lifting structure 108. When transfer tray 112 and the empty keycap tray A reach lifting structure 108, short-distance belt conveyor 1087 connects to the upper conveyor, causing transfer tray 112 to move onto short-distance belt conveyor 1087, and the empty keycap tray A is removed. The conveyor belt 1087 descends to connect with the lower conveyor to transport the empty transfer pallet 112 to the lower conveyor. The lower conveyor moves the empty transfer pallet 112 to the lifting structure 107, which lifts the empty transfer pallet 112 upward. Then, the picking robot 103 continues to put the keycap tray A with the keyboard into the tray. This cycle is repeated to complete the loading and inspection of the keycaps. During the process, as the picking robot 103 takes away the keycap tray A on the pallet 104, the pallet 104 gradually rises.

[0027] Example 3, please refer to Figures 12-25The base plate loading machine 2 includes a loading mechanism 203, which includes a drive structure. The drive structure is connected to a connecting plate 3 2039. A vacuum chamber 2037 is provided below the connecting plate 3 2039. Several small suction cups 20371 are connected to the side of the vacuum chamber 2037 away from the connecting plate 3 2039, and a vacuum connecting pipe 20372 is connected to the side of the vacuum chamber 2037. Several bushings 20373 are installed on the connecting plate 3 2039. Step bolts 20374 are inserted and connected between the bushings 20373 and the connecting plate 3 2039. One end is connected to the vacuum chamber 2037. The outer surface of the stepped bolt 20374 is fitted with a spring 20375 located on the side of the bushing 20373 away from the connecting plate 2039. The spring 20375 is used to provide cushioning at the moment when the small suction cup 20371 contacts the base plate. The small suction cup 20371 can penetrate into the small gap between the key positions of the keyboard circuit base plate and provide multiple adsorption points. Compared with traditional vacuum suction cups, it increases the number of adsorption points with the base plate, making the adsorption more stable and reducing the problem of the base plate falling off due to unstable adsorption during transportation, thereby improving production efficiency and product quality.

[0028] Furthermore, the drive structure includes a linear module four 2031, a connecting frame three 2032 connected to the moving end of the linear module four 2031, a linear module five 2033 connected to the connecting frame three 2032, a linear module six 2034 connected to the moving end of the linear module five 2033, a connecting frame four 2035 connected to the moving end of the linear module six 2034, a rotary motor 2036 mounted on the connecting frame four 2035, and the output end of the rotary motor 2036 connected to the connecting plate three 2039. A mounting plate 20381 is also installed on the connecting plate 3 2039. The mounting plate 20381 is connected to the FPC vacuum suction cup 2038, which is used to adsorb the FPC on the base plate. The linear module 4 2031, the connecting frame 3 2032, the linear module 5 2033, and the linear module 6 2034 work together to drive the vacuum chamber 2037 to move in three axes. The rotary motor 2036 can drive the connecting plate 3 2039 to rotate, thereby driving the vacuum chamber 2037 to rotate.

[0029] Furthermore, the feeding mechanism 203 is connected to the feeding machine cover 202, and the bottom of the feeding machine cover 202 is connected to the feeding machine cabinet 201, and the linear module four 2031 is installed on the top inside the feeding machine cover 202.

[0030] Furthermore, the loading cabinet 201 is equipped with a positioning component 208 and a pallet recycling cart 209 located on one side of the positioning component 208. The positioning component 208 is equipped with several loading pallets 207 for carrying the keyboard base plate. The loading cabinet 201 is also equipped with a detection structure 204 and a lifting structure 205. The lifting structure 205 is equipped with a transfer tray 206. A base plate positioning frame 2061 is installed on the top of the transfer tray 206, and rollers 2062 are connected to the four corners of the transfer tray 206. The transfer tray 206 and the base plate positioning frame 2061 cooperate with each other to position the base plate, so that the base plate is straight. For ease of understanding, this application uses C to represent the base plate and it is marked in the figure.

[0031] Furthermore, the detection structure 204 includes a mounting bracket 2041 installed in the loading cabinet 201. The mounting bracket 2041 is equipped with a second detection camera 2043 and a supplementary light 2042 located above the second detection camera 2043. After the loading mechanism 203 picks up the bottom plate from the loading tray 207, it moves it to the detection structure 204. Visual inspection is performed by the second detection camera 2043 to determine whether the bottom plate is in the correct position. If there is any deviation, the rotary motor 2036 rotates to adjust the position of the bottom plate.

[0032] Furthermore, the positioning component 208 includes a second support frame 2081 mounted on the loading cabinet 201. A second support plate 20813 is connected to the bottom of the second support frame 2081. An adjusting screw 2082 is rotatably connected between the second support plate 20813 and the second support frame 2081 via a bearing. The adjusting screw 2082 is equipped with a drive motor, and a transmission seat 2083 is threaded onto the adjusting screw 2082. A second pallet 2084 is connected to the side of the transmission seat 2083, and the loading pallet 207 is placed on it. On pallet 2084, a connecting plate 2086 is connected, and a slider 2087 is connected to the connecting plate 2086. The slider 2087 is slidably connected to a slide rail 2088. The slide rail 2088 is installed on the inner side of the support frame 2081. The drive motor can drive pallet 2084 to rise and fall by adjusting the lead screw 2082 and the transmission seat 2083, thereby adjusting the height of pallet 2084 according to the number of loading pallets 207 on pallet 2084. The second support plate 20813 is also equipped with a second cylinder 20810. The telescopic end of the second cylinder 20810 is connected to a clamping plate 20811, and the clamping plate 20811 is in contact with the pallet recycling cart 209. The clamping plate 20811 and the second cylinder 20810 cooperate to fix the pallet recycling cart 209 in the loading cabinet 201, so as to reduce the situation of the pallet recycling cart 209 moving on its own.

[0033] Furthermore, a fixing frame 20817 is provided on the top of the support plate 20813. Positioning posts 20812 are installed on the tops of the movable plates 20814, 20815, and 30816. The tops of the positioning posts 20812 pass through the support plate 2084 and extend above it. The second plate 2084 has a notch for the positioning post 20812 to move and pass through. The positioning posts 20812 on the top of the first moving plate 20814, the second moving plate 20815, the fixed frame 20817, and the third moving plate 20816 are respectively located on the four sides of the loading pallet 207 to form a positioning area for positioning the loading pallet 207. The positioning posts 20812 can position the loading pallet 207 to reduce the displacement of the loading pallet 207.

[0034] Furthermore, sliders 3 are installed at the bottom of movable plates 1 (20814), 2 (20815), and 3 (20816), and sliders 3 are connected to slide rails 3 (20819). Slide rails 3 (20819) are installed on the top of support plate 2 (20813). Cylinders 3 (20818) are installed on movable plates 1 (20814), 2 (20815), and 3 (20816). The telescopic end of cylinders 3 (20818) is connected to a limit block, and the limit block contacts the top of support plate 2 (20813). The moving direction of slide rails 3 (20819) is perpendicular to that of movable plate 2 (20815), and the moving direction of movable plate 2 (20815) is the same as that of movable plate 3 (20816). By moving movable plates 1 (20814), 2 (20815), and 3 (20816), the corresponding positioning columns 20812 can be adjusted, thereby adapting to different sizes of loading pallets 207.

[0035] Furthermore, a material detection sensor 2085 is installed at the bottom of pallet 2084. The number of material detection sensors 2085 is the same as the number of positioning areas, and pallet 2084 has detection through holes corresponding to the material detection sensors 2085. When the loading tray 207 on pallet 2084 is completely removed, the material detection sensor 2085 cannot detect the tray through the detection through hole, thus triggering a signal. By configuring an alarm, the staff can be reminded to load material onto the top of pallet 2084.

[0036] Furthermore, the lifting structure 3 205 includes a protective cabinet 2051 located at the loading cabinet 201. The protective cabinet 2051 contains a lifting plate 1 2052 and a belt-driven linear module 2059 connected to the lifting plate 1 2052. The belt-driven linear module 2059 drives the lifting plate 1 2052 to lift. A slider 1 2057 is connected to the lifting plate 1 2052, and a slide rail 2058 is connected to the slider 1 2057. The slide rail 2058 is installed inside the protective cabinet 2051. A cylinder 2054 is installed at the bottom of the lifting plate 1 2052. The telescopic end of the cylinder 2054 is connected to a lifting plate 2053 located above the lifting plate 1 2052. A short-stroke belt conveyor is installed at the top of the lifting plate 2053. The bottom of conveyor 2055 and lifting plate 2053 is equipped with a vertical rod 2056. The bottom end of the vertical rod 2056 passes through lifting plate 1 2052 and extends to the bottom of lifting plate 1 2052. The transfer tray 206 is placed on top of short-distance belt conveyor 2055. The belt-type linear module 2059 drives lifting plate 1 2052 to rise and fall, thereby driving short-distance belt conveyor 2055 to rise and fall. The side of lifting structure 3 205 away from the loading cabinet 201 is used in conjunction with the existing double-layer belt conveyor. The upper layer of the double-layer belt conveyor is used to transport the transfer tray 206 with the bottom plate to other processing equipment, while the upper layer of the double-layer belt conveyor is used to transport the empty transfer tray 206 back to short-distance belt conveyor 2055.

[0037] The control of each component in this application relies on the existing PLC control system. The various sensors, solenoid valves, drivers and circuit connections required for the operation of the PLC control system are all existing technologies. The specific circuit layout and program writing can be configured according to the actual equipment parameters. This is existing technology and will not be described in detail in this application. Cylinder 3 20818 adopts a manual control mode, which facilitates flexible adjustment of the position of the positioning column 20812 during equipment debugging and maintenance.

[0038] Adjusting screw 2082 rotates to drive transmission seat 2083 to descend. Transmission seat 2083 drives pallet 2084 to descend, and then the loading tray 207 with the base plate is stacked on top of pallet 2084. Linear module 4 2031, connecting frame 3 2032, linear module 5 2033, and linear module 6 2034 work together to drive vacuum chamber 2037 to move in three axes, so as to move vacuum chamber 2037 to loading tray 207, and small suction cup 2037. 1. The vacuum suction cup 2038 contacts and adsorbs the FPC on the base plate. Then, the vacuum chamber 2037 moves towards the detection structure 204. The detection structure 204 performs visual inspection to determine if the base plate is deflected. If it is deflected, the rotary motor 2036 causes the vacuum chamber 2037 to rotate and straighten the base plate. After straightening, the feeding mechanism 203 places the base plate between the top of the transfer tray 206 and the base plate positioning frame 2061. The short-distance belt conveyor 205... 5. The transfer tray 206 is driven to the upper layer of the existing double-layer belt conveyor, so that the transfer tray 206 and the base plate are transported to the corresponding processing area via the double-layer belt conveyor. When the short-stroke belt conveyor 2055 separates from the transfer tray 206, the lifting plate 2052 and the short-stroke belt conveyor 2055, etc., move downward under the drive of the belt-type linear module 2059, so that the short-stroke belt conveyor 2055 connects to the lower layer of the double-layer belt conveyor, and the lower layer will be empty. The transfer tray 206 is conveyed to the short-distance belt conveyor 2055. Then, the lifting plate 2052 and the short-distance belt conveyor 2055 continue to produce and put the bottom plate into the transfer tray 206. This cycle continues. During the process, as the bottom plate on the loading tray 207 is taken away by the loading mechanism 203, the pallet 2084 gradually rises. Each time the loading mechanism 203 puts the bottom plate into the transfer tray 206 and resets, it picks up the empty loading tray 207 and puts it into the tray recycling cart 209 for recycling.

Claims

1. A keyboard automated assembly and testing integrated process, employing an automated production line to realize keyboard assembly and testing, the automated production line including a keyboard keycap testing machine (1), a base plate loading machine (2), a labeling machine (3), a keycap assembly integrated machine (4), and testing equipment, characterized in that, The process includes the following steps: S1. Keycap inspection and loading: The keycap tray A, which carries the keycaps, is placed on the tray 1 (104) of the keyboard keycap testing machine (1). The keycap tray A is positioned by the positioning rod (1066) of the positioning structure (106). The drive motor drives the lifting screw (1062) to rotate. The height of the tray 1 (104) is adjusted to the appropriate picking position by the transmission block (1063). The linear modules 1 (1031), 2 (1036), and 3 (1038) of the picking robot (103) work together with the drive tray vacuum suction cup (1035) to move above the keycap tray A, and after adsorbing the keycap tray A, transfer it to the transfer tray (112) at the lifting structure 1 (107). The keycap tray A is fixed by the limiting frame (1121) at the top of the transfer tray (112). The lifting structure (107) transports the transfer tray (112) containing the keycap tray A to the upper conveyor of the double-layer conveyor (109). During the transfer, the detection camera (111) on the gantry (110) collects images of the keycap tray A in conjunction with the lighting. The visual detection system determines whether the keycaps are missing. If a keycap is detected to be missing, an alarm is triggered, and the unqualified tray is removed manually. If the detection is qualified, the transfer tray (112) continues to be transported to the feeding end of the keycap assembly machine (4). S2. Base plate loading and labeling: The loading tray (207) carrying the keyboard base plate is stacked on the second tray (2084) of the base plate loading machine (2). The positioning area is formed by the positioning column (20812) of the positioning component (208) to position the loading tray (207). The drive motor drives the adjusting screw (2082) to rotate, and the height of the second tray (2084) is adjusted to the appropriate material picking position through the transmission seat (2083). The linear modules four (2031), five (2033), and six (2034) of the feeding mechanism (203) work together to drive the vacuum chamber (2037) to move above the feeding tray (207). The small suction cups (20371) at the bottom of the vacuum chamber (2037) come into contact with the base plate and adsorb, while the FPC vacuum suction cup (2038) adsorbs the FPC on the base plate. The feeding mechanism (203) moves the adsorbed base plate to the detection structure (204), the supplementary light (2042) provides supplementary light, the detection camera (2043) collects the image of the base plate, and determines whether the position of the base plate is deviated. If there is a deviation, the rotary motor (2036) drives the connecting plate (2039) to rotate, thereby adjusting the base plate to the correct position. After positioning, the base plate is conveyed to the labeling machine (3), where the labeling machine (3) affixes a QR code and a waterproof label to the base plate. After labeling, the base plate is conveyed to the feeding end of the keycap assembly machine (4). S3 assembly operation: The keycap assembly machine (4) receives the qualified keycaps in step S1 and the labeled base plate in step S2, and completes the automated assembly of the keycaps and the base plate. The assembled semi-finished products are transported to the irregular key manual assembly station (6), where manual workers complete the supplementary assembly of the irregular keys.

2. The integrated automated keyboard assembly and testing process according to claim 1, characterized in that, In S1, the empty keycap tray A after the keycaps are removed moves to the lifting structure two (108) along with the transfer tray (112). The short-range belt conveyor one (1087) of the lifting structure two (108) docks with the upper conveyor to receive the transfer tray (112). After the empty keycap tray A is removed, the belt-type linear module one (1089) drives the short-range belt conveyor one (1087) to descend and dock with the lower conveyor, transporting the empty transfer tray (112) back to the lifting structure one (107) to complete the cycle.

3. The integrated automated keyboard assembly and testing process according to claim 1, characterized in that, In S2, the labeled base plate is placed in the base plate positioning frame (2061) of the transfer plate (206). The short-range belt conveyor (2055) of the lifting structure (205) transports the transfer plate (206) to the upper layer of the double-layer belt conveyor. The empty transfer plate (206) is transported back to the short-range belt conveyor (2055) through the lower layer of the double-layer belt conveyor, completing the cycle. The empty loading pallet (207) is picked up by the loading mechanism (203) and put into the pallet recycling vehicle (209) for recycling.

4. The integrated automated keyboard assembly and testing process according to any one of claims 1-3, characterized in that, The testing equipment includes, in sequence, a key core appearance inspection machine (8), a key core crack inspection machine (9), a key core noise detection machine (10), a key core pull-out and key height testing machine (12), an ATE testing machine (13), a key core backlight plate attaching and pressure holding machine (14), a key core backlight uniformity testing machine (15), a key core front and back light leakage detection and indicator light detection machine (16), a multi-functional testing machine (17), and a second lifting machine (18); the output direction of the keycap assembly machine (4) is provided with a manual assembly position for irregular keys (6).

5. The integrated automated keyboard assembly and testing process according to claim 4, characterized in that, Manual repair point 1 (7) is set up at the key core appearance full inspection machine (8), manual repair point 2 (11) is set up at the key core pull-out and key height test machine (12), and manual repair point 3 (19) is set up at the ATE test machine (13).

6. The integrated automated keyboard assembly and testing process according to claim 5, characterized in that, It also includes S4 multi-station inspection, specifically including: Key core appearance inspection: The semi-finished products after the irregular key assembly are sent to the key core appearance full inspection machine (8) for a comprehensive inspection of the key core appearance. Products that fail the inspection are transferred to manual repair point 1 (7) for repair. Key core crack detection: Products that pass the appearance inspection are sent to the key core crack full inspection machine (9) to detect whether there are cracks in the key core; Key core noise detection: Products that pass the crack detection are sent to the key core noise detection machine (10) to detect whether there is any noise when the key core is pressed; Key core pulling and key height test: Products that pass the noise test are sent to the key core pulling and key height tester (12) for key core pulling test and key height dimension test. Products that fail the test are transferred to manual repair point 2 (11) for repair.

7. The integrated automated keyboard assembly and testing process according to claim 6, characterized in that, Multi-station inspection also includes: ATE Testing: Products that pass the pull-out and key height tests are sent to the ATE testing machine (13) for electrical performance testing. Products that fail the tests are sent to the manual repair point three (19) for repair. Backlight panel mounting and pressure holding: Products that pass ATE testing are transported to the backlight panel mounting and pressure holding machine (14) to complete the backlight panel mounting and pressure holding process; Backlight uniformity test: After pressure holding, the product is transported to the key core backlight uniformity tester (15) to test the backlight uniformity of the key core. Light leakage and indicator light detection: Products that pass the backlight uniformity test are sent to the key core front and back light leakage detection and indicator light detection machine (16) to detect whether there is light leakage on the key core front and back and whether the indicator lights are working properly.

8. The integrated automated keyboard assembly and testing process according to claim 7, characterized in that, Multi-station inspection also includes: Multifunctional testing: Products that pass the light leakage and indicator light tests are sent to the multifunctional testing machine (17) for AIO character, conductive film PIN and GAP testing; Finished product output: Products that pass the multi-functional inspection are transported to the finished product area by the No. 2 elevator (18) to complete the entire assembly and inspection process.

9. The integrated automated keyboard assembly and testing process according to claim 8, characterized in that, The multi-functional testing machine (17) integrates an optical character recognition module, a conductive film PIN detection module, and a GAP detection module; The optical character recognition module is used to read AIO characters and compare them with the standard character library; the conductive film PIN detection module detects the conductivity and contact resistance of the conductive film PIN pins by contacting them with probes; the GAP detection module uses a laser rangefinder sensor to detect the gap size between the key core and the base plate.

10. The integrated automated keyboard assembly and testing process according to claim 5, characterized in that, The key core appearance inspection machine (8) uses machine vision inspection technology to collect key core appearance images through a high-definition camera and compare them with preset standard appearance images to detect whether there are scratches, stains, deformations and defects on the key core surface.

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