Automatic coil assembling production line and assembling method

Abstract

The invention discloses an automatic coil assembling production line and an assembling method. The automatic coil assembling production line comprises a circulating conveying device, a secondary winding feeding device, a first press-fitting mechanism, a magnet assembling device, an iron core assembling device, a filling block assembling device, a second press-fitting mechanism, a low-voltage head assembling device, a conduction testing mechanism, a capacitance-resistance testing mechanism, a defective product discharging device and a finished product receiving device. The automatic coil assembling method comprises the steps of assembling of the primary winding and the secondary winding, assembling of the magnet, assembling of the C iron core, assembling of the filling block, assembling of the shell, assembling of the low-voltage head, conduction testing of the coil, measurement of the capacitance and the resistance of the coil, discharging of unqualified products and discharging of qualified products. Through full-process automation, flexible station design, key process optimization and an intelligent detection and material receiving system, high-efficiency, high-quality and flexible production of coils is realized.

Description

Technical Field

[0001] This invention belongs to the field of automation equipment technology, and in particular relates to an automatic coil assembly production line and assembly method. Background Technology

[0002] The engine ignition system is a crucial component of a car engine, and the coil is a key part of this system. The voltage from the battery is converted into high-voltage electricity after passing through the coil, providing sufficient ignition voltage to the spark plugs. Current coils consist of primary windings, secondary windings, magnets, a C-core, filler block, low-voltage head, and a housing, among other parts. Their specific structures can be referenced in the coils disclosed in Chinese utility model patent announcements CN209822427U and CN220420420U. The basic structures of the coils are similar, with slight differences in assembly. For some coils, the filler block or low-voltage head may be integrated with other components, eliminating the need for assembly. However, for others, all the aforementioned parts require individual assembly. Therefore, there is a pressing need for automated equipment capable of assembling these components and adapting to various coil structures.

[0003] In existing technologies, such as the coil assembly and testing production line and method disclosed in Chinese Invention Patent Publication No. CN115255929B, the main focus is on the assembly and testing of the housing and sheath, without mentioning the assembly of other parts. Similarly, the coil and assembly method disclosed in Chinese Invention Patent Publication No. CN104979090B only discloses the assembly method of the secondary winding. Furthermore, the automatic assembly system for automotive ignition wires disclosed in Chinese Invention Patent Application Publication No. CN106710865A uses two six-axis robots to complete coil welding, core assembly, and resistance and inductance testing. This solution, on the one hand, does not mention the assembly of the low-voltage head or the housing; on the other hand, it relies entirely on robotic operations, resulting in high production costs. Therefore, the existing technologies do not form a complete coil assembly production line, nor do they provide corresponding assembly methods. Moreover, the coil assembly in existing technologies is done at single or partial workstations, with the coil then moved to other workstations after completion, leading to process interruptions and low efficiency.

[0004] Therefore, it is necessary to provide an automated coil assembly production line and assembly method to solve the above-mentioned technical problems. Summary of the Invention

[0005] The main objective of this invention is to provide an automated coil assembly production line that achieves efficient, high-quality, and flexible coil production through full-process automation, flexible chemical station design, key process optimization, and intelligent detection and receiving system.

[0006] This invention achieves the above-mentioned objective through the following technical solution: an automatic coil assembly production line, comprising a circulating conveying device for a conveying carrier, and sequentially arranged along the conveying direction of the circulating conveying device are a first loading station, a first pressing station, a first assembly station, a second loading station, a second assembly station, a third assembly station, a second pressing station, a fourth assembly station, a first testing station, a second testing station, a defective product unloading station, and a finished product receiving station. A secondary winding feeding device is provided at the first loading station, and a secondary winding feeding device is provided at the first pressing station. The assembly includes a first pressing mechanism, a magnet assembly device at the first assembly station, an iron core assembly device at the second assembly station, a filler block assembly device at the third assembly station, a second pressing mechanism at the second pressing station, a low-pressure head assembly device at the fourth assembly station, a continuity testing mechanism at the first testing station, a capacitance and resistance testing mechanism at the second testing station, a defective product unloading device at the defective product unloading station, and a finished product receiving device at the finished product receiving station.

[0007] Furthermore, the circulating conveying device includes a first conveying line and a second conveying line arranged in parallel, a first connecting unit connected to one end of the first conveying line and the second conveying line, and a second connecting unit connected to the other end of the first conveying line and the second conveying line. The first connecting unit and the second connecting unit each include a first linear drive member, a first connecting plate connected to the movable end of the first linear drive member, and a second linear drive member disposed on the first connecting plate.

[0008] Furthermore, the secondary winding feeding device includes a feeding unit for placing a material tray, a tray removal unit for removing the material tray from the feeding unit, and a material removal robot. A first vision inspection camera and a defective product placement unit are arranged next to the material removal robot.

[0009] Furthermore, the first pressing mechanism includes a first X-axis drive member, a first support plate driven by the first X-axis drive member to move along the X direction, a first pressing cylinder disposed on the first support plate, and a first pressing head driven by the first pressing cylinder to move up and down; the second pressing mechanism includes a second X-axis drive member, a second support plate driven by the second X-axis drive member to move along the X direction, a second pressing cylinder disposed on the second support plate, and a second pressing head driven by the second pressing cylinder to move up and down.

[0010] Furthermore, the magnet assembly device includes a magnet feeding unit, a material dispensing and positioning unit, and an adsorption unit; The magnet feeding unit includes several vertically extending material boxes, a first mounting plate for mounting the material boxes, a material changing cylinder for driving the first mounting plate to move, and a material pressing assembly for pressing the material boxes inside. The material dispensing and positioning unit includes a material dispensing cylinder and a first positioning plate connected to the movable end of the material dispensing cylinder. The first positioning plate is located below the material box, and a first positioning groove is provided at one end of the first positioning plate.

[0011] Furthermore, the core assembly device includes a core assembly unit and a first conveying mechanism; The iron core assembly unit includes a rotary disk and a loading station and a unloading station arranged on the rotary disk. An assembly mechanism is provided at both the loading station and the unloading station. The assembly mechanism includes a first positioning seat, a first pressing component disposed at one end of the first positioning seat, a second pressing component disposed at the other end of the first positioning seat, a first positioning module disposed on one side of the first positioning seat, and a second positioning module disposed on the other side of the first positioning seat.

[0012] Furthermore, the filling block assembly device includes a positioning seat and a second conveying mechanism. The positioning seat is provided with a first contour positioning groove. The second conveying mechanism includes a first XYZ drive module, a third support plate connected to the movable end of the first XYZ drive module, a first rotary drive member disposed on the third support plate, a fourth support plate driven by the first rotary drive member to rotate around a vertical axis, a first clamping component disposed on the fourth support plate, and a second clamping component.

[0013] Furthermore, the low-pressure head assembly device includes a third X-axis drive component, a fifth support plate that is driven by the third X-axis drive component to move along the X direction, and a third clamping component, a pressing component, and a positioning component that are sequentially arranged on the fifth support plate.

[0014] Furthermore, both the continuity testing mechanism and the capacitance testing mechanism include a fourth X-axis drive component, a sixth support plate that moves along the X direction driven by the fourth X-axis drive component, a first detection component disposed on the sixth support plate, and a second detection component disposed below the first detection component.

[0015] Furthermore, the defective product unloading device includes a first conveying module and a third transport mechanism disposed above the first conveying module.

[0016] Furthermore, the finished product receiving device includes a conveying device for conveying customized material trays and a fourth handling mechanism disposed above the conveying device; The conveying device includes an upper first conveying mechanism, a lower second conveying mechanism, and a lifting mechanism connected to one end of both the first and second conveying mechanisms. The first and / or second conveying mechanisms are equipped with a detection module for detecting the direction of the customized material tray.

[0017] Furthermore, each of the aforementioned workstations is equipped with a stop assembly, a lifting and positioning mechanism, and a sensor array; The sensor group is located on both sides of the vehicle, and the sensor group includes several sensors; The stop assembly includes a stop block and a stop cylinder that drives the stop block to rotate or move up and down; The lifting and positioning mechanism includes a lifting plate and a lifting cylinder that drives the lifting plate to move up and down.

[0018] Another object of the present invention is to provide an automatic coil assembly method, which is based on the above-mentioned automatic coil assembly production line and includes the following steps: S1. The circulating conveying device transports the carrier to the first loading station, the secondary winding feeding device positions the secondary winding on the carrier, and at the same time positions the outer shell on the carrier, and then positions the primary winding inside the secondary winding. S2. The circulating conveying device transports the carrier to the first pressing station, and the first pressing mechanism presses the primary winding into the interior of the secondary winding to obtain the first winding assembly. S3. The circulating conveying device transports the carrier to the first assembly station, and the magnet assembly device assembles the magnet onto the first winding assembly to obtain the second winding assembly. S4. The circulating conveyor transports the carrier to the second loading station and positions the filling block and low-pressure head onto the carrier. S5. The circulating conveying device transports the carrier to the second assembly station, and the core assembly device assembles the C core onto the outer periphery of the second winding assembly to obtain the first coil assembly. S6. The circulating conveying device transports the carrier to the third assembly station. The filler block assembly device first removes the first coil assembly from the iron core assembly device. Then, the filler block assembly device pre-assembles the filler block onto the first coil assembly to obtain a pre-assembled second coil assembly. Then, the filler block assembly device clamps the pre-assembled second coil assembly and moves it above the carrier to pre-assemble the pre-assembled second coil assembly onto the outer shell. S7. The circulating conveying device transports the carrier to the second pressing station, and the second pressing mechanism presses the pre-assembled second coil assembly and filler block completely into the housing to obtain the third coil assembly. S8. The circulating conveyor transports the carrier to the fourth assembly station, and the low-pressure head assembly device assembles the low-pressure head onto the third coil assembly to obtain the coil. S9. The circulating conveying device transports the carrier to the first test station, and the continuity testing mechanism performs an electrical continuity test on the coil. S10. The circulating conveying device transports the carrier to the second testing station, and the capacitance and resistance testing mechanism measures the capacitance and resistance of the coil. S11. The circulating conveying device transports the carrier to the defective product unloading station, and the defective product unloading device removes the unqualified coils. S12. The circulating conveyor transports the carrier to the finished product receiving station, and the finished product receiving device removes the qualified coil.

[0019] Compared with the prior art, the advantages of the automatic coil assembly production line and assembly method of the present invention are as follows: 1. Achieve fully automated assembly process and improve production efficiency: (1) By designing a complete assembly production line with multiple continuous workstations, the entire process from feeding multiple parts and assembling multiple parts to final product testing and receiving is fully automated, solving the problems of process interruption and low efficiency caused by single workstation or partial workstation operation in the existing technology; (2) The coordinated operation of the circulating conveyor and the various workstations ensures the seamless flow of materials between processes, greatly reduces manual intervention and waiting time, and improves overall production efficiency. 2. Highly flexible design, adaptable to various coil structures: (1) The carrier is equipped with multiple sets of contour positioning slots (such as double secondary winding slots, double shell slots, etc.), which can be compatible with the assembly requirements of coils with different structures, thus enhancing the versatility of the production line; (2) Key work stations (such as filler block assembly and low-pressure head assembly) have selective operation capabilities, and the process flow can be flexibly adjusted according to the product structure to achieve "one machine for multiple uses" and reduce equipment investment costs. 3. Optimize key processes to improve assembly quality and yield: (1) Anti-fracture design for magnet assembly: The magnet is slowly moved along the mounting surface by the adsorption unit, which avoids the problem of magnet breakage caused by uneven local force and improves the assembly reliability. (2) Precise positioning of iron core assembly: The rotary disc dual-station design, combined with multiple sets of clamping and positioning modules, ensures the precise splicing of C iron core and winding assembly, and improves the structural stability of the product; (3) Pressing and positioning coordination: During the low-pressure head pressing process, the locating pin and the pressing head work together to prevent component displacement and ensure the stability and consistency of the pressing process. 4. Integrated testing system for comprehensive quality monitoring: (1) Set up sensor groups and vision inspection cameras at each workstation to monitor the position, appearance and assembly status of parts in real time to ensure the pass rate of each process; (2) The continuity test and capacitance test stations conduct comprehensive electrical performance tests on the finished products. Combined with the automatic sorting mechanism for defective products, the quality and reliability of the products leaving the factory are effectively guaranteed.

[0020] 5. Intelligent logistics and material receiving system to improve the intelligence level of the production line. (1) The customized tray orientation detection module uses dual sensors in conjunction with the blocking mechanism to automatically identify the tray orientation and prevent material receiving errors caused by tray reversal; (2) The cleaning mechanism is set at the end of the circulating conveyor to realize the automatic cleaning and recycling of the carrier, which further improves the automation and intelligence of the production line; 6. Reduce production costs and reliance on manpower: (1) By replacing manual labor with automated equipment to complete highly repetitive and high-precision assembly operations, labor costs and human error are significantly reduced, and production consistency is improved; (2) The modular design of the workstations facilitates maintenance and expansion, reduces equipment downtime, and improves the overall economic benefits of the production line; 7. Technology integration and innovation to drive industry technological progress: By organically integrating various technologies such as visual inspection, robotic handling, precision pressing, and intelligent sensing, a set of efficient and reliable automated coil assembly solutions has been formed, providing a technological paradigm that can be learned from for the automotive parts manufacturing industry; Therefore, this solution achieves efficient, high-quality, and flexible production of coils through full-process automation, flexible chemical station design, key process optimization, and intelligent detection and material collection system. Attached Figure Description

[0021] Figure 1 This is a top view of the automatic coil assembly production line according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of the first conveyor line, the second conveyor line, and the first connecting unit according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the secondary winding feeding device according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of the first pressing mechanism, lifting and positioning mechanism, stop assembly, and sensor group in an embodiment of the present invention; Figure 5 This is a schematic diagram of the magnet assembly device according to an embodiment of the present invention; Figure 6 This is a schematic diagram of the structure of the magnet feeding unit and the material dispensing and positioning unit according to an embodiment of the present invention; Figure 7This is a schematic diagram of the structure of the core assembly device and the filler block assembly device according to an embodiment of the present invention; Figure 8 This is a schematic diagram of the assembly mechanism of the iron core assembly device according to an embodiment of the present invention; Figure 9 This is a schematic diagram of the first handling mechanism of the iron core assembly device according to an embodiment of the present invention; Figure 10 This is a schematic diagram of the second transport mechanism of the filler block assembly device according to an embodiment of the present invention; Figure 11 This is a schematic diagram of the structure of the second pressing mechanism according to an embodiment of the present invention; Figure 12 This is a schematic diagram of the low-pressure head assembly device according to an embodiment of the present invention; Figure 13 This is a schematic diagram of the low-pressure head assembly device of the present invention without the third X-axis drive component; Figure 14 This is a schematic diagram of the continuity testing mechanism or capacitance-resistance testing mechanism according to an embodiment of the present invention; Figure 15 This is a schematic diagram of the defective product unloading device according to an embodiment of the present invention; Figure 16 This is a schematic diagram of the finished product receiving device according to an embodiment of the present invention; Figure 17 This is a schematic diagram of the fourth conveying mechanism according to an embodiment of the present invention; Figure 18 This is a schematic diagram of the structure of the customized material tray and detection module in an embodiment of the present invention; Figure 19 This is a schematic diagram of the structure of the customized material tray in an embodiment of the present invention; The numbers in the diagram represent: 100-coil automated assembly line; 1-Circulating conveying device, 11-Carrier, 111-Secondary winding positioning slot, 112-Outer shell positioning slot, 113-Filling block positioning slot, 114-Low pressure head positioning slot, 12-First conveying line, 13-Second conveying line, 14-First connecting unit, 141-First linear drive, 142-First connecting plate, 143-Second linear drive, 15-Second connecting unit; 2-Secondary winding feeding device, 22-Feeding unit, 221-Material rack, 223-First lifting drive, 23-Pan picking unit, 231-Pan picking cylinder, 232-First bearing plate, 24-Picking robot, 241-Multi-axis manipulator, 242-First picking and placing assembly, 25-First vision inspection camera, 26-Defective product placement unit, 261-Second conveying module, 262-Baffle, 263-First placement area; 3-First pressing mechanism, 31-First X-axis drive component, 32-First support plate, 33-First pressing cylinder, 34-First pressing head; 4-Magnet assembly device, 41-Magnet feeding unit, 411-Material box, 412-First mounting plate, 413-Material changing cylinder, 414-Pressing assembly, 4141-Pressing rod, 4142-Pressing cylinder, 415-First sensor, 42-Material dispensing and positioning unit, 421-Material dispensing cylinder, 422-First positioning plate, 423-First positioning groove, 424-Second sensor, 43-Adsorption unit, 431-Second XYZ drive module, 432-Eighth support plate, 433-First adsorption assembly, 434-Second vision inspection camera, 44-First support frame, 45-First waste collection box; 5-Core assembly device, 51-Core assembly unit, 511-Rotating disk, 512-Loading station, 513-Unloading station, 514-Assembly mechanism, 5141-First positioning seat, 51411-First positioning structure, 51412-First limiting block, 51414-Second clearance hole, 5142-First clamping assembly, 51421-First clamping block, 51422-First driving component, 5143-Second clamping assembly, 51431-Second clamping block, 51432-Clamping cylinder, 5144-First positioning module, 51 45-Second positioning module, 51451-Third cylinder, 51452-First moving plate, 51453-First positioning block, 51454-Second positioning block, 51455-Fourth cylinder, 51456-Adsorption magnet, 51457-Fourth sensor, 51458-Fifth sensor, 515-First motor, 52-First conveying mechanism, 521-Third XYZ drive module, 522-Ninth support plate, 523-Second rotary drive component, 524-Tenth support plate, 525-First gripping cylinder, 526-First gripper; 6- Filler block assembly device, 61- Positioning seat, 611- First contour positioning groove, 612- Eighth sensor, 62- Second conveying mechanism, 621- First XYZ drive module, 622- Third support plate, 623- First rotary drive component, 624- Fourth support plate, 625- First clamping assembly, 6251- Second clamping cylinder, 6252- Second gripper, 626- Second clamping assembly; 7-Second pressing mechanism, 71-Second X-axis drive component, 72-Second support plate, 73-Second pressing cylinder, 74-Second pressing head; 8-Low-pressure head assembly device, 81-Third X-axis drive component, 82-Fifth support plate, 83-Third clamping assembly, 831-Sixth cylinder, 832-Eleventh support plate, 833-Seventh cylinder, 834-Third gripper, 84-Pressure assembly, 841-Third drive component, 842-Third pressure head, 85-Positioning assembly, 851-Fourth drive component, 852-First positioning pin; 9-Conductivity testing mechanism, 91-Fourth X-axis drive component, 92-Sixth support plate, 93-First detection component, 931-First cylinder, 932-First mounting block, 933-First probe, 94-Second detection component; 10 - Capacitive and resistive testing equipment; 20 - Defective product unloading device, 201 - First conveying module, 202 - Third handling mechanism, 2021 - First Y-axis drive component, 2022 - Twelfth support plate, 2023 - Sixth X-axis drive component, 2024 - Thirteenth support plate, 2025 - Fifth cylinder, 2026 - Fifteenth support plate, 2027 - Ninth cylinder, 2028 - Fourth gripper; 30-Finished product receiving device, 301-Conveying device, 3011-First conveying mechanism, 3012-Second conveying mechanism, 3013-Lifting mechanism, 3014-Detection module, 30141-Blocking plate, 30142-Blocking cylinder, 30143-Sixth sensor, 30144-Seventh sensor, 302-Fourth handling mechanism, 3021-Fourth XYZ drive module, 3022-Fourteenth support plate, 3023-Third rotary drive component, 3024-Eighth cylinder, 3025-Fifth gripper, 303-Customized tray, 3031-Plate, 3032-Second bearing plate, 3033-Bearing seat, 3034-Support column, 3035-Handle, 3036-Limiting plate, 30361-First blocking side, 30362-Second blocking side; 40-Lifting and positioning mechanism; 401-Lifting plate; 402-Lifting cylinder; 50-Stop assembly; 501-Stop block; 502-Stop cylinder; 60-Sensor group; 70-Cleaning mechanism. Detailed Implementation

[0022] Please refer to Figures 1-19This embodiment is an automatic coil assembly production line 100. The assembled coil is used in automobile engine ignition and functions as a transformer. The automatic coil assembly production line 100 includes a circulating conveying device 1 with a conveying carrier 11. Along the conveying direction of the circulating conveying device 1, there are sequentially arranged a first loading station, a first pressing station, a first assembly station, a second loading station, a second assembly station, a third assembly station, a second pressing station, a fourth assembly station, a first testing station, a second testing station, a defective product unloading station, and a finished product receiving station. The first loading station is equipped with a defective product unloading station. The device includes a winding feeding device 2, a first pressing mechanism 3 at the first pressing station, a magnet assembly device 4 at the first assembly station, an iron core assembly device 5 at the second assembly station, a filler block assembly device 6 at the third assembly station, a second pressing mechanism 7 at the second pressing station, a low-voltage head assembly device 8 at the fourth assembly station, a continuity testing mechanism 9 at the first testing station, a capacitance and resistance testing mechanism 10 at the second testing station, a defective product unloading device 20 at the defective product unloading station, and a finished product receiving device 30 at the finished product receiving station.

[0023] In this embodiment, the circulating conveyor 1 is configured in a "U" shape. The circulating conveyor 1 includes a first conveyor line 12 and a second conveyor line 13 arranged in parallel, a first connecting unit 14 connected to one end of the first conveyor line 12 and the second conveyor line 13, and a second connecting unit 15 connected to the other end of the first conveyor line 12 and the second conveyor line 13. The direction parallel to the conveying direction of the first conveyor line 12 and the second conveyor line 13 is the X direction, the direction perpendicular to the conveying direction of the first conveyor line 12 and the second conveyor line 13 is the Y direction, and the vertical direction is the Z direction. In this embodiment, a reversing mechanism is provided at the corner S of the first conveyor line 12 and the second conveyor line 13, which can change the direction of the conveyor line. The reversing mechanism can perform a 90° reversal or a reversal at other angles. The reversing mechanism is existing technology, and its design can be adopted, so it will not be described in detail here. In other embodiments, the circulating conveyor 1 can be configured as a ring-shaped circulating conveyor, an elliptical circulating conveyor, or a loop-shaped circulating conveyor. The specific structure of the circulating conveyor 1 is not limited here and can be adjusted according to the actual workstation layout and space.

[0024] The carrier 11 is provided with several positioning slots for positioning various parts. These slots are designed to mimic the structural shape of the parts for precise positioning. The positioning slots include a secondary winding positioning slot 111, a housing positioning slot 112, a filler block positioning slot 113, and a low-voltage head positioning slot 114. Some parts may have two or more positioning slots to allow for the assembly of coils with different structures. For example, in this embodiment, there are two secondary winding positioning slots 111 and two housing positioning slots 112, enabling the assembly of two different coil structures. Since some coils only have filler blocks and no low-voltage head, while others only have low-voltage head and no filler blocks, only one filler block positioning slot 113 and one low-voltage head positioning slot 114 are provided. In other embodiments, positioning slots with other structures can be added, and the number of positioning slots for each structure can be set according to actual conditions; no limitation is imposed here.

[0025] In this embodiment, the first connecting unit 14 and the second connecting unit 15 have the same or similar structures, and both include a first linear drive 141, a first connecting plate 142 connected to the movable end of the first linear drive 141, and a second linear drive 143 disposed on the first connecting plate 142. The second linear drive 143 drives the carrier 11 to move along the conveying direction of the first conveying line 12 or the second conveying line 13, and the first linear drive 141 drives the first connecting plate 142 to move along the conveying direction perpendicular to the first conveying line 12 or the second conveying line 13. The second connecting unit 15 transfers the carrier 11 on the second conveyor line 13 to the first conveyor line 12. The first connecting unit 14 transfers the carrier 11 on the first conveyor line 12 to the second conveyor line 13. Specifically, the working process of the first connecting unit 14 is as follows: when the carrier 11 moves to the end of the first conveyor line 12, the second linear drive 143 receives the carrier 11 and continues to convey the carrier 11 forward until the carrier 11 is completely on the second linear drive 143. The second linear drive 143 stops driving, and the first linear drive 141 drives the first connecting plate 142 to move the second linear drive 143 and the carrier 11 perpendicular to the first conveyor line 12 until the second linear drive 143 docks with the second conveyor line 13. The first linear drive 141 stops driving, and the second linear drive 143 reverses its driving direction to transfer the carrier to the second conveyor line 13. The working process of the first connecting unit 14 is similar to that of the second connecting unit 15, except that the direction of movement is opposite, and will not be described in detail here.

[0026] Each workstation is equipped with a stop assembly 50, a lifting and positioning mechanism 40, and a sensor group 60. The sensor group 60 is located on both sides of the carrier 11 and is used to detect whether various parts are placed on the carrier 11. It can also simultaneously detect the position and appearance of the parts for any abnormalities. The sensor group 60 includes several sensors, and their specific number and position can be set according to actual conditions and are not limited here. The stop assembly 50 is located on the first conveyor line 12 and the second conveyor line 13. It is used to stop the carrier 11. The stop assembly 50 includes a stop block 501 and a stop cylinder 502 that drives the stop block 501 to rotate or move up and down. Each workstation is set along the conveying direction of the first conveyor line 12 and the second conveyor line 13. Therefore, the lifting and positioning mechanism 40 is set below the first conveyor line 12 and the second conveyor line 13. The lifting and positioning mechanism 40 includes a lifting plate 401 and a lifting cylinder 402 that drives the lifting plate 401 to move up and down. After the stop assembly 50 stops the carrier 11, the lifting cylinder 402 drives the lifting plate 401 to rise and lift the carrier 11 to facilitate assembly. The lifting plate 401 is provided with several positioning pins to accurately position the carrier 11.

[0027] The secondary winding feeding device 2 includes a feeding unit 22 for placing a tray, a tray-removing unit 23 for removing the tray from the feeding unit 2, and a tray-removing robot 24 for removing the secondary winding from the tray. A first visual inspection camera 25 and a defective product placement unit 26 are also provided beside the tray-removing robot 24. The feeding unit 22 includes a tray rack 221 and a first lifting drive 223 for driving the tray rack 221 up and down. Several pairs of support components for carrying the tray are spaced vertically on both sides of the tray rack 221. The tray rack 221 is open along the moving direction of the tray-removing unit 23 to allow the tray-removing unit 23 to extend into the tray rack 221 to remove the tray. The tray-removing unit 23 includes a tray-removing cylinder 231 and a first support plate 232 driven by the tray-removing cylinder 231 to move horizontally. Several positioning components are provided on the first support plate 232, and a first positioning hole that mates with the positioning components is provided at the bottom of the tray to facilitate positioning of the first support plate 232 and the tray. The tray-removing cylinder 231 drives the first support plate 232 to extend into the bottom of the tray layer. The first lifting drive component 223 drives the material rack 221 to lower the tray, positioning it on the first support plate 232. The tray-removing cylinder 231 then drives the first support plate 232 to extend. After the secondary windings on the tray layer are removed, the tray-removing cylinder 231 drives the first support plate 232 to extend directly above the support component that is empty of trays. The first lifting drive component 223 then drives the material rack 221 to raise the support component to receive the empty tray, thus realizing the tray-removing and placing action.

[0028] The material handling robot 24 includes a multi-axis manipulator 241 and a first pick-and-place assembly 242 disposed at the movable end of the multi-axis manipulator 241. The first pick-and-place assembly 242 includes a first pick-and-place cylinder and a pair of pick-and-place claws that are driven by the first pick-and-place cylinder to open or clamp. When the pair of pick-and-place claws are open, they can support the inner wall of the secondary winding to facilitate the removal of the secondary winding. When the pick-and-place claws are clamped, they disengage from the inner wall of the secondary winding to facilitate the placement of the secondary winding. During inspection at the first visual inspection camera 25, the multi-axis manipulator 241 drives the first pick-and-place assembly 242 to move or rotate in multiple directions, enabling multi-angle inspection of the secondary winding, thereby ensuring the accuracy of the inspection. If the secondary winding passes the visual inspection, the picking robot 24 places it into the secondary winding positioning slot 111 on the carrier 11 of the first conveyor line 12. If the visual inspection fails, it is placed on the defective product placement unit 26. The defective product placement unit 26 includes a second conveying module 261 and several partitions 262 that are equally spaced and parallel to each other on the second conveying module 261. A first placement interval 263 for placing secondary windings is formed between two adjacent partitions 262. After the defective secondary winding is placed in the first placement interval 263, the second conveying module 261 drives the secondary winding to move forward so that more defective secondary windings can be placed.

[0029] The first pressing mechanism 3 includes a first X-axis drive 31, a first support plate 32 driven by the first X-axis drive 31 to move along the X direction, a first pressing cylinder 33 mounted on the first support plate 32, and a first pressing head 34 driven by the first pressing cylinder 33 to move up and down. At the first feeding station, the secondary winding is automatically fed by a material tray, while the primary winding and the outer shell are manually fed. Therefore, the first feeding station is equipped with several material frames for placing the primary winding and the outer shell. The outer shell is manually placed into the outer shell positioning slot 112, and the primary winding is placed inside the secondary winding. The first pressing mechanism 3 is used to press the primary winding downward and completely press the primary winding inside the secondary winding. That is, the first X-axis drive 31 drives the first support plate 32 to move the first pressing head 34 to directly above the primary winding, and the first pressing cylinder 33 drives the first pressing head 34 downward and completely presses the primary winding inside the secondary winding to obtain the first winding assembly, thus realizing the pressing action of the primary winding and the secondary winding. In other embodiments, a corresponding conveying mechanism can be set up to realize the automatic feeding action of the primary winding and the outer shell, thereby achieving fully automated production.

[0030] The magnet assembly device 4 includes a magnet feeding unit 41, a dispensing and positioning unit 42 for dispensing individual magnets from the magnet feeding unit 41, and an adsorption unit 43 for adsorbing individual magnets from the dispensing and positioning unit 42. The magnet feeding unit 41 and the dispensing and positioning unit 42 are jointly arranged on a first support frame 44 and located on the side of the first conveyor line 12. The adsorption unit 43 is located above the first conveyor line 12. A first waste collection box 45 is arranged on the side of the first support frame 44.

[0031] The magnet feeding unit 41 includes several vertically extending material boxes 411, a first mounting plate 412 for mounting the material boxes 411, a material changing cylinder 413 for driving the first mounting plate 412 to switch between different material boxes 411, and a pressing assembly 414 that presses against the uppermost magnet inside the material box 411. A first sensor 415 for detecting whether there is a magnet inside the material box 411 is provided at the bottom of the material box 411. Both the material changing cylinder 413 and the first sensor 415 are mounted on a first support frame 44. The pressing assembly 414 includes a pressing rod 4141 and a pressing cylinder 4142 for driving the pressing rod 4141 to move up and down. The pressing cylinder 4142 is mounted on the first support frame 44.

[0032] The material dispensing and positioning unit 42 includes a material dispensing cylinder 421 and a first positioning plate 422 connected to the movable end of the material dispensing cylinder 421. The first positioning plate 422 is located below the material box 411. One end of the first positioning plate 422 is provided with a first positioning groove 423 for positioning magnets, and the other end of the first positioning plate 422 can be supported on the bottom of the material box 411 to prevent magnets inside the material box 411 from falling out. A second sensor 424 is provided below the first positioning groove 423, and a first clearance hole is provided in the first positioning groove 423 for the detection line of the second sensor 424 to pass through. The height of the first positioning groove 423 is contoured to the height of a single magnet, that is, the first positioning groove 423 can only accommodate one magnet, so as to realize the dispensing action of magnets.

[0033] The adsorption unit 43 includes a second XYZ drive module 431, an eighth support plate 432 connected to the active end of the second XYZ drive module 431, and a first adsorption component 433 and a second visual inspection camera 434 disposed on the eighth support plate 432. The first adsorption component 433 includes an adsorption block and a suction nozzle disposed on the adsorption block.

[0034] The assembly process of the magnet assembly device 4 is as follows: The material box 411 is filled with magnets. The dispensing cylinder 421 drives the first positioning plate 422 to move, positioning the first positioning groove 423 directly below the material box 411. A magnet falls into the first positioning groove 423. The second sensor 424 detects the magnet in the first positioning groove 423 and sends a signal to the dispensing cylinder 421. The dispensing cylinder 421 drives the first positioning plate 422 to move the magnet towards the adsorption unit 43. That is, one end of the first positioning plate 422 with the first positioning groove 423 moves closer to the adsorption unit 43 to facilitate the adsorption and transport of the magnet. Simultaneously, the other end of the first positioning plate 422... The end is blocked at the bottom of the material box 411 to prevent the magnet inside the material box 411 from falling out. As the magnet inside the material box 411 continues to move downward, the pressing cylinder 4142 continuously drives the pressing rod 4141 downward, so that the pressing rod 4141 presses against the uppermost magnet, so that the lower magnet can move downward smoothly. After the first positioning plate 422 moves into place, the second XYZ drive module 431 drives the second vision inspection camera 434 to move directly above the magnet. First, it takes a picture of the magnet on the first positioning groove 423 for inspection. If the magnet fails the inspection, the second XYZ drive module 431 drives the first adsorption component 433. The magnet is placed in the first waste collection box 45. If the magnet passes the inspection, the second XYZ drive module 431 drives the first adsorption component 433 to adsorb the magnet and transport it to the carrier 11. The magnet is then assembled onto the magnet mounting surface of the first winding component to form the second winding component. The magnet mounting surface of the first winding component is made of iron, which allows it to attract the magnet. However, the magnet is thin and flat. If the magnet is placed directly onto the magnet mounting surface, the magnet will attract the magnet, and the magnet may break due to uneven local force. To solve this problem, this solution optimizes the magnet assembly. During the assembly process, the second XYZ drive module 431 drives the first adsorption component 433 to lower the magnet to a set height and position it on one side of the magnet mounting surface. The second XYZ drive module 431 then drives the first adsorption component 433 to move the magnet toward the magnet mounting surface, where it automatically adheres. The second XYZ drive module 431 then drives the first adsorption component 433 to continue moving the magnet along the magnet mounting surface until it is in place, thus assembling the magnet. The magnet moves slowly along the surface of the magnet mounting surface, and the magnet mounting surface can also adsorb and support the magnet, preventing the aforementioned problem of magnet breakage.

[0035] The second feeding station is located between the magnet assembly device 4 and the iron core assembly device 5. In this embodiment, the feeding of the filler block, low-pressure head and C iron core is carried out manually at the second feeding station. In other embodiments, a corresponding conveying mechanism can be set to realize the automatic feeding of the filler block, low-pressure head and C iron core, thereby realizing fully automated production.

[0036] The core assembly device 5 includes a core assembly unit 51 and a first conveying mechanism 52 that transports the second winding assembly from the carrier 11 to the core assembly unit 51. The core assembly unit 51 includes a rotary disk 511 and a loading station 512 and a unloading station 513 disposed on the rotary disk 511. An assembly mechanism 514 is provided at both the loading station 512 and the unloading station 513. A first motor 515 that drives the rotary disk 511 to rotate is disposed below the rotary disk 511. The assembly mechanism 514 includes a first positioning seat 5141 for positioning the second winding assembly, a first clamping component 5142 disposed at one end of the first positioning seat 5141 and restricting the second winding assembly from moving up and down, a second clamping component 5143 disposed at the other end of the first positioning seat 5141 and restricting the second winding assembly from moving horizontally, a first positioning module 5144 disposed on one side of the first positioning seat 5141 and positioning the first C-core, and a second positioning module 5145 disposed on the other side of the first positioning seat 5141 and positioning the second C-core. The first C-core and the second C-core have the same structure, and the first C-core and the second C-core are spliced ​​and assembled on the outer periphery of the second winding assembly to obtain the first coil assembly. Specifically, one end of the first C-core and the second C-core are attracted and fastened with a magnet, and the other end is engaged with the tail of the primary winding to achieve splicing and assembly.

[0037] A first positioning structure 51411 for positioning a second winding assembly is provided on the first positioning base 51411. A first limiting block 51412 for restricting the horizontal movement of the second winding assembly is provided at one end of the first positioning structure 51411. A second clamping assembly 5143 is provided at the other end of the first positioning structure 51411. The first limiting block 51412 and the second clamping assembly 5143 limit the two ends of the second winding assembly, preventing the second winding assembly from moving in the horizontal direction. A third sensor for detecting whether a second winding assembly is positioned is provided below the first positioning base 5141. A second clearance hole 51414 for the detection line of the third sensor to pass through is provided on the first positioning base 5141. The first clamping assembly 5142 includes a first clamping block 51421 and a first driving member 51422 that drives the first clamping block 51421 to move away from the upper surface of the second winding assembly. The first driving member 51422 can drive the first clamping block 51421 to rotate and rise simultaneously. The first driving member 51422 drives the first clamping block 51421 to rotate and fall synchronously to press against the upper surface of the second winding assembly, and the first driving member 51422 drives the first clamping block 51421 to rotate and rise synchronously to move away from the upper surface of the second winding assembly. The first clamping block 51421 and the first positioning structure 51411 are jointly positioned on the upper and lower surfaces of the second winding assembly, which can prevent the second winding assembly from moving in the vertical direction. The second clamping assembly 5143 includes a second clamping block 51431 and a clamping cylinder 51432 that drives the second clamping block 51431 to move closer to or away from one end of the second winding assembly. The second clamping block 51431 and the first limiting block 51412 are pressed together at the front and rear ends of the second winding assembly to prevent the second winding assembly from moving in the horizontal direction. The first positioning module 5144 and the second positioning module 5145 have the same structure and are symmetrically arranged on both sides of the first positioning seat 5141. Both the first positioning module 5144 and the second positioning module 5145 include a third cylinder 51451 and a first moving plate 51452 driven by the third cylinder 51451 to move closer to or away from the first positioning seat 5141. The first moving plate 51452 has a first positioning block 51453 on the side close to the first positioning seat 5141 and a second positioning block 51454 on the outer side of one end close to the first positioning seat 5141. The second positioning block 51454 is movably arranged and driven by the fourth cylinder 51455 to move closer to the end of the first positioning seat 5141. The bottom surface of the first C-core or the second C-core is supported on the end of the first moving plate 51452. The side of the first C-core or the second C-core is positioned on the first positioning block 51453. The fourth cylinder 51455 drives the second positioning block 51454 to approach the end of the first C-core or the second C-core to position the end of the first C-core or the second C-core, so as to ensure that the first C-core or the second C-core is smoothly assembled to the outer periphery of the second winding assembly.To ensure that the first or second C-core is stably supported at the end of the first moving plate 51452, several adsorption magnets 51456 are provided at the end of the first moving plate 51452 to attract and hold the first or second C-core, preventing it from falling off. A fourth sensor 51457 is provided on the first moving plate 51452, and a fifth sensor 51458 is provided on the first positioning block 51453. The fifth sensor 51458 can detect whether the first or second C-core is positioned at the first positioning block 51453, and the fourth sensor 51457 can detect whether the first or second C-core is incorrectly placed.

[0038] The first conveying mechanism 52 includes a third XYZ drive module 521, a ninth support plate 522 connected to the movable end of the third XYZ drive module 521, a second rotary drive member 523 disposed on the ninth support plate 522, a tenth support plate 524 driven by the second rotary drive member 523 to rotate around a horizontal axis, a first clamping cylinder 525 disposed on the tenth support plate 524, and a pair of first grippers 526 driven by the first clamping cylinder 525 to open or clamp.

[0039] The filler block assembly device 6 includes a positioning seat 61 and a second conveying mechanism 62 for conveying operations. The positioning seat 61 has a first contoured positioning groove 611 for positioning the first coil assembly, and several eighth sensors 612 for detecting whether there is material in the first contoured positioning groove 611 are provided on the side of the positioning seat 61. The second conveying mechanism 62 includes a first XYZ drive module 621, a third support plate 622 connected to the movable end of the first XYZ drive module 621, a first rotary drive member 623 disposed on the third support plate 622, a fourth support plate 624 driven by the first rotary drive member 623 to rotate around a vertical axis, a first clamping assembly 625 and a second clamping assembly 626 disposed on the fourth support plate 624. Both the first clamping assembly 625 and the second clamping assembly 626 include a second clamping cylinder 6251 and a pair of second grippers 6252 driven by the second clamping cylinder 6251 to open or clamp.

[0040] The assembly process of the iron core assembly device 5 and the filler block assembly device 6 is as follows: two C iron cores are manually placed on the assembly mechanism 514 of the loading station 512, that is, the two C iron cores are respectively positioned at the two first positioning blocks 51453, and the bottoms of the two C iron cores are held by the adsorption magnets 51456. The third XYZ drive module 521 drives the ninth support plate 522 to drive the first gripper 526 to clamp the second winding assembly on the carrier 11, and the second rotation drive component 523 drives the tenth support plate 524 to drive the first gripper 526 to rotate around the horizontal axis. The second winding assembly is angled 90° to change from a vertical to a horizontal position. Then, the third XYZ drive module 521 drives the ninth support plate 522 to move the first gripper 526 to place the second winding assembly onto the first positioning seat 5141. One end of the second winding assembly is restrained on the first limiting block 51412. Simultaneously, the clamping cylinder 51432 drives the second clamping block 51431 to press against the other end of the second winding assembly, and the first drive member 51422 drives the first clamping block 51421 to rotate and descend synchronously, pressing against the second winding assembly. The upper surface of the component is used to position the second winding assembly in both the horizontal and vertical directions. Then, the fourth cylinder 51455 drives the second positioning block 51454 to approach the end of the C-core, so that the end of the C-core abuts against the surface of the magnet. At the same time, the third cylinder 51451 drives the first moving plate 51452 to approach the side of the first positioning seat 5141, so that the C-core is assembled onto the side of the second winding assembly and onto the surface of the magnet. After the two C-cores are assembled, the first coil assembly is obtained. The first motor 515 drives the rotating disk 511 to rotate. At 180°, the first coil assembly is located at the unloading station 513. The first clamping component 625 of the second transport mechanism 62 transports the first coil assembly to the first contour positioning groove 611 of the positioning seat 61. Then, the first clamping component 625 of the second transport mechanism 62 pre-assembles the filling block on the carrier 11 onto the first coil assembly to obtain a pre-assembled second coil assembly. Then, the first clamping component 625 of the second transport mechanism 62 clamps the pre-assembled second coil assembly and moves it above the carrier 11 to pre-assemble the pre-assembled second coil assembly onto the outer shell.

[0041] Since the filler block assembly device 6 only places the pre-assembled second coil assembly and filler block into the corresponding positions on the outer shell and performs pre-assembly, but does not fully assemble them, a second pressing mechanism 7 is provided to ensure complete assembly. The second pressing mechanism 7 includes a second X-axis drive member 71, a second support plate 72 driven by the second X-axis drive member 71 to move along the X direction, a second pressing cylinder 73 disposed on the second support plate 72, and a second pressing head 74 driven by the second pressing cylinder 73 to move up and down.

[0042] The pressing process of the second pressing mechanism 7 is as follows: the second X-axis drive 71 drives the second support plate 72 to move the second pressing head 74 to directly above the pre-assembled second coil assembly. The second pressing cylinder 73 drives the second pressing head 74 to descend and press the pre-assembled second coil assembly into the housing, so that the pre-assembled second coil assembly is firmly assembled with the housing. At the same time, during the pressing process of the second pressing head 74, the second pressing head 74 can also synchronously press and assemble the filler block into the first coil assembly, so that the filler block is firmly assembled with the first coil assembly. The pre-assembled second coil assembly and the filler block are firmly assembled to obtain the third coil assembly.

[0043] The low-pressure head assembly device 8 includes a third X-axis drive component 81, a fifth support plate 82 driven by the third X-axis drive component 81 to move along the X direction, and a third clamping assembly 83, a pressing assembly 84, and a positioning assembly 85 sequentially arranged on the fifth support plate 82. The third clamping assembly 83 includes a sixth cylinder 831 arranged on the fifth support plate 82, an eleventh support plate 832 driven by the sixth cylinder 831 to move up and down, a seventh cylinder 833 arranged on the eleventh support plate 832, and a pair of third grippers 834 opened or clamped by the seventh cylinder 833. The pressing assembly 84 includes a third drive component 841 arranged on the fifth support plate 82 and a third pressing head 842 driven by the third drive component 841 to move up and down. The positioning component 85 includes a fourth driving member 851 disposed on the fifth support plate 82 and a first positioning pin 852 driven by the fourth driving member 851 to move up and down. The third coil assembly is provided with a press-fit positioning hole that cooperates with the first positioning pin 852. The press-fit positioning hole and the low-pressure head installation position are respectively located at both ends of the third coil assembly. The press-fit component 84 presses the low-pressure head onto one end of the third coil assembly. At the same time, the other end of the third coil assembly is pressed by the positioning component 85. The positioning component 85 and the press-fit component 84 cooperate to prevent the third coil assembly from moving, thereby ensuring the stability of the press-fit process between the third coil assembly and the low-pressure head.

[0044] The assembly process of the low-pressure head assembly device 8 is as follows: the third clamping component 83 starts working first; the third X-axis drive component 81 drives the fifth support plate 82 to move the third clamping component 83 directly above the low-pressure head; the sixth cylinder 831 drives the eleventh support plate 832 to move the third gripper 834 downward to clamp the low-pressure head; the third X-axis drive component 81 drives the fifth support plate 82 to move the third clamping component 83 to the low-pressure head installation position of the third coil assembly; the sixth cylinder 831 drives the eleventh support plate 832 to move the third gripper 834 downward. 834 moves downward to place the low-pressure head at the low-pressure head installation position. The third X-axis drive 81 drives the fifth support plate 82 to move and reset the third clamping assembly 83. At this time, the pressing assembly 84 is directly above the low-pressure head installation position and the positioning assembly 85 is directly above the pressing positioning hole. Then, the fourth drive 851 drives the first positioning pin 852 to be inserted into the pressing positioning hole. Then, the third drive 841 drives the third pressing head 842 to descend and press the low-pressure head to assemble the low-pressure head onto the third coil assembly to obtain the coil.

[0045] The continuity testing mechanism 9 and the capacitance-resistance testing mechanism 10 have similar structures. Both include a fourth X-axis drive component 91, a sixth support plate 92 driven by the fourth X-axis drive component 91 to move along the X direction, a first detection component 93 disposed on the sixth support plate 92, and a second detection component 94 disposed below the first detection component 93. Both the first detection component 93 and the second detection component 94 include a first cylinder 931, a first mounting block 932 driven by the first cylinder 931 to move up and down, and several first probes 933 disposed on the first mounting block 932. The first detection component 93 contacts the upper pin of the coil for testing, and the second detection component 94 is mounted on the lifting and positioning mechanism 40 of the first and second testing stations and contacts the lower pin of the coil for testing. The continuity testing mechanism 9 performs electrical continuity testing on the coil, while the capacitance-resistance testing mechanism 10 measures the capacitance and resistance of the coil. Therefore, the probe positions or the number of probes in the continuity testing mechanism 9 and the capacitance-resistance testing mechanism 10 are slightly different, but their other basic structures are the same.

[0046] The defective product unloading device 20 includes a first conveying module 201 for placing defective products and a third transport mechanism 202 disposed above the first conveying module 201 for clamping defective products from the carrier 11 onto the first conveying module 201. The structure of the first conveying module 201 is similar to that of the defective product placement unit 26, and will not be described in detail here. The third conveying mechanism 202 includes a first Y-axis drive member 2021, a twelfth support plate 2022 driven by the first Y-axis drive member 2021 to move along the Y direction, a sixth X-axis drive member 2023 disposed on the twelfth support plate 2022, a thirteenth support plate 2024 driven by the sixth X-axis drive member 2023 to move along the X direction, a fifth cylinder 2025 disposed on the thirteenth support plate 2024, a fifteenth support plate 2026 driven by the fifth cylinder 2025 to move up and down, a ninth cylinder 2027 disposed on the fifteenth support plate 2026, and a pair of fourth grippers 2028 driven by the ninth cylinder 2027 to perform opening or clamping actions.

[0047] The finished product receiving device 30 includes a conveying device 301 for conveying customized material trays 303 and a fourth handling mechanism 302 disposed above the conveying device 301 for clamping good products into the customized material trays 303. The conveying device 301 includes an upper first conveying mechanism 3011, a lower second conveying mechanism 3012, and a lifting mechanism 3013 connected to one end of both the first and second conveying mechanisms 3011 and 3012. The first and / or second conveying mechanisms 3011 and 3012 are equipped with a detection module 3014 for detecting whether the customized material trays 303 are reversed. In this embodiment, both the first and second conveying mechanisms 3011 and 3012 are equipped with detection modules 3014 for detecting whether the customized material trays 303 are reversed; this dual detection ensures accuracy and production stability.

[0048] The customized material tray 303 includes a lower support plate 3031, an upper second support plate 3032, and several support seats 3033 disposed on the second support plate 3032 for accommodating coils. Handles 3035 are provided at both ends of the support plate 3031 for easy gripping and handling of the customized material tray 303. The upper second support plate 3032 is positioned above the support plate 3031 via support columns 3034. A clearance space is formed between the second support plate 3032 and the support plate 3031 for the bottom of the coil to enter. The support seats 3033 are shaped to conform to the coil and are arranged on the second support plate 3032 in a predetermined direction. Therefore, the customized material tray 303 needs to have a certain orientation. To prevent the customized material tray 303 from being placed in the wrong direction, a detection module 3014 is provided on the second conveying mechanism 3012 to detect whether the customized material tray 303 is reversed.

[0049] The detection module 3014 includes a baffle plate 30141, a blocking cylinder 30142 that drives the baffle plate 30141 to extend or retract, and a sixth sensor 30143 and a seventh sensor 30144 used in conjunction with it. The sixth sensor 30143 and the seventh sensor 30144 are installed on the second conveying mechanism 3012 and are located on the left and right sides of the baffle plate 30141, respectively. The distance between the sixth sensor 30143 and the seventh sensor 30144 is less than the length of a customized material tray 303, so as to detect whether the customized material tray 303 is placed in the wrong direction. A limiting plate 3036 that cooperates with the baffle plate 30141 is provided on one side of the tray 3031. When the customized material tray 303 is actually conveyed, the limiting plates 3036 are uniformly arranged facing left or right. The side of the limiting plate 3036 near the end is the first blocking side 30361, and the other side is the second blocking side 30362.

[0050] The detection module 3014 detects the direction of the customized material tray on the second conveying mechanism 3012 as follows: (1) If the limit plate 3036 of the customized material tray 303 is set to flow into the second conveying mechanism 3012 with the limit plate 3036 facing left, then the first blocking side 30361 faces left and the second blocking side 30362 faces right. When the blocking plate 30141 extends, it blocks the second blocking side 30362. At this time, both the sixth sensor 30143 and the seventh sensor 30144 can detect the customized material tray 303. If the bottom of tray 303 is correct, the orientation of the custom tray 303 is determined to be correct. If one of the custom trays 303 is reversed, the first blocking side 30361 faces right and the second blocking side 30362 faces left. When the blocking plate 30141 extends, it blocks the first blocking side 30361. At this time, the sixth sensor 30143 can detect the bottom of the custom tray 303, while the seventh sensor 30144 cannot detect the bottom of the custom tray 303. Therefore, it is determined that the custom tray 303 is reversed. If the custom material tray 303 is reversed, an alarm will be triggered to ask staff to check it; (2) If the limit plate 3036 of the custom material tray 303 is set to flow into the second conveying mechanism 3012 with the limit plate 3036 facing right, the first blocking side 30361 faces right and the second blocking side 30362 faces left. When the blocking plate 30141 extends, it blocks the first blocking side 30361. The sixth sensor 30143 can detect the bottom of the custom material tray 303, while the seventh sensor 30144 cannot detect the bottom of the custom material tray 303. Then it is determined that the direction of the custom material tray 303 is correct; If one of the custom material trays 303 is reversed, the first blocking side 30361 faces left and the second blocking side 30362 faces right. When the blocking plate 30141 extends, it blocks the second blocking side 30362. At this time, both the sixth sensor 30143 and the seventh sensor 30144 can detect the bottom of the custom material tray 303. Then it is determined that the custom material tray 303 is reversed and an alarm will be triggered to ask staff to check it. The detection module 3014 detects the direction of the customized material tray on the first conveying mechanism 3011 in a similar manner to the above, and will not be repeated here.

[0051] The fourth conveying mechanism 302 includes a fourth XYZ drive module 3021, a fourteenth support plate 3022 that moves along the XYZ direction under the influence of the fourth XYZ drive module 3021, a third rotary drive member 3023 disposed on the fourteenth support plate 3022, an eighth cylinder 3024 that rotates around a vertical axis under the influence of the third rotary drive member 3023, and a pair of fifth grippers 3025 that perform opening or clamping actions under the influence of the eighth cylinder 3024.

[0052] Each device or mechanism at each workstation is electrically connected to the defective product unloading device 20 and the finished product receiving device 30. If a part or product is abnormal or unqualified, a non-conforming signal will be given, and the defective product unloading device 20 will take off the non-conforming product. If all parts are qualified, a qualified signal will be given, and the finished product receiving device 30 will take off the qualified product.

[0053] The material receiving device 30 performs the following actions: an empty custom material tray 303 is input from one end of the second conveying mechanism 3012. The detection module 3014 detects whether the positioning tray 303 is reversed. If the detection fails, an alarm is triggered to prompt manual inspection. If the detection passes, the material continues to flow forward to the other end of the second conveying mechanism 3012. It is then lifted by the lifting mechanism 3013 and conveyed to one end of the first conveying mechanism 3011. The detection module 3014 on the first conveying mechanism 3011 detects again whether the positioning tray 303 is reversed. If the detection passes, the custom material tray 303 is conveyed to the set position by the first conveying mechanism 3011 and receives the assembled coils. After the entire custom material tray 303 is filled, the custom material tray 303, carrying several coils, flows out from the other end of the first conveying mechanism 3011 for subsequent operations.

[0054] A cleaning mechanism 70 is also provided on one side of the finished product receiving device 30. After the coil is received, the carrier 11 above the second conveyor line 13 flows into the cleaning mechanism 70. The cleaning mechanism 70 blows air on the carrier 11 to clean it. The cleaned carrier 11 continues to be conveyed forward and transferred to the first conveyor line 12 via the second connecting unit 15 to continue the coil assembly operation.

[0055] Since some coils do not require the assembly of filler blocks or low-voltage heads, certain structures of the filler block assembly device 6 or the low-voltage head assembly device 8 can be selectively used. If the filler block assembly is not required, after the core assembly is completed, the second transport mechanism 62 of the filler block assembly device 6 directly transports the first coil assembly onto the housing to obtain the third coil assembly, and then continues with subsequent operations. If the low-voltage head assembly is not required, the coil is directly obtained after the second pressing mechanism 7 presses it in, and then the low-voltage head assembly device 8 is skipped to continue with subsequent continuity and capacitance tests. Therefore, this solution provides a complete coil assembly production line, and can selectively use some of the devices or structures at certain workstations to perform assembly operations according to the actual structure of the coil. It can adapt to coils with various structures, thereby completing the assembly of various coils, and has strong versatility.

[0056] This solution also provides an automatic coil assembly method, which is based on the aforementioned automatic coil assembly production line and includes the following steps: S1. The circulating conveyor 1 transports the carrier 11 to the first loading station, the secondary winding feeding device 2 positions the secondary winding on the carrier 11, and at the same time positions the outer shell on the carrier 11, and then positions the primary winding inside the secondary winding. S2. The circulating conveyor 1 transports the carrier 11 to the first pressing station, and the first pressing mechanism 3 presses the primary winding into the interior of the secondary winding to obtain the first winding assembly. S3. The circulating conveyor 1 transports the carrier 11 to the first assembly station, and the magnet assembly device 4 assembles the magnets onto the first winding assembly to obtain the second winding assembly. S4. The circulating conveyor 1 transports the carrier 11 to the second loading station and positions the filling block and low-pressure head onto the carrier 11. S5. The circulating conveyor 1 transports the carrier 11 to the second assembly station, and the iron core assembly device 5 assembles the C iron core on the outer periphery of the second winding assembly to obtain the first coil assembly. S6. The circulating conveyor 1 transports the carrier 11 to the third assembly station. The filler block assembly device 6 first removes the first coil assembly from the iron core assembly device 5. Then, the filler block assembly device 6 pre-assembles the filler block onto the first coil assembly to obtain the pre-assembled second coil assembly. Then, the filler block assembly device 6 clamps the pre-assembled second coil assembly and moves it above the carrier 11 to pre-assemble the pre-assembled second coil assembly onto the outer shell. S7. The circulating conveyor 1 transports the carrier 11 to the second pressing station, and the second pressing mechanism 7 presses the pre-assembled second coil assembly and filler block into the housing to obtain the third coil assembly. S8. The circulating conveyor 1 transports the carrier 11 to the fourth assembly station, and the low-pressure head assembly device 8 assembles the low-pressure head onto the third coil assembly to obtain the coil. S9. The circulating conveyor 1 transports the carrier 11 to the first test station, and the continuity test mechanism 9 performs an electrical continuity test on the coil. S10, the circulating conveyor 1 transports the carrier 11 to the second test station, and the capacitance and resistance testing mechanism 10 measures the capacitance and resistance of the coil. S11, the circulating conveyor 1 transports the carrier 11 to the defective product unloading station, and the defective product unloading device 20 removes the unqualified coils; S12, the circulating conveyor 1 transports the carrier 11 to the finished product receiving station, and the finished product receiving device 30 removes the qualified coil.

[0057] If the coil does not require the assembly of filler blocks or low-voltage heads, then part of the structure of the filler block assembly device 6 or the low-voltage head assembly device 8 can be used selectively. If the filler block does not need to be assembled, then the step of assembling the filler block is removed in step S6, and the step of pressing the filler block is also removed in step S7. If the low-voltage head does not need to be assembled, then step S8 is skipped.

[0058] The above descriptions are merely some embodiments of the present invention. Those skilled in the art can make various modifications and improvements without departing from the inventive concept of the present invention, and these all fall within the scope of protection of the present invention.

Claims

1. An automated coil assembly production line, characterized in that: It includes a circulating conveying device for a conveying carrier, and along the conveying direction of the circulating conveying device are arranged sequentially a first feeding station, a first pressing station, a first assembly station, a second feeding station, a second assembly station, a third assembly station, a second pressing station, a fourth assembly station, a first testing station, a second testing station, a defective product unloading station, and a finished product receiving station. The first feeding station is equipped with a secondary winding feeding device, the first pressing station is equipped with a first pressing mechanism, the first assembly station is equipped with a magnet assembly device, the second assembly station is equipped with an iron core assembly device, the third assembly station is equipped with a filler block assembly device, the second pressing station is equipped with a second pressing mechanism, the fourth assembly station is equipped with a low-pressure head assembly device, the first testing station is equipped with a continuity testing mechanism, the second testing station is equipped with a capacitance and resistance testing mechanism, the defective product unloading station is equipped with a defective product unloading device, and the finished product receiving station is equipped with a finished product receiving device.

2. The automatic coil assembly production line as described in claim 1, characterized in that: The circulating conveying device includes a first conveying line and a second conveying line arranged in parallel, a first connecting unit connected to one end of the first conveying line and the second conveying line, and a second connecting unit connected to the other end of the first conveying line and the second conveying line. The first connecting unit and the second connecting unit each include a first linear drive, a first connecting plate connected to the movable end of the first linear drive, and a second linear drive disposed on the first connecting plate.

3. The automatic coil assembly production line as described in claim 1, characterized in that: The secondary winding feeding device includes a feeding unit for placing a material tray, a tray removal unit for removing the material tray from the feeding unit, and a material removal robot. A first vision inspection camera and a defective product placement unit are arranged next to the material removal robot.

4. The automatic coil assembly production line as described in claim 1, characterized in that: The first pressing mechanism includes a first X-axis drive, a first support plate that moves along the X direction driven by the first X-axis drive, a first pressing cylinder disposed on the first support plate, and a first pressing head that moves up and down driven by the first pressing cylinder; the second pressing mechanism includes a second X-axis drive, a second support plate that moves along the X direction driven by the second X-axis drive, a second pressing cylinder disposed on the second support plate, and a second pressing head that moves up and down driven by the second pressing cylinder.

5. The automatic coil assembly production line as described in claim 1, characterized in that: The magnet assembly device includes a magnet feeding unit, a material dispensing and positioning unit, and an adsorption unit. The magnet feeding unit includes several vertically extending material boxes, a first mounting plate for mounting the material boxes, a material changing cylinder for driving the first mounting plate to move, and a material pressing assembly for pressing the material boxes inside. The material dispensing and positioning unit includes a material dispensing cylinder and a first positioning plate connected to the movable end of the material dispensing cylinder. The first positioning plate is located below the material box, and a first positioning groove is provided at one end of the first positioning plate.

6. The automatic coil assembly production line as described in claim 1, characterized in that: The core assembly device includes a core assembly unit and a first transport mechanism. The iron core assembly unit includes a rotary disk and a loading station and a unloading station arranged on the rotary disk. An assembly mechanism is provided at both the loading station and the unloading station. The assembly mechanism includes a first positioning seat, a first pressing component disposed at one end of the first positioning seat, a second pressing component disposed at the other end of the first positioning seat, a first positioning module disposed on one side of the first positioning seat, and a second positioning module disposed on the other side of the first positioning seat.

7. The automatic coil assembly production line as described in claim 1, characterized in that: The filling block assembly device includes a positioning seat and a second conveying mechanism. The positioning seat is provided with a first contour positioning groove. The second conveying mechanism includes a first XYZ drive module, a third support plate connected to the movable end of the first XYZ drive module, a first rotary drive component disposed on the third support plate, a fourth support plate driven by the first rotary drive component to rotate around a vertical axis, a first clamping component disposed on the fourth support plate, and a second clamping component.

8. The automatic coil assembly production line as described in claim 1, characterized in that: The low-pressure head assembly device includes a third X-axis drive component, a fifth support plate driven by the third X-axis drive component to move along the X direction, and a third clamping component, a pressing component, and a positioning component sequentially arranged on the fifth support plate.

9. The automatic coil assembly production line as described in claim 1, characterized in that: Both the continuity testing mechanism and the capacitance testing mechanism include a fourth X-axis drive component, a sixth support plate that moves along the X direction driven by the fourth X-axis drive component, a first detection component disposed on the sixth support plate, and a second detection component disposed below the first detection component.

10. The automatic coil assembly production line as described in claim 1, characterized in that: The defective product unloading device includes a first conveying module and a third handling mechanism disposed above the first conveying module.

11. The automatic coil assembly production line as described in claim 1, characterized in that: The finished product receiving device includes a conveying device for conveying customized material trays and a fourth handling mechanism disposed above the conveying device. The conveying device includes an upper first conveying mechanism, a lower second conveying mechanism, and a lifting mechanism connected to one end of both the first and second conveying mechanisms. The first and / or second conveying mechanisms are equipped with a detection module for detecting the direction of the customized material tray.

12. The automatic coil assembly production line as described in claim 1, characterized in that: Each of the aforementioned workstations is equipped with a stop assembly, a lifting and positioning mechanism, and a sensor group; The sensor group is located on both sides of the vehicle, and the sensor group includes several sensors; The stop assembly includes a stop block and a stop cylinder that drives the stop block to rotate or move up and down; The lifting and positioning mechanism includes a lifting plate and a lifting cylinder that drives the lifting plate to move up and down.

13. The automatic coil assembly method as described in claim 1, characterized in that, It is completed based on an automated coil assembly production line according to any one of claims 1 to 12, and includes the following steps: S1. The circulating conveying device transports the carrier to the first loading station, the secondary winding feeding device positions the secondary winding on the carrier, and at the same time positions the outer shell on the carrier, and then positions the primary winding inside the secondary winding. S2. The circulating conveying device transports the carrier to the first pressing station, and the first pressing mechanism presses the primary winding into the interior of the secondary winding to obtain the first winding assembly. S3. The circulating conveying device transports the carrier to the first assembly station, and the magnet assembly device assembles the magnet onto the first winding assembly to obtain the second winding assembly. S4. The circulating conveyor transports the carrier to the second loading station and positions the filling block and low-pressure head onto the carrier. S5. The circulating conveying device transports the carrier to the second assembly station, and the core assembly device assembles the C core onto the outer periphery of the second winding assembly to obtain the first coil assembly. S6. The circulating conveying device transports the carrier to the third assembly station. The filler block assembly device first removes the first coil assembly from the iron core assembly device. Then, the filler block assembly device pre-assembles the filler block onto the first coil assembly to obtain a pre-assembled second coil assembly. Then, the filler block assembly device clamps the pre-assembled second coil assembly and moves it above the carrier to pre-assemble the pre-assembled second coil assembly onto the outer shell. S7. The circulating conveying device transports the carrier to the second pressing station, and the second pressing mechanism presses the pre-assembled second coil assembly and filler block completely into the housing to obtain the third coil assembly. S8. The circulating conveyor transports the carrier to the fourth assembly station, and the low-pressure head assembly device assembles the low-pressure head onto the third coil assembly to obtain the coil. S9. The circulating conveying device transports the carrier to the first test station, and the continuity testing mechanism performs an electrical continuity test on the coil. S10. The circulating conveying device transports the carrier to the second testing station, and the capacitance and resistance testing mechanism measures the capacitance and resistance of the coil. S11. The circulating conveying device transports the carrier to the defective product unloading station, and the defective product unloading device removes the unqualified coils. S12. The circulating conveyor transports the carrier to the finished product receiving station, and the finished product receiving device removes the qualified coil.

Images