A junction box assembly apparatus and method

Abstract

The application provides a terminal box assembling device and method, which is used for assembling a terminal box with a main piece with a lead, comprising a rack, a first feeding mechanism, a second feeding mechanism, a grabbing mechanism, a conveying mechanism, a lead righting mechanism and a mounting and transferring mechanism. The application has high integration degree, compact structure and smooth connection of each process. The positioning, identification, insertion, bending and other operations in the assembling process are accurately completed by mechanical structure, effectively avoiding the problems of insertion deviation, uneven force, lead bending out of position and the like in the existing operation, improving the assembling precision and connection stability of the terminal box and the main piece, reducing the product repair rate, reducing the labor cost investment, avoiding the operation errors caused by high-intensity manual work, and improving the production safety and product quality consistency of the terminal box assembling link of the photovoltaic module.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic equipment technology, specifically to a junction box assembly device and method. Background Technology

[0002] In the production and assembly of photovoltaic modules, the junction box, as a core electrical connection component, plays a crucial role in collecting the current generated by the photovoltaic panel, protecting circuit safety, and connecting the module to external circuits. Its installation accuracy and stability directly affect the power generation efficiency and lifespan of the photovoltaic module. The photovoltaic panel junction box needs to be precisely assembled with the main components containing pre-set leads to form a complete electrical path.

[0003] Based on functional and structural differences, photovoltaic panel junction boxes are mainly divided into three categories: First, positive junction boxes with leads, which are equipped with dedicated positive lead wires to achieve positive current output; second, negative junction boxes with leads, which complete the current loop connection through negative lead wires. The leads of the positive and negative junction boxes must correspond to the positive and negative interfaces of the main component leads to ensure polarity matching; third, transition junction boxes without leads, which are mainly used for the transfer and convergence of current inside the photovoltaic module. They form an embedded connection with the main component leads through conductive terminals inside the box, without the need for additional lead wires, but their interface structure is significantly different from that of the positive and negative junction boxes.

[0004] Currently, there is no complete processing system for the assembly of junction boxes and main component leads in photovoltaic module production lines. As a result, the drawbacks in the actual processing are becoming increasingly prominent: First, errors are prone to occur in the type and orientation of junction boxes, resulting in a high rate of misassembly, which leads to increased product rework and reduced production efficiency. Second, due to the easy bending of the main component leads, universal insertion mechanisms cannot accurately thread the bent leads into the junction box. This not only easily causes poor contact between the junction box and the leads, affecting conductivity, but may also damage the junction box or the main component leads, causing unnecessary losses. Third, existing processing technologies cannot achieve integrated operation of junction box type identification, orientation positioning, main component adjustment, and insertion accuracy control. This results in poor adaptability and makes it difficult to meet the assembly requirements of photovoltaic modules of different specifications.

[0005] Currently, there is no dedicated large-scale equipment in the industry for assembling photovoltaic panel junction boxes and main component leads. There is a lack of integrated equipment that can integrate functions such as junction box type compatibility, accurate positioning in both directions, automated insertion, main component lead correction, and assembly quality inspection. This makes it impossible to meet the needs of large-scale, high-precision photovoltaic module production, which restricts the automation upgrade of the photovoltaic module assembly process and the improvement of product quality stability.

[0006] Therefore, developing specialized equipment that is compatible with different types of junction boxes and can achieve precise directional positioning and automated assembly has become an urgent technical problem to be solved in the photovoltaic module manufacturing industry. Summary of the Invention

[0007] Therefore, the technical problem to be solved by the present invention is to overcome the problem that the assembly of different types of junction boxes and main components cannot be automated in the prior art, and to provide a junction box assembly device and method.

[0008] To solve the above-mentioned technical problems, the present invention provides a junction box assembly device for assembling junction boxes with main components having leads. The junction box includes a first junction box with leads and a second junction box without leads. The device includes: a frame; a first feeding mechanism, the first feeding mechanism including a material box, a feeding identification camera, a feeding robotic arm, and a flip-transfer assembly. The first junction box is located in the material box and is movable toward the flip-transfer assembly. The feeding robotic arm is disposed between the material box and the flip-transfer assembly. The feeding identification camera is connected to the frame and located at the feeding end of the flip-transfer assembly to detect the orientation of the first junction box. The flip-transfer assembly includes... The system comprises a flipping plate and a first receiving belt. The flipping plate can rotate a first junction box facing in the opposite direction to output a first junction box facing in the forward direction to the first receiving belt. A second feeding mechanism includes a guide chute and a flexible vibrating disc, through which the second junction box enters the flexible vibrating disc. A gripping mechanism includes a gripping robotic arm, a first recognition camera, and a second recognition camera. The first recognition camera is connected to the frame and faces the discharge end of the first receiving belt. The second recognition camera is connected to the frame and faces the flexible vibrating disc. The gripping robotic arm is positioned at the discharge ends of both the first receiving belt and the flexible vibrating disc, and is respectively connected to... The first and second identification cameras are used to grasp the forward-facing junction box; a transmission mechanism is disposed on one side of the grasping mechanism and includes multiple transmission platforms, through which the junction box enters different transmission platforms and moves along a first direction; a lead wire straightening mechanism is slidably connected to the frame and disposed above the main component supply line, and includes a straightening component, which includes a pusher and two clamping arms. The pusher can move along the first direction to pass between two leads of the main component, and the two clamping arms are disposed on both sides of the pusher and can move along the first and / or second directions, with the leads of the main component located in the clamping arms. Between the arm and the pusher claw, each of the clamping arms includes a limiting hook that bends toward the pusher claw to straighten the lead wire; an installation and transfer mechanism is slidably connected to the frame and can move between the transmission mechanism and the main component supply line. The installation and transfer mechanism includes an assembly frame, a transfer component, a material feeding component, and a lead wire identification camera. The transfer component is located on the side of the assembly frame facing the transmission mechanism and includes a transfer clamping claw that can hold a junction box. The material feeding component is located corresponding to the transfer component and includes two material feeding claws that can open and close along the main component lead wire arrangement direction. The lead wire identification camera is located on the side of the assembly frame away from the transmission mechanism and is connected to the material feeding component.The transfer gripper inserts the orthogonal junction box into the main component after the lead wire has been aligned, and then the feed claw bends the lead wire to connect the junction box to the main component.

[0009] In one embodiment of the present invention, the first feeding mechanism includes a material box circulation assembly, which includes a fixed frame, two docking conveyor belts, a lifting platform, and a feeding belt. The fixed frame is disposed at one end of the frame in a first direction. The two docking conveyor belts are arranged vertically on the fixed frame, and the two docking conveyor belts have opposite transmission directions. The lifting platform is disposed inside the frame and located between the fixed frame and the flipping conveyor assembly. The lifting platform can move up and down in a vertical direction. The feeding belt is disposed on the lifting platform and moves synchronously with the lifting platform to dock with any one of the docking conveyor belts. The material box can enter the frame through one docking conveyor belt and leave the frame through the other docking conveyor belt for cyclic feeding.

[0010] In one embodiment of the present invention, the flipping transmission assembly further includes a mounting plate, a stop plate, and a stop driver. The mounting plate is connected to the frame, and the flipping plate is rotatably connected to the mounting plate about a rotation center line. The stop driver is disposed at the bottom of the flipping plate, and the stop plate is connected to the power output end of the stop driver and disposed between the flipping plate and the first receiving belt. When the feeding identification camera identifies the first junction box as being in the forward direction, the stop plate is in a retracted state, and the flipping plate is tilted toward the first receiving belt to directly output the first junction box. When the feeding identification camera identifies the first junction box as being in the reverse direction, the stop plate is in an extended state, and the flipping plate flips toward the first receiving belt to flip the first junction box to the forward direction before outputting it.

[0011] In one embodiment of the present invention, the flipping and conveying assembly further includes two guide ribs and a buffer platform. The buffer platform is connected to the frame and located at the output end of the first receiving belt. The two guide ribs are respectively connected to the mounting plate and extend inwardly from the edge of the first receiving belt in the width direction in the direction toward the buffer platform.

[0012] In one embodiment of the present invention, the second feeding mechanism further includes a second receiving belt and a pusher feeding machine. The second receiving belt is connected to the frame, is disposed at the discharge end of the guide trough, and can transmit the second junction box toward the pusher feeding machine. The flexible vibrating plate is disposed at the discharge end of the pusher feeding machine.

[0013] In one embodiment of the present invention, both the first feeding mechanism and the second feeding mechanism are provided with a recycling channel, and the recycling channel is located on one side of the gripping mechanism.

[0014] In one embodiment of the present invention, the transmission mechanism includes a housing, a support panel, a plurality of transmission platforms, and a transmission drive assembly. The housing is connected to the frame, the plurality of transmission platforms are disposed in the housing and arranged at intervals along a second direction, the transmission drive assembly drives the plurality of transmission platforms to reciprocate along a first direction, the support panel is fastened to the top of the housing and is provided with a plurality of material transfer channels extending along the first direction, the transmission platforms can pass through the material transfer channels to the top of the support panel, and the lead-out end of the first junction box can be supported on the support panel.

[0015] In one embodiment of the present invention, the transmission platform includes a movable base frame, a platform body, two limiting plates, and a limiting driver. The movable base frame is connected to the power output end of the transmission drive assembly. The platform body is disposed on the movable base frame, and a limiting protrusion is provided at one end in a second direction. The limiting driver is connected to the movable base frame and located on one side of the platform body. The two limiting plates are respectively disposed on both sides of the platform body in a first direction and are respectively connected to the power output end of the limiting driver for relative opening and closing movement.

[0016] In one embodiment of the present invention, the lead wire straightening mechanism includes an installation beam and a lifting beam. The installation beam is connected to the frame, and the lifting beam is slidably connected to the installation beam along a third direction. A horizontal adjustment module is provided at the bottom of the lifting beam, and a plurality of straightening components are respectively disposed on the horizontal adjustment module to move along a second direction.

[0017] In one embodiment of the present invention, the straightening component further includes a top push driver and a side pressure driver. The top push driver is connected to the horizontal adjustment module, and the push claw is connected to the power output end of the top push driver to move along the first direction. The side pressure driver is disposed at the bottom of the top push driver, and the two clamping arms are respectively connected to the power output end of the side pressure driver to move relative to each other on both sides of the push claw along the second direction.

[0018] In one embodiment of the present invention, the installation and transfer mechanism includes a slide, which is slidably connected to the frame along a first direction, and a transfer module extending along a second direction is provided on the slide. A plurality of assembly racks are slidably connected to the transfer module, and each assembly rack is provided with a lifting module. The transfer component is slidably connected to the lifting module along a third direction.

[0019] In one embodiment of the present invention, the transfer assembly includes a fine-tuning module and a transfer driver. The fine-tuning module is disposed on the assembly frame and extends along a second direction. The transfer driver is slidably connected to the fine-tuning module. The two transfer grippers are respectively connected to the power output end of the transfer driver and move relative to each other along a first direction.

[0020] In one embodiment of the present invention, the material feeding assembly further includes a connecting beam and a material feeding module. The connecting beam is connected to the bottom of the transfer driver and is located between the two transfer grippers. The material feeding module is disposed on the connecting beam and extends along a second direction. The two material feeding grippers are slidably connected to the material feeding module and move open and close along the second direction. The surfaces of any material feeding grippers that are far apart from each other are configured as inclined structures that can be inserted between two adjacent leads of the main component.

[0021] In one embodiment of the present invention, the junction box assembly equipment further includes a control mechanism, wherein the first feeding mechanism, the second feeding mechanism, the gripping mechanism, the transmission mechanism, the lead wire straightening mechanism, and the installation and transfer mechanism are respectively signal-connected to the control mechanism.

[0022] This invention also provides a junction box assembly method, which assembles a junction box with a main component having leads using the aforementioned junction box assembly equipment. The method includes: Step S1, feeding a first junction box with leads using a first feeding mechanism, and simultaneously feeding a second junction box without leads using a second feeding mechanism; Step S2, identifying the front and back of the first junction box, outputting it directly when it is facing forward, and outputting it after flipping it to the front when it is facing backward; simultaneously, vibrating the second junction box using a flexible vibrating disc to vibrate it so that at least part of the lead wire is properly aligned. The second junction box is in the forward orientation; Step S3: The forward junction box is gripped by the gripping mechanism and moved into the transmission mechanism; Step S4: The lead wire attitude is identified by the lead wire recognition camera in the installation transfer mechanism, and the lead wire on the main component is straightened by the lead wire straightening mechanism until the lead wire extends vertically upward; Step S5: The junction box in the transmission mechanism is inserted into the main component after the lead wire is straightened by the transfer component in the installation transfer mechanism; Step S6: The lead wire passing through the junction box is bent by the material feeding component in the installation transfer mechanism to connect the junction box and the main component.

[0023] In one embodiment of the present invention, step S2 specifically involves: identifying the front and back of the first junction box; when the first junction box is facing forward, the stop plate in the flip transmission assembly is in a retracted state, and the flip plate is tilted 30-60° toward the first receiving belt to directly output the first junction box; when the first junction box is facing backward, the stop plate in the flip transmission assembly is in an extended state to stop the first junction box on the flip plate, and the flip plate is tilted 130-150° toward the first receiving belt to flip the first junction box to the forward position before outputting it.

[0024] The technical solution of the present invention has the following advantages compared with the prior art:

[0025] The junction box assembly equipment and method described in this invention can realize the integrated automated assembly of a first junction box with a lead-out end and a second junction box without a lead-out end, effectively adapting to the assembly requirements of two types of junction boxes and lead-wire main components.

[0026] By combining the feeding recognition camera of the first feeding mechanism with the flipping transmission component, the positive and negative states of the first junction box can be accurately detected and corrected, ensuring that the first junction box is output in the positive direction to the subsequent process. The second feeding mechanism realizes the stable feeding and orderly supply of the second junction box through the guide chute and flexible vibrating plate. With the help of the dual recognition camera of the gripping mechanism, the two types of positive junction boxes are accurately identified respectively. Then, the gripping robot arm completes the accurate gripping of the two types of junction boxes and classifies and transfers them to different transmission platforms of the transmission mechanism, realizing the orderly transmission and feeding connection of the two types of junction boxes, effectively avoiding the problems of junction box type confusion and direction deviation.

[0027] The lead wire straightening mechanism in this junction box assembly equipment can separate and position the two leads of the main component by inserting the push claws between them, and then the clamping arms with limit hooks on both sides move in multiple directions to clamp and straighten the leads. This can quickly arrange the leads of the main component to a regular assembly position, solving the problem of the main component's leads being crooked and unevenly spaced, which affects the junction box insertion, and laying the foundation for the accurate assembly of the junction box. Meanwhile, the installation and transfer mechanism accurately identifies the position of the main component's lead wire after alignment using a lead wire recognition camera. In conjunction with the transfer grippers, it precisely inserts the forward-facing junction box onto the main component's lead wire. Then, the material-pulling claw moves along the lead wire's arrangement direction to complete the lead wire bending operation. This achieves integrated operation of junction box insertion and lead wire bending, completing the assembly of the junction box and main component without manual intervention. Furthermore, the coordinated operation of various mechanisms enables fully automated operation from junction box loading, orientation correction, type sorting, and precise gripping, to main component lead wire alignment, precise junction box insertion, and lead wire bending. This replaces traditional manual assembly methods using small hand tools, significantly improving the assembly efficiency of the junction box and main component, and adapting to the needs of large-scale production.

[0028] Furthermore, this equipment is highly integrated, with a compact structure and smooth connections between various processes. Positioning, identification, insertion, and bending operations during assembly are all precisely completed by the mechanical structure, effectively avoiding problems such as insertion deviation, uneven force, and incomplete bending of lead wires that are prone to occur in existing operations. This improves the assembly accuracy and connection stability of the junction box and the main components, reduces the product rework rate, reduces labor costs, avoids operational errors caused by high-intensity manual work, and improves the production safety and product quality consistency of the photovoltaic module junction box assembly process. Attached Figure Description

[0029] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0030] Figure 1 This is a three-dimensional structural diagram of the junction box assembly equipment in a preferred embodiment of the present invention;

[0031] Figure 2 yes Figure 1 Enlarged structural diagram at point A in the middle;

[0032] Figure 3 yes Figure 1 A three-dimensional structural diagram of the loading robotic arm in the junction box assembly equipment shown.

[0033] Figure 4 yes Figure 1 A three-dimensional structural diagram of the flip transmission component in the junction box assembly equipment shown.

[0034] Figure 5 yes Figure 1 A three-dimensional structural diagram of the flip transmission component in the junction box assembly equipment shown from another perspective;

[0035] Figure 6 yes Figure 1 A three-dimensional structural diagram of the second feeding mechanism in the junction box assembly equipment shown.

[0036] Figure 7 yes Figure 1 A three-dimensional structural diagram of the gripping mechanism in the junction box assembly equipment shown.

[0037] Figure 8 yes Figure 1 A three-dimensional structural diagram of the transmission mechanism in the junction box assembly equipment shown.

[0038] Figure 9 yes Figure 1 A schematic diagram of the internal structure of the transmission mechanism in the junction box assembly equipment shown.

[0039] Figure 10 yes Figure 1A three-dimensional structural diagram of the transmission station in the junction box assembly equipment shown.

[0040] Figure 11 yes Figure 1 A three-dimensional structural diagram of the lead wire straightening mechanism in the junction box assembly equipment shown.

[0041] Figure 12 yes Figure 1 A three-dimensional structural diagram of the straightening component in the junction box assembly equipment shown;

[0042] Figure 13 yes Figure 1 A three-dimensional structural diagram of the transfer mechanism installed in the junction box assembly equipment shown;

[0043] Figure 14 yes Figure 1 The diagram shows a three-dimensional structural schematic of a portion of the installation and transfer mechanism in the junction box assembly equipment.

[0044] Explanation of reference numerals in the accompanying drawings: 100, frame; 200, first feeding mechanism; 210, material box; 220, material box circulation assembly; 221, fixed frame; 222, docking conveyor belt; 223, lifting platform; 224, feeding belt; 230, feeding robotic arm; 231, feeding gripper; 240, flipping conveyor assembly; 241, mounting plate; 242, flipping plate; 243, stop plate; 244, stop actuator; 245, first receiving belt; 246. 247. Guide rib; 250. Feed recognition camera; 260. Position recognition camera; 300. Second feeding mechanism; 310. Guide chute; 320. Second receiving belt; 330. Push plate feeder; 340. Flexible vibrating disc; 400. Gripping mechanism; 410. Gripping robotic arm; 411. Gripping gripper; 420. First recognition camera; 430. Second recognition camera; 500. Transmission mechanism; 510. Housing; 520. Support panel; 530. 0. Transmission table; 531. Moving base frame; 532. Platform body; 5321. Limiting protrusion; 533. Limiting plate; 534. Limiting driver; 540. Transmission drive assembly; 600. Lead wire straightening mechanism; 610. Mounting beam; 620. Lifting beam; 630. Horizontal adjustment module; 640. Straightening assembly; 641. Push claw; 642. Top push driver; 643. Clamping arm; 6431. Limiting hook; 644. Side pressure driver; 700. Installation transfer machine Structure; 710, Carriage; 720, Transfer Module; 730, Assembly Rack; 731, Lifting Module; 740, Transfer Assembly; 741, Fine-tuning Module; 742, Transfer Driver; 743, Transfer Gripper; 750, Material Picking Assembly; 751, Connecting Beam; 752, Material Picking Module; 753, Material Picking Gripper; 760, Lead Wire Recognition Camera; 800, Main Component Supply Line; 1001, Rotation Center Line; X, First Direction; Y, Second Direction; Z, Third Direction. Detailed Implementation

[0045] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0046] Example 1: See Figures 1 to 14As shown, this embodiment provides a junction box assembly device for assembling junction boxes with main components having leads. The junction boxes include a first junction box (positive junction box and negative junction box) with leads and a second junction box (transition junction box) without leads. The device includes: a frame 100; a first feeding mechanism 200, which includes a material box 210, a feeding identification camera 250, a feeding robotic arm 230, and a flipping transmission assembly 240. The first junction box is located in the material box 210, which is movable toward the flipping transmission assembly 240. The feeding robotic arm 230 is disposed between the material box 210 and the flipping transmission assembly 240. A camera 250 is connected to the frame 100 and located at the feed end of the flip-transfer assembly 240 to detect the orientation of the first junction box. The flip-transfer assembly 240 includes a flip plate 242 and a first receiving belt 245. The flip plate 242 can rotate the first junction box facing the opposite direction to output the first junction box facing the correct direction to the first receiving belt 245. A second feeding mechanism 300 includes a guide trough 310 and a flexible vibrating plate 340. The second junction box enters the flexible vibrating plate 340 through the guide trough 310. A gripping mechanism 400 includes a gripping robotic arm 410, a first recognition camera 420, and a second recognition camera 430. The first identification camera 420 is connected to the frame 100 and is positioned facing the discharge end of the first receiving belt 245. The second identification camera 430 is connected to the frame 100 and is positioned facing the flexible vibrating disc 340. The gripping robotic arm 410 is positioned at the discharge ends of the first receiving belt 245 and the flexible vibrating disc 340, and is connected to the first identification camera 420 and the second identification camera 430 respectively, to grip the forward-facing junction box. A transmission mechanism 500 is located on one side of the gripping mechanism 400 and includes multiple transmission platforms 530. Junction boxes enter different transmission platforms 530 through the gripping mechanism 400 and are transported by the transmission platform 530. The conveyor 530 moves along the first direction X; the lead wire straightening mechanism 600 is slidably connected to the frame 100 and is disposed above the main component supply line 800. It includes a straightening component 640, which includes a pusher 641 and two clamping arms 643. The pusher 641 can move along the first direction X to pass between the two leads of the main component. The two clamping arms 643 are disposed on both sides of the pusher 641 and can move along the first direction X and / or the second direction Y. The lead of the main component is located between the clamping arms 643 and the pusher 641. Each clamping arm 643 includes a limiting hook 6431 that bends toward the pusher 641 to straighten the lead wire.The mounting and transfer mechanism 700 is slidably connected to the frame 100 and is movable between the transmission mechanism 500 and the main component supply line 800. The mounting and transfer mechanism 700 includes an assembly frame 730, a transfer assembly 740, a material feeding assembly 750, and a lead wire identification camera 760. The transfer assembly 740 is located on the side of the assembly frame 730 facing the transmission mechanism 500 and includes transfer grippers 743 capable of holding junction boxes. The material feeding assembly 750 is configured corresponding to the transfer assembly 740, and includes two feeding claws 753 that can open and close along the direction of the main component's lead wire arrangement. The lead wire identification camera 760 is located on the side of the assembly frame 730 away from the transmission mechanism 500 and is connected to the material feeding assembly 750. The transfer claws 743 insert the positively oriented junction box into the main component after the lead wire has been aligned, and then bend the lead wire using the feeding claws 753 to connect the junction box to the main component.

[0047] It should be noted that, for ease of description, in this embodiment, the length direction of the junction box assembly equipment is defined as the first direction X, the width direction of the junction box assembly equipment is defined as the second direction Y, and the height direction of the junction box assembly equipment is defined as the third direction Z. The first direction X, the second direction Y, and the third direction Z are arranged perpendicular to each other in pairs, and the first direction X and the second direction Y are located in the same plane.

[0048] In this embodiment, the frame 100 serves as the basic support structure for the entire junction box assembly equipment, providing a fixing and installation carrier for all functional mechanisms of the equipment. This enables precise spatial arrangement of each mechanism, ensuring the structural stability and motion coordination of each mechanism during operation. At the same time, it provides a unified installation benchmark for the coordinated operation of each mechanism, ensuring the overall structural compactness and operational reliability of the equipment.

[0049] The first feeding mechanism 200 is a dedicated feeding and orientation correction unit for the first junction box with lead-out ends. The material box 210 is used to store the first junction box to be assembled and can move towards the flip transmission component 240 to achieve orderly feeding. Specifically, the first feeding mechanism 200 includes a material box circulation assembly 220, which includes a fixed frame 221, two docking conveyor belts 222, a lifting platform 223, and a feeding belt 224. The fixed frame 221 is located at one end of the frame 100 in the first direction X. The two docking conveyor belts 222 are arranged vertically on the fixed frame 221, and the two docking conveyor belts 222 have opposite transmission directions. The lifting platform 223 is located inside the frame 100 and between the fixed frame 221 and the flipping conveyor assembly 240. The lifting platform 223 can move up and down in the vertical direction. The feeding belt 224 is located on the lifting platform 223 and moves synchronously with the lifting platform 223 to dock with any one of the docking conveyor belts 222. The material box 210 can enter the frame 100 through one docking conveyor belt 222 and leave the frame 100 through the other docking conveyor belt 222 for cyclic feeding.

[0050] The fixed frame 221 provides basic installation and positioning support for the entire circulating material supply structure, enabling the orderly spatial arrangement of each transmission component. Two vertically arranged and oppositely oriented conveyor belts 222 form a circulating transmission channel for the material box 210, respectively conveying the material box 210 loaded with the first junction box to be assembled into the frame 100 and returning the empty material box 210 to the outside of the frame 100. The lifting platform 223 can be flexibly raised and lowered vertically, and the feeding belt 224 mounted on it moves synchronously with the lifting platform 223, enabling precise docking. Any docking conveyor belt 222 enables the transfer of the material box 210 between the docking conveyor belt 222 and the flipping conveyor component 240. This allows the material box 210 to enter the frame 100 for feeding via one docking conveyor belt 222 and leave the frame 100 for empty box recycling via the other docking conveyor belt 222, forming an automated cyclic feeding mode for the material box 210. This ensures a continuous and orderly feeding of the first junction box, eliminating the need for frequent manual replenishment and box collection, and improving the feeding efficiency and automation level of the first feeding mechanism 200.

[0051] In this embodiment, the position recognition camera 260 is used to detect the loading position of the first junction box and convert it into specific coordinates so that the loading robot arm 230 can connect the material box 210 and the flipping transmission component 240 to complete the transfer operation of the first junction box from the material box 210 to the flipping transmission component 240. Its moving end is provided with a loading gripper 231 for holding the junction box. The feeding recognition camera 250 performs forward and reverse state detection on the first junction box transferred to this location at the feeding end of the flipping transmission component 240 to provide a detection basis for subsequent orientation correction.

[0052] The flip plate 242 of the flip transmission assembly 240 can accurately flip and correct the first junction box in the reverse direction according to the detection results, and then the corrected first junction box in the forward direction is stably transmitted to the subsequent gripping station through the first receiving belt 245. This realizes the integrated operation of loading, detection, correction and transmission of the first junction box, ensuring that the first junction box output to the subsequent process is in the same direction, laying the foundation for accurate assembly.

[0053] Specifically, the flipping transmission assembly 240 further includes a mounting plate 241, a stop plate 243, and a stop driver 244. The mounting plate 241 is connected to the frame 100. The flipping plate 242 is rotatably connected to the mounting plate 241 around the rotation center line 1001. The stop driver 244 is disposed at the bottom of the flipping plate 242. The stop plate 243 is connected to the power output end of the stop driver 244 and is disposed between the flipping plate 242 and the first receiving belt 245. When the feed identification camera 250 identifies the first junction box as being in the forward position, the stop plate 243 is in a retracted state, and the flipping plate 242 is tilted towards the first receiving belt 245 to directly output the first junction box. When the feed identification camera 250 identifies the first junction box as being in the reverse position, the stop plate 243 is in an extended state, and the flipping plate 242 flips towards the first receiving belt 245 to flip the first junction box to the forward position before outputting it.

[0054] The mounting plate 241 of the flip transmission assembly 240 serves as an integrated mounting carrier for the flip plate 242, the stop plate 243, and the stop driver 244, providing a stable mounting foundation and precise positioning for each component, ensuring the coordination and reliability of the flipping and stopping actions. The stop driver 244 provides power output for the extension and retraction of the stop plate 243, and can precisely control the extension and retraction of the stop plate 243 based on the identification result of the feed identification camera 250 of the forward and reverse state of the first junction box. The stop plate 243 is located between the flip plate 242 and the first receiving belt 245, and its extension and retraction state directly coordinates with the action of the flip plate 242 to realize the transmission and flipping control of the first junction box. When the first junction box is identified as being in the forward position, the stop plate 243 is in the retracted state, at which time the flip plate 242 faces the first receiving belt 245. The 45° tilt setting allows the first junction box, facing forward, to slide directly into the first receiving belt 245 along the tilted flip plate 242 to complete the output. When the first junction box is detected to be in reverse, the stop plate 243 extends and limits the reverse first junction box, preventing it from sliding directly into the first receiving belt 245. At the same time, the flip plate 242 rotates 135° around the rotation center line 1001, driving the reverse first junction box to complete the direction correction. After it is flipped to the forward position, the stop plate 243 cooperates to allow the corrected first junction box to smoothly enter the first receiving belt 245. Through the linkage and cooperation of various components, the automatic control of the first junction box's direct forward transmission and precise reverse flipping and correction transmission is realized, ensuring that the first junction box output to the subsequent process is completely uniform in direction, providing a reliable guarantee for subsequent precise gripping and assembly.

[0055] Furthermore, the flipping and conveying assembly 240 also includes two guide ribs 246 and a buffer platform 247. The buffer platform 247 is connected to the frame 100 and is located at the output end of the first receiving belt 245. The two guide ribs 246 are respectively connected to the mounting plate 241 and gradually extend inward from the edge of the first receiving belt 245 in the width direction toward the buffer platform 247. The two guide ribs 246 of the flipping transmission component 240 can accurately guide and limit the first junction box transmitted on the first receiving belt 245, effectively preventing the junction box from deviating from the transmission path due to positional shift or shaking during transmission, and ensuring that the junction box is smoothly conveyed to the buffer platform 247 along the preset trajectory. The buffer platform 247 is used to temporarily receive the first junction box after being guided by the guide ribs 246, forming a short-term material buffer, balancing the rhythm of flipping transmission and subsequent gripping processes, and avoiding material accumulation or supply interruption due to mismatch in the rates of the preceding and following processes. The combination of the two can not only ensure the positional regularity of the first junction box during transmission, but also achieve orderly buffering and connection of materials, further improving the stability and continuity of the entire flipping transmission process, and providing a guarantee for the subsequent gripping mechanism 400 to accurately grip the junction box.

[0056] In this embodiment, the second feeding mechanism 300 provides a suitable feeding operation for the second junction box without a lead-out end. The guide trough 310 realizes the directional conveying of the second junction box and guides the second junction box to be assembled to smoothly enter the flexible vibrating material tray 340. The flexible vibrating material tray 340 uses flexible vibration to orderly organize and smoothly feed the entering second junction box, adapting to the structural characteristics of the second junction box without a lead-out end, avoiding collision damage to the product during the feeding process, and ensuring that the second junction box is output to the subsequent gripping station in a regular state, thus achieving efficient and stable feeding of the second junction box.

[0057] Specifically, the second feeding mechanism 300 also includes a second receiving belt 320 and a pusher feeding machine 330. The second receiving belt 320 is connected to the frame 100 and is located at the discharge end of the guide trough 310. It can transmit the second junction box toward the pusher feeding machine 330. The flexible vibrating plate 340 is located at the discharge end of the pusher feeding machine 330. The second receiving belt 320 of the second feeding mechanism 300 receives the second junction box conveyed from the guide chute 310 and smoothly transfers it to the pusher feeder 330, serving as a material transfer and connection point. This ensures smooth material transfer between the guide chute 310 and the pusher feeder 330, preventing the second junction box from accumulating or shifting during transfer. The pusher feeder 330 receives the second junction box conveyed by the second receiving belt 320 and, through a pusher action, orderly feeds the junction box into the flexible vibrating feeder 340 located at its discharge end. This achieves directional material transfer and feeding rhythm control. In conjunction with the flexible vibrating feeder 340, it further organizes the second junction box, forming a complete feeding chain. This ensures the smooth transfer of the second junction box from the guide chute 310 to the flexible vibrating feeder 340, and through step-by-step transfer and pushing, allows the second junction box to enter the flexible vibrating feeder 340 in an orderly state, improving the overall feeding stability and orderliness of the second feeding mechanism 300 and meeting the needs of subsequent gripping processes.

[0058] It should be noted that in different embodiments, both the first feeding mechanism 200 and the second feeding mechanism 300 are equipped with a recycling channel, which is located on one side of the gripping mechanism 400. This allows for the unified recycling of junction boxes that are transported to the gripping station by the two feeding mechanisms and identified as unqualified by the gripping mechanism 400. This enables the rapid separation of unqualified and qualified junction boxes, preventing unqualified products from entering subsequent transmission and assembly processes and affecting assembly quality. At the same time, by centrally locating the recycling channel on one side of the gripping mechanism 400, the recycling path of unqualified products is simplified, enabling the nearby and efficient recycling of both types of unqualified junction boxes. This ensures the orderly supply of qualified junction boxes and improves the equipment's efficiency in handling unqualified products. It also makes the processes of feeding, gripping, and defective product recycling more compact, further optimizing the overall operation flow of the equipment.

[0059] In this embodiment, the gripping mechanism 400 is the core transfer unit connecting the feeding mechanism and the transmission mechanism 500. It simultaneously performs secondary identification and precise gripping of two types of junction boxes before gripping. Its moving end is equipped with gripping claws 411. The first identification camera 420 faces the discharge end of the first receiving belt 245 and performs a second identification on the first junction box that has completed orientation correction before gripping to confirm its positive state. The second identification camera 430 faces the flexible vibrating plate 340 and performs status identification on the sorted second junction box to ensure the validity of the gripping object. The gripping robotic arm 410 connects the two identification cameras. Based on the identification results, it precisely grips the positive first and second junction boxes at the discharge ends of the first receiving belt 245 and the flexible vibrating plate 340, respectively, and transfers the two types of junction boxes to different transmission tables 530 of the transmission mechanism 500. This achieves precise sorting and directional transfer of the two types of junction boxes, avoids type confusion, and ensures the orderly progress of subsequent assembly processes.

[0060] In this embodiment, the transmission mechanism 500 serves as a transfer unit for junction boxes from the gripping station to the assembly station. The arrangement of multiple transmission stations 530 enables the independent transmission of the first and second junction boxes, avoiding interference or confusion between the two types of junction boxes during transmission. The transmission station 530 drives the junction boxes to move stably along the first direction X, accurately and orderly transporting the two types of forward junction boxes to the gripping and assembly station of the subsequent installation and transfer mechanism 700, achieving a smooth connection between the junction boxes from gripping to assembly, and ensuring continuous operation of each process of the equipment.

[0061] Further, the transmission mechanism 500 includes a housing 510, a support panel 520, a plurality of transmission platforms 530, and a transmission drive assembly 540. The housing 510 is connected to the frame 100. The plurality of transmission platforms 530 are disposed in the housing 510 and are arranged at intervals along the second direction Y. The plurality of transmission drive assemblies 540 correspondingly drive the plurality of transmission platforms 530 to reciprocate along the first direction X. The support panel 520 is fastened to the top of the housing 510 and is provided with a plurality of material transfer channels extending along the first direction X. The transmission platforms 530 can pass through the material transfer channels to the top of the support panel 520. The lead-out end of the first junction box can be supported on the support panel 520. The housing 510 of the transmission mechanism 500 is connected to the frame 100, providing a closed and stable mounting and protective carrier for multiple transmission stations 530 and the transmission drive assembly 540, ensuring the orderly arrangement and stable operation of the internal transmission components. Multiple transmission stations 530 are spaced apart along the second direction Y within the housing 510, respectively receiving the first junction box and the second junction box, enabling independent transmission of the two types of junction boxes and avoiding mutual interference and confusion. The transmission drive assembly 540 and the transmission stations 530 provide power to the transmission stations 530, driving them to reciprocate along the first direction X, precisely moving the junction boxes between the gripping station and the assembly station, ensuring the transmission rhythm matches the subsequent processes. The support panel 520 is fastened to the top of the housing 510. This structure not only protects the internal transmission components but also provides clearance for the lifting and movement of the transmission table 530 through multiple material transfer channels extending along the first direction X. This allows the transmission table 530 to pass through the material transfer channels and extend above the support panel 520 to receive and transfer the junction box. At the same time, the support panel 520 supports the lead-out end of the first junction box, adapting to the structural characteristics of the first junction box with lead-out ends. This prevents the lead-out ends from bending, being damaged, or shifting in position due to shaking or sagging during transmission, ensuring that the first junction box is transported to the assembly station in a neat posture, further guaranteeing the accuracy of subsequent assembly. The overall structure, through the coordinated cooperation of various components, achieves classified, stable, and accurate transmission of junction boxes, taking into account both structural protection and adaptability.

[0062] Specifically, the transmission platform 530 includes a movable base frame 531, a platform body 532, two limiting plates 533, and a limiting driver 534. The movable base frame 531 is connected to the power output end of the transmission drive assembly 540. The platform body 532 is disposed on the movable base frame 531, and a limiting protrusion 5321 is provided at one end in the second direction Y. The limiting driver 534 is connected to the movable base frame 531 and is located on one side of the platform body 532. The two limiting plates 533 are respectively disposed on both sides of the platform body 532 in the first direction X, and are respectively connected to the power output end of the limiting driver 534 for relative opening and closing movement. The movable base 531 of the transmission platform 530 serves as the core load-bearing structure. It is connected to the power output of the transmission drive assembly 540 and reciprocates along the first direction X under the drive of the transmission drive assembly 540, thereby driving the platform 532 and the junction box it supports to complete the workpiece transport. The platform 532 is mounted on the movable base 531 and is used to directly support the first or second junction box. A limiting protrusion 5321 at one end in the second direction Y can provide end positioning for the supported junction box, preventing it from shifting along the second direction Y during transmission. The limiting actuator 534 is connected to the movable base 531 and located on one side of the platform 532, consisting of two limiting plates 53. The action of 3 provides power support. Two limit plates 533 are respectively arranged on both sides of the platform 532 in the first direction X and are connected to the power output end of the limit driver 534. They can open and close relative to each other under the drive of the limit driver 534. When the junction box is placed on the platform 532, the limit plates 533 close and can clamp and limit the junction boxes of different specifications from both sides of the first direction X. Together with the limit protrusions 5321 of the platform 532, they form multi-directional positioning to ensure that the junction box maintains a stable position during transmission and subsequent gripping, and avoids directional deviation or falling due to shaking. It adapts to the structural characteristics of the two types of junction boxes and ensures transmission accuracy and the reliability of subsequent process connections.

[0063] In this embodiment, the lead wire straightening mechanism 600 is a dedicated mechanism for achieving the regular positioning of the main component's lead wires. Its slidable connection to the frame 100 allows it to adapt to the lead wire straightening operation of main components at different positions on the main component supply line 800. The pusher 641 of the straightening component 640 can move along the first direction X and pass between the two leads of the main component to achieve preliminary separation and positioning of the two leads, preventing the leads from sticking together. The clamping arms 643 on both sides of the pusher 641 can move flexibly along the first direction X and / or the second direction Y to clamp the main component's lead wires between the clamping arms 643 and the pusher 641. With the help of the limiting hooks 6431 on the clamping arms 643 that bend towards the pusher 641, the leads are limited, clamped, and straightened, effectively correcting the problems of skewed and unevenly spaced main component leads. The leads are arranged to a regular assembly position that matches the junction box insertion, ensuring accurate insertion of the junction box and leads, and avoiding insertion failure or poor contact caused by lead wire position deviation.

[0064] Furthermore, the lead wire straightening mechanism 600 includes a mounting beam 610 and a lifting beam 620. The mounting beam 610 is connected to the frame 100, and the lifting beam 620 is slidably connected to the mounting beam 610 along the third direction Z. A horizontal adjustment module 630 is provided at the bottom of the lifting beam 620, and multiple straightening components 640 are respectively disposed on the horizontal adjustment module 630 to move along the second direction Y. The mounting beam 610, connected to the frame 100, provides a stable mounting reference and support for the lifting beam 620 and subsequent functional components, ensuring the structural stability of the entire mechanism. The lifting beam 620, slidably connected to the mounting beam 610 along the third direction Z, can drive the horizontal adjustment module 630 and the straightening components 640 below to move up and down, flexibly adapting to the lead wire straightening requirements of main components of different heights and ensuring that the straightening components 640 can accurately align with the lead wire position of the main component. The horizontal adjustment module 630 at the bottom of the lifting beam 620 provides installation and driving support for the multiple straightening components 640. It can drive multiple straightening components 640 to move synchronously or independently along the second direction Y, which can not only adapt to the straightening operation of lead wires with different spacing on the main component, but also meet the batch operation needs of straightening multiple main components at the same time. With the push claw 641, clamping arm 643 and limiting hook 6431 structure of the straightening component 640 itself, it can achieve precise positioning and straightening of the lead wire of the main component. Through the coordinated cooperation of the mounting beam 610, lifting beam 620 and horizontal adjustment module 630, the lead wire straightening mechanism 600 has multi-directional adjustment capability, adapts to different specifications of main components and lead wire layouts, and improves the versatility and straightening accuracy of the mechanism.

[0065] Specifically, the straightening component 640 further includes a push driver 642 and a side pressure driver 644. The push driver 642 is connected to the horizontal adjustment module 630. The push claw 641 is connected to the power output end of the push driver 642 to move along the first direction X. The side pressure driver 644 is disposed at the bottom of the push driver 642. The two clamping arms 643 are respectively connected to the power output end of the side pressure driver 644 to move relative to each other on both sides of the push claw 641 along the second direction Y. The push driver 642 provides power to the push claw 641, driving it to move precisely along the first direction X, allowing it to smoothly pass between the two leads of the main component, achieving initial separation and positioning of the leads. The side pressure driver 644 is located at the bottom of the push driver 642, serving as the power source for the two clamping arms 643. It drives the clamping arms 643 on both sides of the push claw 641 to open and close relative to each other along the second direction Y. The clamping width can be adjusted according to the actual spacing of the main component leads, stably clamping the leads between the clamping arms 643 and the push claw 641. With the help of the limiting hooks 6431 on the clamping arms 643, the leads are straightened and limited. Each driver controls the push claw 641 and the clamping arms 643 to move in different directions, achieving step-by-step precise operation of the main component leads. This makes the separation, clamping, and straightening processes of the leads smoother, further improving the accuracy and stability of lead straightening, and ensuring that the leads are always in the correct position for insertion into the junction box.

[0066] In this embodiment, the installation and transfer mechanism 700 is the core execution unit for achieving precise assembly of the junction box and the main component lead wire. Its slidable connection to the frame 100 allows it to move flexibly between the transmission mechanism 500 and the main component supply line 800, achieving spatial connection between the junction box gripping and assembly. The assembly frame 730 provides an integrated installation carrier for the transfer component 740, the material feeding component 750, and the lead wire recognition camera 760, ensuring the linkage and coordination of each component. The lead wire recognition camera 760 accurately identifies the position of the main component lead wire after alignment, providing a positional basis for the precise insertion of the junction box. The transfer gripper 743 of the transfer component 740 grips the forward-facing junction box from the transmission table 530 of the transmission mechanism 500, and, based on the detection result of the lead wire recognition camera 760, precisely inserts the junction box onto the aligned main component lead wire, completing the junction box insertion operation.

[0067] Furthermore, the installation and transfer mechanism 700 includes a slide 710, which is slidably connected to the frame 100 along a first direction X. A transfer module 720 extending along a second direction Y is provided on the slide 710. A plurality of assembly racks 730 are slidably connected to the transfer module 720 respectively. Each assembly rack 730 is provided with a lifting module 731. The transfer assembly 740 is slidably connected to the lifting module 731 along a third direction Z. The carriage 710 provides basic support and a motion carrier for the first direction X movement of the entire mechanism, realizing the overall displacement of the mechanism between the transmission mechanism 500 and the main component supply line 800. The carriage 710 is equipped with a transfer module 720 extending along the second direction Y, which can drive multiple assembly racks 730 to slide synchronously or independently along the second direction Y, adapting to the simultaneous assembly requirements of multiple sets of leads on the main component. It can also adjust the position of the assembly rack 730 in the second direction Y according to the alignment requirements of the junction box and the main component, improving the flexibility and adaptability of the assembly. Each assembly rack 730 is equipped with a lifting module 731, and the transfer component 740 is slidably connected to the lifting module 731 along the third direction Z. The lowering module 731 can drive the transfer assembly 740 to complete the lifting action in the third direction Z, realizing the precise adjustment of the transfer gripper 743 in the height direction, adapting to the insertion height requirements of different specifications of junction boxes and main components; through the three-axis linkage of the slide 710, transfer module 720 and lifting module 731, the assembly frame 730 and transfer assembly 740 are driven to achieve precise spatial position adjustment in the first X, second Y and third Z directions, ensuring that the transfer gripper 743 can accurately grab the junction box on the transmission mechanism 500 and accurately transfer the junction box to the preset insertion position of the main component lead, greatly improving the alignment accuracy of the junction box and the main component lead, and ensuring the accuracy and reliability of the insertion operation.

[0068] Furthermore, the transfer assembly 740 includes a transfer driver 742, and two transfer grippers 743 are respectively connected to the power output end of the transfer driver 742, and move relative to each other along the first direction X. The transfer driver 742 of the transfer assembly 740 provides power output and mounting base for the transfer grippers 743. The two transfer grippers 743 are connected to the power output end of the transfer driver 742 and can move relative to each other along the first direction X under its drive. The clamping distance can be flexibly adjusted according to the size of different specifications of junction boxes to achieve stable clamping of various junction boxes, avoid loosening or displacement of junction boxes during transfer and insertion, ensure that the junction box completes the insertion operation with the main component lead in a precise posture, and ensure the stability and accuracy of the assembly process.

[0069] It should be noted that, since the first junction box has a lead-out end, its structure differs from that of the second junction box without a lead-out end. To ensure the accuracy of the transfer and insertion of the first junction box, the transfer component 740 used to transfer the first junction box in this embodiment is also equipped with a fine-tuning module 741. The fine-tuning module 741 is set on the assembly frame 730 and extends along the second direction Y. It can drive the transfer driver 742 and the transfer gripper 743 to perform high-precision position fine-tuning along the second direction Y, adapting to the structural layout of the lead-out end of the first junction box and the alignment requirements of the main component lead wire, avoiding interference between the lead-out end and other components, and compensating for the slight positional deviation that may occur during transmission or positioning. This ensures that the lead-out end of the first junction box is accurately aligned with the main component lead wire, further improving the accuracy and reliability of the assembly of the first junction box and the main component. This allows the transfer component 740 to adapt to the structural characteristics of the two types of junction boxes respectively, ensuring the adaptability and stability of the assembly operation of different types of junction boxes. Since the second junction box does not have an output terminal, the fine-tuning module 741 can be omitted to simplify the overall structure of the equipment.

[0070] In this embodiment, the two feeding claws 753 are set to the transfer component 740. They can open and close along the arrangement direction of the main component lead wires. After the junction box is plugged in, the main component lead wires are precisely bent to make the lead wires reliably connected to the junction box. This completes the assembly process of the junction box and the main component, realizing the integrated operation of plugging and bending, and improving assembly efficiency and connection reliability.

[0071] Furthermore, the material feeding assembly 750 also includes a connecting beam 751 and a material feeding module 752. The connecting beam 751 is connected to the bottom of the transfer driver 742 and is located between the two transfer grippers 743. The material feeding module 752 is disposed on the connecting beam 751 and extends along the second direction Y. The two material feeding grippers 753 are slidably connected to the material feeding module 752 and move open and close along the second direction Y. The surfaces of any material feeding grippers 753 that are far apart from each other are configured as inclined structures that can be inserted between two adjacent leads of the main component. The connecting beam 751 is connected to the bottom of the transfer driver 742 and is located between the two transfer grippers 743. It provides a stable mounting carrier for the material feeding module 752 and the material feeding grippers 753, realizing the linkage movement of the material feeding component 750 and the transfer grippers 743, and ensuring the continuity of the junction box insertion and lead wire bending processes. The material feeding module 752 is set on the connecting beam 751 and extends along the second direction Y, providing sliding guidance and driving support for the two material feeding grippers 753, driving the material feeding grippers 753 to move precisely in the second direction Y, adapting to the bending requirements of lead wires with different spacing in the main component.

[0072] Two feeding claws 753 are slidably connected to the feeding module 752. The surfaces of their opposite sides are designed with an inclined structure. This inclined surface can smoothly pass between two adjacent leads of the main component, achieving precise separation of the leads and avoiding damage caused by rubbing or squeezing when the feeding claws 753 move. At the same time, driven by the feeding module 752, the opening and closing movement of the feeding claws 753 precisely bends the upright main component leads, enabling a reliable connection between the leads and the plugged-in junction box. The coordinated operation of all components achieves integrated operation of lead separation and precise bending, ensuring the accuracy and stability of lead bending, adapting to the layout characteristics of the main component leads, avoiding damage to the leads during operation, and further improving the assembly quality of the junction box and the main component.

[0073] The junction box assembly equipment in this embodiment also includes a control mechanism. The first feeding mechanism 200, the second feeding mechanism 300, the gripping mechanism 400, the transmission mechanism 500, the lead wire straightening mechanism 600, and the installation and transfer mechanism 700 are respectively signal-connected to the control mechanism. In actual production and processing, operators can adjust the above structures in real time through the control mechanism, thereby improving the flexibility of the equipment. Parameters can also be preset through the control mechanism, thereby improving the automation level of the equipment.

[0074] Example 2: This example provides a junction box assembly method, which assembles the junction box with a main component having leads using the junction box assembly equipment described in Example 1, and includes:

[0075] Step S1: The first feeding mechanism 200 feeds the first junction box with leads, while the second feeding mechanism 300 feeds the second junction box without leads. This provides the basic material supply for the entire assembly process. The first feeding mechanism 200 and the second feeding mechanism 300 feed the first junction box with leads and the second junction box without leads simultaneously and independently. Dedicated feeding paths are matched according to the structural differences between the two types of junction boxes to avoid confusion between the two types of junction boxes during the feeding stage. This achieves orderly and synchronous feeding of junction boxes with different structures, ensuring the continuous supply of materials for subsequent assembly processes and laying the material foundation for the efficient operation of the entire assembly process.

[0076] Step S2: The first junction box is identified by its front and back orientation. When the first junction box is facing forward, it is output directly. When the first junction box is facing backward, it is flipped to face forward before output. At the same time, the second junction box is vibrated by the flexible vibrating plate 340 to make at least a portion of the second junction box face forward. This achieves accurate front and back orientation identification and orientation correction for the first junction box. Forward junction boxes are output directly, and reverse junction boxes are output after being flipped, ensuring that the orientation of the first junction boxes entering subsequent processes is completely consistent, thus avoiding assembly failures caused by orientation deviations from the source. At the same time, the second junction box is oriented by the vibration of the flexible vibrating plate 340, so that at least a portion of the second junction box is in a forward orientation. This not only adapts to the structural characteristics of the second junction box without leads, but also provides a forward-oriented and qualified work object for the subsequent gripping process, realizing the standardization of the orientation of the two types of junction boxes and ensuring the accuracy of subsequent gripping and assembly.

[0077] Furthermore, step S2 in this embodiment specifically involves: identifying the front and back of the first junction box.

[0078] When the first junction box is in the positive direction, the stop plate 243 in the flip transmission assembly 240 is in the retracted state, and the flip plate 242 is tilted at 45° toward the first receiving belt 245 to directly output the first junction box.

[0079] When the first junction box is in the reverse direction, the stop plate 243 in the flip transmission assembly 240 is in the extended state to stop the first junction box on the flip plate 242. The flip plate 242 is tilted 135° toward the first receiving belt 245 to flip the first junction box to the forward direction for output.

[0080] In different embodiments, when the first junction box is facing forward, the flip plate 242 can be tilted 30~60° toward the first receiving strip 245 according to actual usage requirements. Correspondingly, when the first junction box is facing backward, the flip plate 242 can be tilted 130~150° toward the first receiving strip 245 according to actual usage requirements. The present invention does not impose specific limitations on this.

[0081] Step S3: The gripping mechanism 400 grips the forward junction box and moves it to the transmission mechanism 500. This achieves precise material connection between the feeding and assembly processes. The gripping mechanism 400 precisely grips the first and second forward junction boxes processed in step S2, effectively identifying and screening qualified forward junction boxes to prevent unqualified products from entering the subsequent transmission and assembly stages. At the same time, the gripped forward junction boxes are transferred to the transmission mechanism 500, which achieves directional and stable transmission of the junction boxes from the gripping station to the assembly station, ensuring that the junction boxes remain stable in position and direction during the transfer process, thus preparing the station and materials for the subsequent precise insertion of the main component leads.

[0082] Step S4: The lead wire posture is identified by the lead wire identification camera 760 in the transfer mechanism 700, and the lead wire straightening mechanism 600 straightens the lead wire on the main component until it extends vertically upward. Specifically, step S4 is a key pre-process for achieving accurate insertion of the junction box and the main component lead wire. First, the lead wire identification camera 760 in the transfer mechanism 700 accurately identifies the actual posture of the main component lead wire, providing accurate posture basis for lead wire straightening and ensuring the targeting and effectiveness of the straightening action. Then, the lead wire straightening mechanism 600 straightens the main component lead wire until it extends vertically upward, thoroughly correcting problems such as lead wire skew, uneven spacing, and irregular posture, and aligning the lead wire to a standard posture and position that matches the junction box insertion. This avoids problems such as incomplete junction box insertion and poor contact due to lead wire posture deviation, providing a reliable lead wire foundation for subsequent accurate insertion.

[0083] Step S5: The junction box in the transmission mechanism 500 is inserted into the main component after the lead wire has been aligned by the transfer component 740 in the installation transfer mechanism 700. Specifically, step S5 is the core assembly process of the junction box and the main component. The transfer component 740 of the installation transfer mechanism 700 picks up the forward-facing junction box from the transmission mechanism 500, and relies on the multi-directional movement and positioning capability of the installation transfer mechanism 700 to accurately transfer the junction box to the lead wire of the main component after it has been aligned in step S4, so as to achieve accurate insertion of the junction box and the lead wire of the main component, and form a preliminary electrical connection between the junction box and the main component. This step relies on the results of the previous processing of the junction box orientation standardization and lead wire posture standardization to ensure the accuracy and stability of the insertion process, effectively improve the insertion fit of the junction box and the lead wire of the main component, and avoid component damage and assembly failure caused by misalignment.

[0084] Step S6: The lead wire passing through the junction box is bent using the material-pulling component 750 in the installation transfer mechanism 700 to connect the junction box and the main component. Step S6 is the core finishing process for completing the assembly of the junction box and the main component. After the junction box is connected to the main component lead wire, the material-pulling component 750 in the installation transfer mechanism 700 performs a precise bending operation on the main component lead wire passing through the junction box. The structural design of the material-pulling component 750 achieves orderly and standardized bending of the lead wire, forming a reliable mechanical and electrical connection between the lead wire and the junction box, thus completely completing the assembly of the junction box and the main component. This step replaces manual operation with automated mechanical bending, ensuring that the bending angle and position of the lead wire are uniform and standardized, improving the firmness and stability of the connection between the junction box and the main component, ensuring that the overall structure after assembly has good electrical conductivity and structural reliability, and avoiding problems such as lead wire loosening and poor contact during subsequent use.

[0085] In summary, the junction box assembly equipment and method described in this invention can realize the integrated automated assembly of a first junction box with leads and a second junction box without leads, effectively adapting to the assembly requirements of two types of junction boxes and leaded main components.

[0086] With the cooperation of the feeding recognition camera 250 and the flipping transmission component 240 of the first feeding mechanism 200, the orientation of the first junction box can be accurately detected and corrected, ensuring that the first junction box is output in the correct orientation to the subsequent process. The second feeding mechanism 300 realizes the stable feeding and orderly supply of the second junction box through the guide chute 310 and the flexible vibrating plate 340. With the cooperation of the dual recognition camera of the gripping mechanism 400, the two types of correct orientation junction boxes are accurately identified. Then, the gripping robotic arm 410 completes the accurate gripping of the two types of junction boxes and classifies and transfers them to different transmission tables 530 of the transmission mechanism 500, realizing the orderly transmission and feeding connection of the two types of junction boxes, effectively avoiding the problems of junction box type confusion and orientation deviation.

[0087] The lead wire straightening mechanism 600 in this junction box assembly equipment can separate and position the two leads of the main component by inserting the push claw 641 between them. Then, the clamping arms 643 with limit hooks 6431 on both sides move in multiple directions to clamp and straighten the leads. This can quickly arrange the leads of the main component to a regular assembly position, solving the problem that the skewed and uneven spacing of the main component leads affects the connection of the junction box, and laying the foundation for the accurate assembly of the junction box. Meanwhile, the installation and transfer mechanism 700 accurately identifies the position of the main component's lead wire after it has been straightened using the lead wire recognition camera 760. In conjunction with the transfer gripper 743, it precisely inserts the forward-facing junction box onto the main component's lead wire. Then, the material-pulling claw 753 moves along the lead wire arrangement direction to complete the lead wire bending operation, realizing an integrated operation of junction box insertion and lead wire bending. The complete assembly of the junction box and the main component can be completed without manual intervention. Moreover, the coordinated operation of each mechanism realizes the fully automated operation from junction box feeding, direction correction, type sorting, and precise gripping, to main component lead wire straightening, precise junction box insertion, and lead wire bending. This replaces the traditional manual assembly method with small hand tools, greatly improving the assembly efficiency of the junction box and the main component, and adapting to the needs of large-scale production.

[0088] Furthermore, this equipment is highly integrated, with a compact structure and smooth connections between various processes. Positioning, identification, insertion, and bending operations during assembly are all precisely completed by the mechanical structure, effectively avoiding problems such as insertion deviation, uneven force, and incomplete bending of lead wires that are prone to occur in existing operations. This improves the assembly accuracy and connection stability of the junction box and the main components, reduces the product rework rate, reduces labor costs, avoids operational errors caused by high-intensity manual work, and improves the production safety and product quality consistency of the photovoltaic module junction box assembly process.

[0089] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A junction box assembly device, characterized in that: For assembling a junction box with a main component having leads, the junction box includes a first junction box with leads and a second junction box without leads, comprising: frame; The first feeding mechanism includes a material box, a feeding recognition camera, a feeding robotic arm, and a flipping transmission assembly. A first junction box is located in the material box and can move toward the flipping transmission assembly. The feeding robotic arm is disposed between the material box and the flipping transmission assembly. The feeding recognition camera is connected to the frame and located at the feeding end of the flipping transmission assembly to detect the orientation of the first junction box. The flipping transmission assembly includes a flipping plate and a first receiving belt. The flipping plate can drive the first junction box with the reverse orientation to flip so as to output the first junction box with the forward orientation to the first receiving belt. The second feeding mechanism includes a guide chute and a flexible vibrating plate. The second junction box enters the flexible vibrating plate through the guide chute. A gripping mechanism includes a gripping robotic arm, a first recognition camera, and a second recognition camera. The first recognition camera is connected to the frame and is positioned towards the discharge end of the first receiving belt. The second recognition camera is connected to the frame and is positioned towards the flexible vibrating disc. The gripping robotic arm is positioned at the discharge ends of the first receiving belt and the flexible vibrating disc, and is connected to the first recognition camera and the second recognition camera respectively, to grip a forward-facing junction box. A transmission mechanism is disposed on one side of the gripping mechanism and includes multiple transmission platforms. The junction box enters different transmission platforms through the gripping mechanism and moves along a first direction through the transmission platforms. A lead wire straightening mechanism is slidably connected to the frame and disposed above the main component supply line. The straightening mechanism includes a straightening component, which includes a pusher and two clamping arms. The pusher can move along a first direction to pass between two leads of the main component. The two clamping arms are disposed on both sides of the pusher and can move along the first direction and / or a second direction. The lead wire of the main component is located between the clamping arms and the pusher. Each clamping arm includes a limiting hook that bends toward the pusher to straighten the lead wire. The installation and transfer mechanism is slidably connected to the frame and can move between the transmission mechanism and the main component supply line. The installation and transfer mechanism includes an assembly frame, a transfer component, a material feeding component, and a lead wire identification camera. The transfer component is located on the side of the assembly frame facing the transmission mechanism and includes transfer grippers that can hold junction boxes. The material feeding component is located corresponding to the transfer component and includes two material feeding grippers that can open and close along the main component lead wire arrangement direction. The lead wire identification camera is located on the side of the assembly frame away from the transmission mechanism and is connected to the material feeding component. The transfer gripper inserts the positively oriented junction box into the main component after the lead wire has been aligned, and then the material-pulling gripper bends the lead wire to connect the junction box and the main component.

2. The junction box assembly equipment according to claim 1, characterized in that: The first feeding mechanism includes a material box circulation assembly, which includes a fixed frame, two docking conveyor belts, a lifting platform, and a feeding belt. The fixed frame is located at one end of the frame in a first direction. The two docking conveyor belts are arranged vertically on the fixed frame, and the two docking conveyor belts have opposite transmission directions. The lifting platform is located inside the frame and between the fixed frame and the flipping conveyor assembly. The lifting platform can move up and down vertically. The feeding belt is located on the lifting platform and moves synchronously with the lifting platform to dock with either of the docking conveyor belts. The material box can enter the frame through one docking conveyor belt and leave the frame through the other docking conveyor belt for cyclic feeding.

3. The junction box assembly equipment according to claim 1, characterized in that: The flipping transmission assembly further includes a mounting plate, a stop plate, and a stop driver. The mounting plate is connected to the frame, and the flipping plate is rotatably connected to the mounting plate about a rotation center line. The stop driver is located at the bottom of the flipping plate, and the stop plate is connected to the power output end of the stop driver and positioned between the flipping plate and the first receiving belt. When the feed recognition camera identifies the first junction box as positive, the stop plate is in a retracted state, and the flip plate is tilted toward the first receiving belt to directly output the first junction box; When the feed identification camera identifies the first junction box as being in the reverse direction, the stop plate is in the extended state, and the flip plate flips towards the first receiving belt to flip the first junction box so that it is in the forward direction for output.

4. The junction box assembly equipment according to claim 3, characterized in that: The flipping and conveying assembly also includes two guide ribs and a buffer platform. The buffer platform is connected to the frame and located at the output end of the first receiving belt. The two guide ribs are respectively connected to the mounting plate and gradually extend inward from the edge of the first receiving belt in the width direction toward the buffer platform.

5. The junction box assembly equipment according to claim 1, characterized in that: The second feeding mechanism also includes a second receiving belt and a pusher feeding machine. The second receiving belt is connected to the frame and is located at the discharge end of the guide chute. It can transmit the second junction box toward the pusher feeding machine. The flexible vibrating plate is located at the discharge end of the pusher feeding machine.

6. The junction box assembly equipment according to claim 1, characterized in that: Both the first feeding mechanism and the second feeding mechanism are provided with a recycling channel, and the recycling channel is located on one side of the gripping mechanism.

7. The junction box assembly equipment according to claim 1, characterized in that: The transmission mechanism includes a housing, a support panel, a plurality of transmission platforms, and a transmission drive assembly. The housing is connected to the frame. The plurality of transmission platforms are disposed in the housing and arranged at intervals along a second direction. The transmission drive assembly drives the plurality of transmission platforms to reciprocate along a first direction. The support panel is fastened to the top of the housing and is provided with a plurality of material transfer channels extending along the first direction. The transmission platforms can pass through the material transfer channels to the top of the support panel. The lead-out end of the first junction box can be supported on the support panel.

8. The junction box assembly equipment according to claim 7, characterized in that: The transmission platform includes a movable base frame, a platform body, two limiting plates, and a limiting driver. The movable base frame is connected to the power output end of the transmission drive assembly. The platform body is disposed on the movable base frame, and a limiting protrusion is provided at one end in a second direction. The limiting driver is connected to the movable base frame and is located on one side of the platform body. The two limiting plates are respectively disposed on both sides of the platform body in a first direction and are respectively connected to the power output end of the limiting driver for relative opening and closing movement.

9. The junction box assembly equipment according to claim 1, characterized in that: The lead wire straightening mechanism includes an installation beam and a lifting beam. The installation beam is connected to the frame, and the lifting beam is slidably connected to the installation beam along a third direction. A horizontal adjustment module is provided at the bottom of the lifting beam, and multiple straightening components are respectively disposed on the horizontal adjustment module to move along a second direction.

10. The junction box assembly equipment according to claim 9, characterized in that: The straightening assembly also includes a push drive and a side pressure drive. The push drive is connected to the leveling module. The push claw is connected to the power output end of the push drive to move along the first direction. The side pressure drive is located at the bottom of the push drive. The two clamping arms are respectively connected to the power output end of the side pressure drive to move relative to each other on both sides of the push claw along the second direction.

11. The junction box assembly equipment according to claim 1, characterized in that: The installation and transfer mechanism includes a slide, which is slidably connected to the frame along a first direction. A transfer module extending along a second direction is provided on the slide. Multiple assembly racks are slidably connected to the transfer module. Each assembly rack is provided with a lifting module. The transfer component is slidably connected to the lifting module along a third direction.

12. The junction box assembly equipment according to claim 1, characterized in that: The transfer assembly includes a fine-tuning module and a transfer driver. The fine-tuning module is disposed on the assembly frame and extends along the second direction. The transfer driver is slidably connected to the fine-tuning module. The two transfer grippers are respectively connected to the power output end of the transfer driver and move relative to each other along the first direction.

13. The junction box assembly equipment according to claim 12, characterized in that: The material feeding assembly also includes a connecting beam and a material feeding module. The connecting beam is connected to the bottom of the transfer driver and is located between the two transfer grippers. The material feeding module is disposed on the connecting beam and extends along the second direction. The two material feeding grippers are slidably connected to the material feeding module and move open and close along the second direction. The surfaces of any material feeding grippers that are far apart from each other are configured as inclined structures that can be inserted between two adjacent leads of the main component.

14. The junction box assembly equipment according to claim 1, characterized in that: The junction box assembly equipment also includes a control mechanism, and the first feeding mechanism, the second feeding mechanism, the gripping mechanism, the transmission mechanism, the lead wire straightening mechanism, and the installation and transfer mechanism are respectively signal-connected to the control mechanism.

15. A junction box assembly method, characterized in that: Assembling a junction box with a main component having leads using the junction box assembly equipment according to any one of claims 1 to 14, comprising: Step S1: The first feeding mechanism feeds the first junction box with leads, and the second feeding mechanism feeds the second junction box without leads. Step S2: Identify the front and back of the first junction box. When the first junction box is facing forward, output directly. When the first junction box is facing backward, flip the first junction box to face forward and output. At the same time, vibrate the second junction box with a flexible vibrating plate to make at least part of the second junction box face forward. Step S3: The forward junction box is picked up by the gripping mechanism and moved into the transmission mechanism; Step S4: The lead wire attitude is identified by the lead wire recognition camera in the installation transfer mechanism, and the lead wire on the main component is straightened by the lead wire straightening mechanism until the lead wire extends upward in the vertical direction. Step S5: Connect the junction box in the transmission mechanism to the main component after the lead wire has been aligned by installing the transfer component in the transfer mechanism; Step S6: Bend the lead wire passing through the junction box by installing the material transfer assembly in the transfer mechanism to connect the junction box and the main component.

16. The junction box assembly method according to claim 15, characterized in that: Step S2 specifically involves: identifying the front and back of the first junction box. When the first junction box is in the positive direction, the stop plate in the flip transmission assembly is in the retracted state, and the flip plate is tilted 30~60° toward the first receiving belt to directly output the first junction box. When the first junction box is in the reverse direction, the stop plate in the flip transmission assembly is in the extended state to stop the first junction box on the flip plate. The flip plate is tilted 130~150° toward the first receiving belt to flip the first junction box to the forward direction for output.

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