Coil arranging device, coil arranging method, and coil arranging program

Abstract

The present application relates to a kind of coil sorting, assembly device and coil sorting method.The coil sorting device includes base, material taking module, upper visual module, sorting module, lower visual module and control module, upper visual module is used to shoot the upper visual image of coil to be sorted, lower visual module is used to shoot lower visual image;Control module is used to obtain the first characteristic parameter of coil to be sorted based on upper visual image and lower visual image, and the reference parameter of preset coil template is compared with the first characteristic parameter to generate first correction instruction;One of sorting module or material taking module includes the first component capable of carrying coil to be sorted, sorting module has sorting adjustment surface, one of first component and sorting adjustment surface can be moved relative to the other based on first correction instruction, to deform the lead of coil to be sorted to the morphology corresponding to reference parameter by the lead of coil to be sorted and sorting adjustment surface.

Description

Technical Field

[0001] This invention relates to the technical field of motor coil manufacturing equipment, and in particular to a coil wire management and assembly device and a coil wire management method. Background Technology

[0002] Motors are the core drive units of industrial equipment, and the assembly of motor coil leads is an important step in the motor manufacturing process. The leads need to be sorted first to ensure that they are in contact with the pads on the coil substrate before they are connected.

[0003] The assembly of traditional motor coil leads mostly relies on manual operation, which is inefficient and results in inconsistent product quality. Summary of the Invention

[0004] Therefore, it is necessary to address the current problem that coil assembly mostly relies on manual wire management and attachment, and to provide a coil wire management and assembly device and method that meets the wire management needs of coils of different models and specifications.

[0005] This application first provides a coil management device, including a base, a material picking module, an upper vision module, a wire management module, a lower vision module, and a control module. The material picking module and the upper vision module can move horizontally relative to the base, and the vertical projection area of ​​the moving range of the material picking module is the working area.

[0006] The cable management module and the lower vision module are both located at least partially within the working area. The material picking module is used to pick up and place the cable coil to be managed. The upper vision module is used to capture an upper vision image of the cable coil from the upper side. The lower vision module is used to capture a lower vision image of the cable coil from the lower side. The upper vision module, the cable management module, and the lower vision module are all electrically connected to the control module.

[0007] The control module is used to obtain the first feature parameters of the coil to be processed based on the upper visual image and the lower visual image, and to generate a first correction command by comparing the reference parameters of the preset coil template with the first feature parameters; wherein, the first feature parameters include the coordinates of the two endpoints of the lead of the coil to be processed;

[0008] One of the wire management module or the material handling module includes a first component capable of carrying the coil to be managed. The wire management module has a wire management adjustment surface. One of the first component and the wire management adjustment surface can move relative to the other based on the first correction command, so as to deform the lead wire to the shape corresponding to the reference parameter by abutting the lead wire of the coil to be managed against the wire management adjustment surface.

[0009] In one embodiment, the cable management module further has a positioning adjustment surface, and the control module is used to obtain a second feature parameter of the cable coil to be managed based on the upper visual image and the lower visual image, and to generate a second correction command by comparing the reference parameter of the preset coil template with the second feature parameter; wherein, the second feature parameter includes the position of the cable coil to be managed relative to the first component in the carrying state;

[0010] One of the first component and the positioning adjustment surface can move relative to the other based on the second correction command, so as to adjust the coil to be processed relative to the first component to the relative offset amount and relative offset angle corresponding to the reference parameters by the coil to be processed abutting against the positioning adjustment surface.

[0011] In one embodiment, the cable management module includes a coil fixture and a cable management assembly. The coil fixture is the first assembly, and the cable management assembly has a cable management adjustment surface and a positioning adjustment surface. The coil fixture is capable of carrying the coil to be managed and moving it relative to the cable management adjustment surface and the positioning adjustment surface.

[0012] In one embodiment, the cable management module includes a cable management base, a positioning adjustment part, and a cable management adjustment part. The cable management base is fixed to the base, and the positioning adjustment part and the cable management adjustment part are detachably fixed to the cable management base. The cable management adjustment part has the cable management adjustment surface, and the positioning adjustment part has the positioning adjustment surface.

[0013] In one embodiment, the cable management adjustment unit includes an adjustment base and two cable management levers parallel to the vertical direction. The adjustment base is detachably fixed to the cable management base. The two cable management levers are detachably disposed on the adjustment base and protrude horizontally from the same side of the adjustment base. The projections of the two cable management levers in the vertical direction are inclined and the protruding ends of the two cable management levers are close to each other. The cable management adjustment surface includes the surface of the side of the two cable management levers that are close to each other.

[0014] In one embodiment, the cable management adjustment unit further includes a force sensor connected to the cable management lever, the force sensor being electrically connected to the control module and used to detect the pressure of the cable management lever.

[0015] In one embodiment, the cable management module further includes a pressure plate disposed on the cable management base. The pressure plate includes a vertical limiting part corresponding to the cable management adjustment part in the vertical direction. When the lead wire abuts against the cable management adjustment surface in the horizontal direction, the lead wire abuts against the pressure plate in the vertical direction.

[0016] In one embodiment, the pressure plate is detachably disposed on the cable management base, the pressure plate includes two vertical limiting parts spaced apart in the horizontal direction, and the cable management module includes two sets of cable management adjustment parts corresponding to the two vertical limiting parts respectively.

[0017] In one embodiment, the pressure plate is electrically connected to the control module and is movably disposed on the cable management base in a vertical direction.

[0018] In one embodiment, the positioning adjustment part has a positioning groove on its side along the horizontal direction, and the positioning groove passes through the positioning adjustment part in the vertical direction to form a first side wall and a second side wall that are perpendicular to each other and parallel to the vertical direction. The positioning adjustment surface includes the first side wall and the second side wall.

[0019] In one embodiment, the cable management module has the cable management adjustment surface and the positioning adjustment surface, the material handling module includes the first component, and the first component is movable relative to the cable management adjustment surface and the positioning adjustment surface.

[0020] In one embodiment, the material handling module includes a first suction nozzle capable of picking up the coil of wire to be handled.

[0021] In one embodiment, the material handling module further includes a first vacuum sensor connected to the first suction nozzle, the first vacuum sensor being electrically connected to the control module and used to detect the negative pressure value between the first suction nozzle and the coil of wire to be processed.

[0022] In one embodiment, the first suction nozzle has a plurality of vacuum holes in a horizontal direction, and the diameter of the vacuum holes on the outer side is smaller than the diameter of the vacuum holes on the inner side.

[0023] A second aspect of this application provides a coil assembly apparatus, including the above-mentioned coil wire management device and an attachment module. The attachment module is disposed on the base and is at least partially located in the working area. The material handling module is also capable of picking up and placing the substrate to be assembled.

[0024] The attachment module includes an attachment fixture and a dispensing module. The material handling module can place the substrate to be assembled on the attachment fixture. The dispensing module is used to apply adhesive to the substrate to be assembled. The material handling module can also attach the coil to be assembled to the substrate to be assembled containing the adhesive, so that the lead wire of the coil to be assembled contacts the pad of the substrate to be assembled. The coil to be assembled is the coil to be arranged after the lead wire is deformed.

[0025] A third aspect of this application provides a coil management method applicable to the aforementioned coil management device, comprising the following steps:

[0026] a. The upper vision module acquires the upper vision image of the coil to be processed.

[0027] b. The lower vision module acquires the lower vision image of the coil of wire to be processed;

[0028] c. The control module obtains the first feature parameters of the coil to be processed based on the upper visual image and the lower visual image;

[0029] d. The control module compares the reference parameters of the preset coil template with the first feature parameters, and outputs the first correction command;

[0030] e. The first component moves the coil to be managed relative to the management surface based on the first calibration command, so as to deform the lead wire to the shape corresponding to the reference parameter by having the lead wire of the coil to be managed abut against the management surface.

[0031] In one embodiment, between step b and step c, the following step is further included:

[0032] f. The control module further obtains a second feature parameter of the coil to be processed based on the upper visual image and the lower visual image; wherein, the second feature parameter includes the relative offset and relative offset angle of the coil to be processed relative to the first component in the carrying state;

[0033] g. The control module compares the reference parameters of the preset coil template with the second feature parameters and outputs a second correction command;

[0034] Between step d and step e, the following step is also included:

[0035] h. The first component moves the coil to be managed relative to the positioning adjustment surface of the cable management module based on the second calibration command, so as to adjust the coil to be managed relative to the first component to the position corresponding to the reference parameter by the coil to be managed abutting against the positioning adjustment surface.

[0036] In one embodiment, the first feature parameter further includes a model parameter, which includes the outer contour parameter, inner contour parameter, and / or pad coordinates of the coil to be processed; the control module stores a plurality of preset coil templates, each preset coil template corresponding to a coil parameter range, which includes the outer contour parameter range, inner contour parameter range, and / or pad coordinate range of the coil;

[0037] Between step c and step d, there is an additional step:

[0038] i. The control module compares the model parameter with the range of coil parameters of each preset coil template. If the model parameter is within one of the ranges of coil parameters, the corresponding preset coil template is selected. If the model parameter exceeds the range of each coil parameter, the model parameter of the coil to be processed is recorded and the coil to be processed is discarded.

[0039] In one embodiment, step c includes the step of:

[0040] c1. Preprocessing the upper visual image and the lower visual image; wherein, the preprocessing includes classifying and storing the upper visual image and the lower visual image according to the acquisition angle, performing non-local mean denoising on the upper visual image and the lower visual image, and / or cropping the upper visual image and the lower visual image based on the preset coil template and retaining the local image of the position of the coil lead to be processed.

[0041] In one embodiment, step c further includes the step:

[0042] c2. The control module binarizes the contour coordinates of the leader line in the local image;

[0043] c3. The control module refines the contour coordinates to obtain the centerline coordinates of the lead wire;

[0044] c4. The control module detects and locates the coordinates of the two endpoints of the centerline coordinates.

[0045] In one embodiment, step d includes the following steps:

[0046] d1. The control module compares the first feature parameters detected in each of the upper visual image and the lower visual image with the reference parameters of the preset coil template to obtain the deflection direction and deflection value of the lead wire relative to the lead wire position in the preset coil template from the upper and lower perspectives respectively.

[0047] d2. The control module fuses the deflection direction and the deflection value for the upper and lower viewpoints respectively;

[0048] d3. The control module outputs the first correction command based on the fused deflection direction and the deflection value. The first correction command includes the rotation angle and movement stroke of the coil fixture.

[0049] The aforementioned coil management device acquires the first characteristic parameters of the coil to be managed through the collaborative work of the upper and lower vision modules, and compares them with the reference parameters of the preset coil template to generate a targeted first correction command. This enables the device to automatically adapt to the differences in lead wire morphology of different models and specifications of coils without the need to change tooling or readjust the equipment. This achieves adaptive coil management, saving the time and tooling manufacturing costs associated with changing fixtures and readjusting the equipment in traditional production methods, thus improving overall production efficiency. In addition, the coil management process is transformed from relying on manual experience or fixed mechanical parameters to closed-loop control based on actual measurement data, which significantly improves the accuracy of coil management and product consistency. Attached Figure Description

[0050] Figure 1 This is a schematic diagram of the coil assembly apparatus of this application;

[0051] Figure 2 This is a schematic diagram of the structure of the coil management module in one embodiment of the coil management device of this application;

[0052] Figure 3 This is a schematic diagram of the wire management module and the material handling module in another embodiment of the coil wire management device of this application;

[0053] Figure 4 for Figure 3 A 3D view of the central alignment module;

[0054] Figure 5 for Figure 4 Top view;

[0055] Figure 6 for Figure 3 A 3D view of the first suction nozzle.

[0056] Reference numerals: 10, base; 20, gantry frame; 21, gantry body; 22, gantry mover; 30, material handling module; 31, working head; 32, first suction nozzle; 321, vacuum hole; 40, upper vision module; 50, coil feeding rail; 60, wire management module; 61, coil fixture; 611, third suction nozzle; 62, wire management assembly; 621, wire management base; 622, positioning adjustment part; 6221, positioning groove; 6222, first side wall; 6223, second side wall; 623, wire management adjustment part; 6231, adjustment seat; 6232, wire management lever; 624, pressure plate; 6241, vertical limiting part; 70, lower vision module; 80, substrate feeding rail; 90, attachment module. Detailed Implementation

[0057] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0058] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0059] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0060] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0061] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0062] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0063] Please refer to Figure 1 As shown, this application first provides a coil assembly device, including a base 10, a material picking module 30, an upper vision module 40, a wire arrangement module 60, a lower vision module 70, and a control module. The material picking module 30 and the upper vision module 40 are capable of horizontal movement relative to the base 10, and the projection area of ​​the moving range of the material picking module 30 along the vertical direction C3 is the working area. The wire arrangement module 60 and the lower vision module 70 are both at least partially located within the working area. The material picking module 30 is used to pick up and place coils to be arranged, the upper vision module 40 is used to capture an upper vision image of the coil to be arranged from the upper side, and the lower vision module 70 is used to capture a lower vision image of the coil to be arranged from the lower side. The upper vision module 40 and the wire arrangement module 60 are... Both the upper vision module 60 and the lower vision module 70 are electrically connected to the control module. The control module is used to acquire the first feature parameters of the coil to be managed based on the upper vision image and the lower vision image, and to generate a first correction command by comparing the reference parameters of the preset coil template with the first feature parameters. The first feature parameters include the coordinates of the two endpoints of the lead of the coil to be managed. One of the coil management module 60 or the material handling module 30 includes a first component capable of carrying the coil to be managed. The coil management module 60 has a coil management adjustment surface. At least one of the first component and the coil management adjustment surface can move relative to the other based on the first correction command, so that the lead of the coil to be managed is deformed to the shape corresponding to the reference parameters by abutting against the coil management adjustment surface.

[0064] In this application, the upper vision module 40 and the lower vision module 70 work together to acquire the first characteristic parameters of the coil to be managed, and compare them with the reference parameters of the preset coil template to generate a targeted first correction instruction. This enables the device to automatically adapt to the differences in lead wire shape of different models and specifications of coils without changing tooling or re-adjusting the equipment. This achieves adaptive lead wire management, saving the time and tooling manufacturing costs of changing fixtures and re-adjusting the equipment in traditional production methods, and improving overall production efficiency. In addition, the lead wire management process is transformed from relying on manual experience or fixed mechanical parameters to closed-loop control based on actual measurement data, which significantly improves lead wire management accuracy and product consistency.

[0065] Specifically, after the material handling module 30 moves the coil to be processed to the working area, the upper vision module 40 and the lower vision module 70 take pictures from the upper and lower sides of the coil, respectively. The control module processes the upper vision image and the lower vision image based on the machine vision algorithm to extract the first feature parameter of the coil to be processed.

[0066] The control module compares the extracted first feature parameters with the reference parameters stored in the preset coil template, calculates the deviation between the actual lead position and the target position, and generates a first correction command accordingly. The reference parameters include the coordinates of the two endpoints of the coil lead in the preset coil template. More specifically, the first correction command includes control information such as the path, displacement, or angle of relative movement between the first component and the coil adjustment surface.

[0067] Furthermore, based on the first calibration command, the control module drives the first component (carrying the coil to be managed) to move relative to the management surface (set in the management module 60). During the movement, the lead of the coil to be managed comes into contact with the management surface and generates mechanical interference. By controlling the relative movement trajectory, the management surface applies a directional force to the lead, causing the lead to undergo plastic deformation. Finally, the coordinates of the lead endpoint reach the shape corresponding to the reference parameters, thus completing the management action.

[0068] It is worth mentioning that, in this application, "carrying" refers to the first component carrying the coil to be managed as an example, meaning that the coil to be managed and the first component are relatively fixed in the vertical direction C3, and relatively fixed in the horizontal direction when the external force is less than a threshold. This threshold is greater than the yield force required for the plastic deformation of the lead wire. Therefore, when the wire management adjustment surface abuts against the lead wire and drives the lead wire to deform, there will be no relative movement between the coil to be managed and the first component. In addition, by defining the projection of the moving range of the material picking module 30 in the vertical direction C3 as the working area, and arranging the wire management module 60 and the lower vision module 70 within this working area, the three major functions of visual inspection, material picking and transfer, and wire management correction are integrated in space, ensuring that visual data and mechanical actions are accurately mapped based on the same spatial coordinate system.

[0069] By capturing visual images from both the top and bottom angles using the upper vision module 40 and the lower vision module 70, the upper and lower visual images of the coil to be managed can be obtained respectively. On the one hand, the first feature parameters on both sides can be mutually verified to provide a verification effect. On the other hand, it can also avoid the situation where the upper and lower features of the coil to be managed block each other or reflect light, which would affect the recognition accuracy of the subsequent control module, thereby improving the coil management accuracy of the coil management device of this application.

[0070] At least one of the first component and the thread adjustment surface can move relative to the other based on the first correction command. This can be achieved by the first component moving actively, by the thread adjustment surface (i.e., the thread adjustment module 60) moving, or by the first component and the thread adjustment surface moving together, as long as there is a corresponding relative movement between the first component and the thread adjustment surface.

[0071] In some embodiments, the coil management device further includes a gantry frame 20, which includes a gantry body 21 fixed to the base 10 and a gantry mover 22 movably disposed on the gantry body 21 along a first direction C1. The gantry mover 22 is provided with a material picking module 30 and an upper vision module 40, wherein the first direction C1 is parallel to the horizontal direction.

[0072] Furthermore, the material handling module 30 includes a working head 31 movably disposed on the gantry mover 22 along the vertical direction C3 and a material handling head disposed on the moving end of the working head 31, the material handling head being able to pick up and place the coil to be handled.

[0073] In some embodiments, the coil feeding device further includes coil feeding rails 50 that are spaced apart along the first direction C1 on the base 10 and are at least partially located within the working area. The coil feeding rails 50 are also electrically connected to the control module and are used to carry coils and provide coils to be fed to the working area.

[0074] In some embodiments, the driving part of each module in this application adopts a servo slide, such as the driving part that drives the working head 31 to move in the vertical direction C3, the driving part that drives the gantry mover 22 to move in the first direction C1, and the driving part that drives the module carrying the vibrator to be sorted to move, etc. The repeatability of the servo slide can reach ±0.001mm, so as to improve the operation accuracy.

[0075] In some embodiments, the wire management module 60 further includes a positioning adjustment surface. The control module is used to acquire second characteristic parameters of the wire coil to be managed based on the upper visual image and the lower visual image, and to generate a second correction command by comparing the reference parameters and the second characteristic parameters of the preset coil template. The second characteristic parameters include the relative offset and relative offset angle between the wire coil to be managed and the first component in the carrying state. At least one of the first component and the positioning adjustment surface can move relative to the other based on the second correction command, so as to adjust the wire coil to be managed relative to the first component to the position corresponding to the reference parameters by the wire coil to be managed abutting against the positioning adjustment surface. The reference parameters include the relative offset and relative offset angle between the preset coil template and the first component.

[0076] By introducing the positioning adjustment surface and the detection and correction of the second characteristic parameter, the random positional error (such as eccentricity, rotation angle deviation, etc.) generated when the coil is carried by the first component (e.g., picked up or clamped by the material picking module 30) can be automatically eliminated, ensuring that the coil enters the wire arrangement process in a standard posture.

[0077] It is understandable that before performing deformation correction on the leads, the relative position between the coil and the first component is adjusted to the standard carrying position (i.e., the corresponding relative position in the reference parameters) through the positioning adjustment surface. This provides an accurate reference coordinate system for subsequent lead deformation, avoids errors in the calculation of lead endpoint coordinates due to coil body tilt or offset, and thus improves the repeatability of lead assembly.

[0078] Specifically, the aforementioned "adjusting the coil to be processed relative to the first component to the relative offset and relative offset angle corresponding to the reference parameters by abutting the coil to be processed against the positioning adjustment surface" refers to applying a driving force greater than the threshold of the carrying state in the horizontal direction by abutting the coil to be processed against the positioning adjustment surface, so that the first component and the coil to be processed move relative to each other in the horizontal direction while keeping the vertical direction C3 relatively fixed, thereby completing the adjustment of the relative offset and relative offset angle between the two.

[0079] Furthermore, at least one of the first component and the positioning adjustment surface can move relative to the other based on the second correction command. This can be achieved by the first component moving actively, by the positioning adjustment surface moving, or by the first component and the positioning adjustment surface moving together, as long as the first component and the positioning adjustment surface can move accordingly.

[0080] In some embodiments, during the wire management process, the wire management module 60 has a wire management adjustment surface and a positioning adjustment surface, and the material handling module 30 includes a first component, which can drive the coil to be managed to move relative to the positioning adjustment surface and the wire management adjustment surface to complete the positioning of the coil to be managed and the wire management of the lead wire.

[0081] In other embodiments, please refer to Figure 2 As shown, the wire management module 60 includes a coil fixture 61 and a wire management assembly 62. The coil fixture 61 is the first assembly. The material handling module 30 can place the coil to be managed in the coil fixture 61 so that the coil to be managed can be moved by the coil fixture 61. The wire management assembly 62 has a positioning adjustment surface and a wire management adjustment surface.

[0082] With this configuration, the material handling module 30 can proceed to the next round of material handling after placing the coil to be handled on the coil fixture 61, while the wire handling module 60 can independently complete the wire handling. In other words, the next round of material handling and the wire handling process of the wire handling module 60 can be executed in parallel, thereby speeding up the assembly cycle of the coil wire handling device of this application and improving the processing efficiency.

[0083] Specifically, in some embodiments, the positioning adjustment surface and the wire management adjustment surface are located on both sides of the coil fixture 61 along the same horizontal direction, so as to reduce the amount of movement required for the coil fixture 61 or the wire management assembly 62 during the wire management process and further improve the processing efficiency.

[0084] In some embodiments, the coil jig 61 is provided with a third suction nozzle 611, which can attract and carry the coil to be processed. Of course, in other embodiments, the coil jig 61 can also carry the coil to be processed by clamping along the vertical direction C3 or by other means, which will not be listed in detail here.

[0085] Furthermore, in some embodiments, the coil jig 61 is rotatable along its own vertical axis C3, and the coil jig 61 is provided with two third suction nozzles 611; with this configuration, when one of the third suction nozzles 611 is adsorbing the coil to be sorted for sorting, the material handling module 30 can perform material handling and other operations on the other third suction nozzle 611, thereby further accelerating the assembly cycle of the coil sorting device of this application.

[0086] Please combine Figure 3 as well as Figure 4 As shown, in some embodiments, the cable management module 60 includes a cable management base 621, a positioning adjustment part 622, and a cable management adjustment part 623. The cable management base 621 is fixed to the base 10, and the positioning adjustment part 622 and the cable management adjustment part 623 are detachably fixed to the cable management base 621. The cable management adjustment part 623 has a cable management adjustment surface, and the positioning adjustment part 622 has a positioning adjustment surface.

[0087] It is understandable that the positioning adjustment unit 622 and the wire management adjustment unit 623 have their own adjustment range. When the size of the coil or the required wire management angle is within the adjustment range, the control module can identify the first characteristic parameter and the second characteristic parameter of the coil and output the corresponding first correction command and the second correction command to complete the positioning and wire management operation of the coil to be managed. However, when the size of the coil to be managed or the required wire management angle exceeds the adjustment range (for example, when the size of the coil is greater than the distance between two opposite positioning adjustment surfaces), the wire management operation cannot be completed by parameter adjustment.

[0088] To address this, by designing the positioning adjustment unit 622 and the cable management adjustment unit 623 to be detachably fixed to the cable management base 621, the modularity and rapid adaptation of the cable management module 60 are achieved. By quickly switching physical components to match different coil specifications, the device compatibility is expanded with the lowest hardware adjustment cost.

[0089] Specifically, when dealing with different types of coils (whose size or required wire management angle exceeds the adjustment range of the positioning adjustment unit 622 and the wire management adjustment unit 623), it is only necessary to replace the positioning adjustment unit 622 or the wire management adjustment unit 623 with different adjustment ranges, without having to replace the entire fixture or debugging equipment, which effectively reduces the debugging difficulty and tooling cost.

[0090] It should be noted that although the positioning adjustment unit 622 and the wire management adjustment unit 623, which have a large adjustment range, can be backward compatible with coils with smaller size or smaller required wire management angle, they will increase the travel required by the material picking module 30 or the wire management module 60 during the wire management process, affecting the wire management efficiency. The above embodiment can simultaneously take into account both the compatibility range of the coil and the wire management efficiency.

[0091] Furthermore, in some embodiments, the positioning adjustment surface is adjustablely provided with the positioning adjustment part 622 in the horizontal direction, and the cable management adjustment part is adjustablely provided with the cable management adjustment part 623 in the triaxial direction; for example, a limiting plate with a positioning adjustment surface is threadedly connected to the positioning adjustment part 622.

[0092] In some embodiments, the cable management base 621 has a through hole along the vertical direction C3, located between the positioning adjustment part 622 and the cable management adjustment part 623. The lower vision module 70 is located on the lower side of the cable management base 621 and is directly opposite the through hole along the vertical direction C3, so as to facilitate the lower photography and reduce the amount of movement of the gantry mover 22.

[0093] Please combine Figure 4 as well as Figure 5 As shown, in some embodiments, the cable management adjustment unit 623 includes an adjustment base 6231 and two cable management levers 6232 parallel to the vertical direction C3. The adjustment base 6231 is detachably fixed to the cable management base 621. The two cable management levers 6232 are detachably disposed on the adjustment base 6231 and protrude from the same side of the adjustment base 6231 in the horizontal direction. The two cable management levers 6232 are inclined along the projection of the vertical direction C3 and the protruding ends of the two cable management levers 6232 are close to each other. The cable management adjustment surface includes the surface of the side of the two cable management levers 6232 that are close to each other.

[0094] The cable management adjustment unit 623, through the adjustment seat 6231 and two inclined opposite cable management levers 6232, achieves the guiding deformation of the lead wire. The two cable management levers 6232 have an inverted V-shaped structure in vertical projection, and the inclined surfaces of their adjacent sides are part of the cable management adjustment surface.

[0095] Specifically, the detachable cable management lever 6232 lever design allows this application to support the replacement of cable management levers 6232 with different tilt angles, materials or spacing to adapt to the requirements of lead wire thickness or bending angle; and the inverted V-shaped structure of the two cable management levers 6232 can make the lead wires bear force evenly and avoid the deviation caused by pressure on one side.

[0096] Preferably, in some embodiments, the cable management lever 6232 is inserted into the adjustment seat 6231 in the vertical direction C3 to facilitate the adjustment of the cable management lever 6232.

[0097] It is worth mentioning that the cable management lever 6232 solution has the following problems compared to opening a cable management groove at a fixed angle to form a cable management adjustment surface. On the one hand, the current machining accuracy cannot meet the accuracy requirements of the cable management groove. On the other hand, the groove wall of the cable management groove is fixed, and the cable management adjustment surface cannot be physically adjusted as needed, resulting in lower versatility.

[0098] In some embodiments, the cable management adjustment unit 623 further includes a force sensor connected to the cable management lever 6232. The force sensor is electrically connected to the control module and is used to detect the pressure of the cable management lever 6232.

[0099] The force sensor can detect the pressure data of the cable management tool 6232 on the lead wire in real time during the cable management process, thus solving the problem of lead wire damage or insufficient deformation caused by uncontrollable force in traditional cable management.

[0100] Specifically, the control module compares the pressure value fed back by the force sensor with the preset pressure and dynamically adjusts the first correction command (direction and amount of wire movement) to ensure that the pressure value during the lead wire deformation process is always less than the preset pressure. This avoids lead wire deformation or even breakage due to excessive pressure, thereby improving the wire handling success rate and product yield. More specifically, in some embodiments, the preset pressure is 0.3N.

[0101] Furthermore, in some embodiments, if the control module detects that the feedback pressure value exceeds the preset pressure, it records the visual image of the coil to be processed and controls the material handling module 30 to place the coil to be processed in the waste area to eliminate abnormal components as soon as possible.

[0102] Please combine Figure 2 as well as Figure 5As shown, in some embodiments, the cable management module 60 further includes a pressure plate 624 disposed on the cable management base 621. The pressure plate 624 includes a vertical limiting part 6241 corresponding to the cable management adjustment part 623 along the vertical direction C3. When the lead of the coil to be managed abuts against the cable management adjustment surface along the horizontal direction, the lead abuts against the pressure plate 624 along the vertical direction C3.

[0103] The vertical limiting part 6241 of the pressure plate 624 is used to form a vertical constraint C3 on the lead wire during the wire arrangement process. When the lead wire moves and deforms in the horizontal direction relative to the wire arrangement lever 6232, the vertical limiting part 6241 can apply a limiting force from the vertical C3 side (top and / or bottom) of the lead wire to eliminate warping or displacement (such as bouncing, lifting, etc.) of the lead wire during the deformation process, thereby ensuring that the lead wire is closely attached to the wire arrangement adjustment surface and making the deformation angle in the horizontal direction more accurate.

[0104] Furthermore, in some embodiments, the end of the cable management lever 6232 protruding from the adjustment seat 6231 is tilted along the vertical direction C3 toward the side closer to the corresponding vertical limiting part 6241.

[0105] Please refer to Figure 2 As shown, in some embodiments, the pressure plate 624 is detachably disposed on the cable management base 621. The pressure plate 624 includes two vertical limiting parts 6241 spaced apart in the horizontal direction. The cable management module 60 includes two sets of cable management adjustment parts 623 corresponding to the two vertical limiting parts 6241 respectively.

[0106] Two sets of wire guiding adjustment sections 623, in conjunction with two vertical limiting sections 6241, can synchronously and efficiently process the two leads of the coil to be guided. Furthermore, to address differences in lead positions for coils of different specifications, the spacing of the pressure plates 624 between the vertical limiting sections 6241 can be changed, and the fixing positions of the wire guiding adjustment sections 623 can be adjusted accordingly.

[0107] It can cover the needs of multiple models without replacing the entire module, significantly shortening the tooling adjustment time.

[0108] Preferably, in some embodiments, the two sets of wire management adjustment parts 623 are located on both sides of the pressure plate 624 along the vertical direction C3, and the projections of the two sets of wire management adjustment parts 623 along the vertical direction C3 overlap at least partially, so as to improve the space utilization of the wire management module 60 along the vertical direction C3 and reduce the size of the wire management module 60 along the horizontal direction, which helps to miniaturize the coil wire management device of this application.

[0109] In some embodiments, the cable adjustment surface further includes a vertical limiting portion 6241 on the side of the cable guide 6232 along the vertical direction C3. The cable is deformed in the vertical direction C3 by the relative movement between the cable and the surface of the vertical limiting portion 6241 along the vertical direction C3.

[0110] Specifically, in some embodiments, the pressure plate 624 is electrically connected to the control module and is movably disposed on the cable management base 621 in the vertical direction C3, so that the cable management in the vertical direction C3 is completed by the lifting and lowering of the pressure plate 624 in the vertical direction C3.

[0111] In some other embodiments, the pressure plate 624 remains fixed, and the vertical C3 wire arrangement of the lead is completed by moving the structure carrying the coil to be arranged. For example, when the material picking module 30 picks up the coil to be arranged, the vertical movement of the material picking head drives the coil to be arranged to move; or, when the coil fixture 61 carries the coil to be arranged, the vertical movement of the coil fixture 61 drives the coil to be arranged to move.

[0112] Please combine Figure 4 as well as Figure 5 As shown, in some embodiments, the positioning adjustment part 622 has a positioning groove 6221 on its side along the horizontal direction. The positioning groove 6221 passes through the positioning adjustment part 622 along the vertical direction C3 to form a first side wall 6222 and a second side wall 6223 that are perpendicular to each other and parallel to the vertical direction C3. The positioning adjustment surface includes the first side wall 6222 and the second side wall 6223.

[0113] The first sidewall 6222 and the second sidewall 6223, which are perpendicular to each other and parallel to the vertical direction C3, can meet the correction requirements of two mutually perpendicular directions along the horizontal direction. When the coil to be processed moves relative to the positioning adjustment surface, the outer contour of the coil can abut against the first sidewall 6222 in one horizontal direction and against the second sidewall 6223 in another vertical horizontal direction, thereby passively guiding the coil to correct the positional deviation in the horizontal plane and ensuring that the coil to be processed and the module carrying it maintain a standard relative positional relationship.

[0114] Furthermore, in some embodiments, the protruding ends of the positioning groove 6221 and the cable management lever 6232 are respectively located on opposite sides of the coil to be managed in the standard position along the second direction C2. The second direction C2 is parallel to the horizontal direction and perpendicular to the first direction C1. The inner wall of the positioning groove 6221 includes a first side wall 6222 along the first direction C1 and a second side wall 6223 opposite to the cable management lever 6232 along the second direction C2.

[0115] Please refer to Figure 4As shown, in the above embodiment, the specific wire arrangement process is as follows: the wire coil to be arranged is driven by the material picking module 30 along the first direction C1 to the space between the positioning groove 6221 and the wire arrangement lever 6232; one of the material picking module 30 and the wire arrangement module 60 carries the wire coil to be arranged; the first component moves according to the movement amount of the second direction C2 in the second correction instruction, so that the straight edge of the wire coil to be arranged abuts against the second sidewall 6223. If the wire coil to be arranged has an angular deflection, the angle correction will be completed first under the pressure of the second sidewall 6223 until... The straight edge of the coil to be processed is completely in contact with the second sidewall 6223, and then the displacement correction in the second direction C2 is completed; the first component moves according to the movement amount in the first direction C1 in the second correction instruction, so that the coil to be processed abuts against the first sidewall 6222 and the correction in the first direction C1 is completed. At this time, the coil to be processed and the first component are in the standard carrying position; the first component moves sequentially according to the movement direction and movement amount of the first correction instruction, so that the lead of the coil to be processed abuts against the wire processing adjustment surface and is adjusted to the preset wire processing position.

[0116] Please combine Figure 1 as well as Figure 3 As shown, in some embodiments, the feeding head is a first suction nozzle 32 capable of picking up the coil to be processed.

[0117] The first suction nozzle 32 can extract the coil to be processed by negative pressure adsorption. On the one hand, it can be adapted to coils of different models and sizes, making it highly versatile. On the other hand, it can vertically adsorb the coil to be processed along the vertical direction C3. Compared with other mechanical clamping methods, it is less likely to cause lead wire deformation or coil displacement, thus improving the stability of the processing action.

[0118] In some other embodiments, if the material picking module 30 is not the first component, the material picking module 30 may also be selected from commonly used material picking structures such as flexible clamping mechanisms, as long as it can pick up and put the coil to be processed as needed and meet the transfer requirements; if the material picking module 30 is the first component, the material picking module 30 may also be selected from structures that can lift and clamp the coil to be processed along the vertical direction C3, so as to ensure that it is relatively fixed to the coil to be processed along the vertical direction C3.

[0119] In some embodiments, the material handling module 30 further includes a first vacuum sensor connected to the first suction nozzle 32. The first vacuum sensor is electrically connected to the control module and is used to detect the negative pressure value between the first suction nozzle 32 and the coil of wire to be processed.

[0120] The first vacuum sensor can monitor the negative pressure value between the first suction nozzle 32 and the coil to be treated in real time to achieve stable adsorption of the coil. Specifically, when the detected negative pressure value is lower than the preset negative pressure, an air replenishment operation is triggered to prevent the coil to be treated from shifting or loosening due to insufficient suction.

[0121] Preferably, in some embodiments, the preset negative pressure is -47 kPa.

[0122] Please refer to Figure 6 As shown, in some embodiments, the first suction nozzle 32 has a plurality of vacuum holes 321 along the horizontal direction, and the diameter of the outer vacuum hole 321 is smaller than the diameter of the inner vacuum hole 321.

[0123] Please refer to Figure 1 As shown, this application also provides a coil assembly apparatus, including the above-mentioned coil wire management device, substrate feeding rail 80 and attachment module 90. The substrate feeding rail 80 and the attachment module 90 are both disposed on the base 10 and at least partially located in the working area. The substrate feeding rail 80 is used to carry the substrate and provide the substrate to be assembled to the working area. The substrate to be assembled is the substrate located in the working area.

[0124] The attachment module 90 includes an attachment fixture and a dispensing module. The material handling module 30 can place the substrate to be assembled on the attachment fixture. The dispensing module is used to apply adhesive to the substrate to be assembled. The material handling module 30 can also attach the coil to be assembled to the substrate to be assembled with adhesive, so that the lead wire of the coil to be assembled contacts the pad of the substrate to be assembled. The coil to be assembled is a coil to be arranged after the lead wire is deformed.

[0125] By integrating the coil wire management device, the substrate feeding rail 80, and the bonding module 90, the entire process from coil wire management to substrate bonding is automated. The coil assembly device also has adaptive characteristics, which can handle the assembly of motor coil leads of different models and specifications without changing tooling or debugging equipment, significantly improving production efficiency. At the same time, the precise positioning guided by vision ensures reliable contact between the coil leads and the substrate pads, enhancing product consistency and assembly accuracy.

[0126] Furthermore, in some embodiments, after the wire arrangement is completed, the upper vision module 40 performs a second image acquisition from the upper perspective of the coil to be assembled; the material picking module 30 picks up the coil to be assembled and performs a second image acquisition from the lower perspective through the lower vision module 70; the control module compares the feature parameters identified after the second image acquisition and confirms that they are qualified before proceeding with the subsequent attachment operation, so as to achieve closed-loop verification and effectively reduce the loss rate of the substrate.

[0127] In some embodiments, the bottom of the attachment fixture is provided with a second suction nozzle for adsorbing the substrate to be assembled. The second suction nozzle is connected to a second vacuum sensor. The second vacuum sensor is electrically connected to the control module and is used to detect the negative pressure value between the second suction nozzle and the substrate to be assembled.

[0128] The second vacuum sensor can monitor the negative pressure value between the second nozzle and the substrate to be assembled in real time to achieve stable adsorption of the substrate. Specifically, when the detected negative pressure value is lower than the preset negative pressure, a gas replenishment operation is triggered to prevent the lead wires and pads from shifting due to loosening of the substrate during the attachment process, ensuring that the substrate remains stably positioned throughout the attachment process, thereby improving the contact accuracy between the pads and lead wires.

[0129] In some embodiments, the attachment fixture is provided with a displacement sensor, which is electrically connected to the control module and is used to detect the amount of horizontal offset after the coil to be assembled is attached to the substrate to be assembled.

[0130] The displacement sensor can detect the horizontal offset of the coil after it is attached to the substrate and transmit the data to the control module. The control module identifies the offset between the actual installation position and the expected installation position of the coil to be assembled and compares the offset with a preset tolerance range. If the offset exceeds the preset tolerance range, the offset data is recorded and the product is discarded; if it is within the tolerance range, the process proceeds to the next step.

[0131] Preferably, in some embodiments, the preset tolerance range is ±0.01mm.

[0132] In some embodiments, the attachment fixture is provided with a temperature sensor, which is electrically connected to the control module and is used to detect the temperature of the adhesive.

[0133] The temperature sensor can monitor the temperature of the adhesive liquid dropped onto the substrate by the dispensing module and feed the data back to the control module. The control module dynamically adjusts the bonding process time according to the adhesive curing temperature curve. If the temperature is too low, the curing waiting time is extended; if the temperature is too high, the waiting time is shortened to ensure consistent adhesive strength under different environmental conditions and avoid lead wire contact failure due to poor curing.

[0134] Please refer to Figure 1 As shown, in some embodiments, the gantry body 21 is provided with two gantry movers 22, each of which is provided with a material handling module 30 and an upper vision module 40; one of the gantry movers 22 moves between the coil feeding rail 50 and the lower vision module 70, and the other gantry mover 22 moves between the lower vision module 70 and the substrate feeding rail 80.

[0135] One gantry mover 22 is responsible for moving between the coil feeding rail 50 and the lower vision module 70 to perform coil routing operations, while the other gantry mover 22 moves between the lower vision module 70 and the substrate feeding rail 80 to handle the transfer of coils to be assembled and subsequent attachment operations. This parallel operation design realizes the division of labor and coordination in the production process, reduces the idle time of a single gantry mover 22, avoids waiting between processes through multi-task parallel processing, and improves the assembly efficiency of the coil assembly device. On the other hand, since the two gantry movers 22 share the same gantry body 21, the cost is relatively low and the space occupied is relatively small.

[0136] Of course, in other embodiments, depending on the production line layout space, equipment cost and required processing efficiency, different numbers of gantry frames 20 may be set, and each gantry frame 20 may also be set with one or more different numbers of gantry movers 22. This application will not give examples of each of these.

[0137] Please refer to Figure 1 As shown, in some embodiments, the base 10 is provided with a coil feeding rail 50, a wire management module 60, a lower vision module 70, an attachment module 90 and a substrate feeding rail 80 in sequence along the first direction C1, and the gantry mover 22 is provided with a material picking module 30 and an upper vision module 40 in sequence along the same direction of the first direction C1.

[0138] The sequential arrangement of the modules achieves compact and linear operation of the device. By integrating the modules sequentially along the first direction C1, the movement path of the gantry mover 22 is simplified to a unidirectional linear motion, reducing the complexity of multi-directional switching. At the same time, the co-directional configuration of the material handling module 30 and the upper vision module 40 ensures that the picking and placing actions and visual inspection can be continuously performed during the movement without the need for additional adjustment of the gantry mover 22's posture, thereby shortening the cycle time and improving the stability and operating efficiency of the device.

[0139] This application also provides a coil management method applicable to the above-mentioned coil management device, comprising the following steps:

[0140] a. The upper vision module acquires the upper vision image of the coil to be processed.

[0141] b. The lower vision module acquires the lower vision image of the coil to be processed;

[0142] c. The control module obtains the first characteristic parameters of the coil to be processed based on the upper and lower visual images;

[0143] d. The control module compares the reference parameters of the preset coil template with the first characteristic parameters and outputs the first correction command;

[0144] e. The first component moves the coil to be managed relative to the management surface based on the first calibration command, so as to deform the lead wire to the shape corresponding to the reference parameters by having the lead wire of the coil to be managed abut against the management surface.

[0145] In some embodiments, in step a, the upper vision module 40 can capture multiple coils on the coil feeding rail 50, including the coil to be processed, at once. In this way, after the coil feeding rail 50 provides the coil to be processed to the working area each time, the control module only needs to retrieve the corresponding visual image of the coil to be processed, without the upper vision module 40 needing to move to the position of the coil to be processed each time to capture a separate image, which speeds up the assembly cycle and improves the assembly efficiency.

[0146] In some embodiments, between step b and step c, the following step is further included:

[0147] f. The control module also obtains the second characteristic parameters of the coil to be processed based on the upper visual image and the lower visual image; wherein, the second characteristic parameters include the relative offset and relative offset angle between the coil to be processed and the first component in the carrying state;

[0148] g. The control module compares the reference parameters of the preset coil template with the second characteristic parameters and outputs a second correction command;

[0149] Between step d and step e, the following step is also included:

[0150] h. The first component moves the coil to be processed relative to the positioning adjustment surface of the coil processing module based on the second correction command, so as to adjust the coil to be processed relative to the first component to the position corresponding to the reference parameters by the coil to be processed abutting against the positioning adjustment surface; wherein, the reference parameters include the relative offset and relative offset angle between the preset coil template and the first component.

[0151] In some embodiments, the first feature parameter further includes a model parameter, which includes the outer contour parameter, inner contour parameter and / or pad coordinates of the coil to be processed; the control module stores a plurality of preset coil templates, each preset coil template corresponding to a coil parameter range, the coil parameter range including the outer contour parameter range, inner contour parameter range and / or pad coordinate range of the preset coil template;

[0152] The steps between step c and step d include:

[0153] i. The control module compares the model parameters with the coil parameter range of each preset coil template. If the model parameters are within one of the coil parameter ranges, the corresponding preset coil template is selected. If the model parameters exceed the range of each coil parameter, the model parameters of the coil to be processed are recorded and the coil to be processed is discarded.

[0154] This enables automatic identification of different coil models and automatic switching of process parameters, solving the problems of long downtime and high production costs caused by frequent tooling changes in traditional production lines. In addition, by determining the parameter range, it can automatically identify incorrect materials, mixed materials, or new model samples, preventing unqualified products from flowing into subsequent welding processes and improving product yield. For discarded coils, the system automatically records their model parameters, providing a data basis for establishing new preset coil templates.

[0155] In some embodiments, step c includes the step of:

[0156] c1. Preprocessing the local image; wherein, the preprocessing includes classifying and storing the upper and lower visual images according to the acquisition angle, performing non-local mean denoising on the upper and lower visual images, and / or cropping the upper and lower visual images based on a preset coil template and retaining the local image of the position of the coil lead to be processed.

[0157] Among these features, cropping images can reduce the computational load of subsequent image processing algorithms and improve the real-time performance of the system; non-local mean denoising removes image noise caused by electromagnetic interference in the industrial environment while avoiding the blurring of lead edges caused by traditional Gaussian filtering, ensuring the integrity of the outline of the thin lead lines; and classifying and storing data according to the acquisition angle provides a data alignment basis for subsequent binocular vision fusion, preventing coordinate system errors caused by confusion between images from the upper and lower perspectives.

[0158] In some embodiments, step c further includes the step of:

[0159] c2. The control module binarizes the contour coordinates of the leader lines in the upper and lower visual images;

[0160] c3. The control module refines the contour coordinates to obtain the centerline coordinates of the leader.

[0161] c4. The control module detects and locates the coordinates of the two endpoints of the centerline.

[0162] A progressive feature extraction algorithm of binarization-thinning-endpoint localization is adopted. First, binarization isolates environmental interference such as changes in illumination and surface reflection, ensuring stable extraction of geometric features even when the lead color and material change. Second, thinning abstracts the lead features into mathematical line elements, so that the extraction of endpoint coordinates is not affected by the actual line width of the lead, thereby improving the positioning accuracy. Finally, endpoint localization transforms the complex lead image information into two-dimensional / three-dimensional coordinates (first feature parameter) of the two endpoints, simplifying the subsequent comparison calculation with the preset coil template.

[0163] In some embodiments, step d includes the following steps:

[0164] d1. The control module compares the first feature parameters detected in the upper and lower visual images with the reference parameters of the preset coil template to obtain the deflection direction and deflection value of the lower lead wire relative to the lead wire position in the preset coil template from the upper and lower viewpoints respectively.

[0165] d2. The control module fuses the deflection direction and deflection value of the upper and lower viewpoints respectively;

[0166] d3. The control module outputs a first correction command based on the fused deflection direction and deflection value. The first correction command includes the rotation angle and travel distance of the first component.

[0167] Through a three-level decision-making mechanism of split-view comparison, data fusion, and motion calculation, firstly, by fusing the upper and lower viewpoints, the problem of monocular vision being unable to obtain information on the bending of the lead wire in the height direction is solved, enabling comprehensive detection of the lead wire's spatial attitude. Secondly, by fusing the deflection direction and deflection value separately, the "false horizontal" misjudgment caused by the lead wire tilt in single-view detection is avoided, allowing the wire management module to generate a precise correction path based on the actual spatial distortion shape of the lead wire. Finally, the abstract image deviation is transformed into specific mechanical motion parameters (i.e., the first correction command), establishing a complete control closed loop from visual detection to mechanical execution, ensuring that the interference deformation process between the wire management adjustment surface and the lead wire is controllable and repeatable.

[0168] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0169] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A coil winding device, characterized in that, It includes a base (10), a material picking module (30), an upper vision module (40), a cable management module (60), a lower vision module (70), and a control module. The material picking module (30) and the upper vision module (40) can move horizontally relative to the base (10), and the projection area of ​​the moving range of the material picking module (30) along the vertical direction is the working area. The wire management module (60) and the lower vision module (70) are both located at least partially within the working area. The material handling module (30) is used to pick up and place the wire coil to be managed. The upper vision module (40) is used to capture an upper vision image of the wire coil from the upper side. The lower vision module (70) is used to capture a lower vision image of the wire coil from the lower side. The upper vision module (40), the wire management module (60), and the lower vision module (70) are all electrically connected to the control module. The control module is used to obtain the first feature parameters of the coil to be processed based on the upper visual image and the lower visual image, and to generate a first correction command by comparing the reference parameters of the preset coil template with the first feature parameters; wherein, the first feature parameters include the coordinates of the two endpoints of the lead of the coil to be processed; One of the wire management module (60) or the material handling module (30) includes a first component capable of carrying the coil to be managed. The wire management module (60) has a wire management adjustment surface. At least one of the first component and the wire management adjustment surface can move relative to the other based on the first correction command, so as to deform the lead wire to the shape corresponding to the reference parameter by abutting the lead wire of the coil to be managed against the wire management adjustment surface. The cable management module (60) includes a cable management base (621) and a cable management adjustment part (623). The cable management base (621) is fixed to the base (10), and the cable management adjustment part (623) is detachably fixed to the cable management base (621). The cable management adjustment part (623) has the cable management adjustment surface. The cable management adjustment unit (623) includes an adjustment base (6231) and two cable management levers (6232) parallel to the vertical direction. The adjustment base (6231) is detachably fixed to the cable management base (621). The two cable management levers (6232) are detachably disposed on the adjustment base (6231) and protrude horizontally from the same side of the adjustment base (6231). The two cable management levers (6232) are inclined along the projection of the vertical direction and the protruding ends of the two cable management levers (6232) are close to each other. The cable management adjustment surface includes the surface of the side of the two cable management levers (6232) that are close to each other.

2. The coil winding device according to claim 1, characterized in that, The wire management module (60) also has a positioning adjustment surface, and the control module is also used to obtain the second feature parameters of the coil to be managed based on the upper visual image and the lower visual image, and to generate a second correction command by comparing the reference parameters of the preset coil template with the second feature parameters; wherein, the second feature parameters include the relative offset and relative offset angle between the coil to be managed and the first component in the carrying state; At least one of the first component and the positioning adjustment surface can move relative to the other based on the second correction command, so as to adjust the coil to be processed relative to the first component to the position corresponding to the reference parameter by the coil to be processed abutting against the positioning adjustment surface.

3. The coil winding device according to claim 2, characterized in that, The cable management module (60) includes the first component and the cable management component (62). The cable management component (62) has the cable management adjustment surface and the positioning adjustment surface. The first component can carry the coil to be managed and move it relative to the cable management adjustment surface and the positioning adjustment surface.

4. The coil winding device according to claim 3, characterized in that, The cable management module (60) includes a positioning adjustment part (622), which is detachably fixed to the cable management base (621), wherein the positioning adjustment part (622) has the positioning adjustment surface.

5. The coil winding device according to claim 1, characterized in that, The cable management adjustment unit (623) also includes a force sensor connected to the cable management lever (6232). The force sensor is electrically connected to the control module and is used to detect the pressure of the cable management lever (6232).

6. The coil winding device according to claim 1, characterized in that, The cable management module (60) further includes a pressure plate (624) disposed on the cable management base (621). The pressure plate (624) includes a vertical limiting part (6241) corresponding to the cable management adjustment part (623) in the vertical direction. When the lead wire abuts against the cable management adjustment surface in the horizontal direction, the lead wire abuts against the pressure plate (624) in the vertical direction.

7. The coil winding device according to claim 6, characterized in that, The pressure plate (624) is detachably disposed on the cable management base (621). The pressure plate (624) includes two vertical limiting parts (6241) spaced apart in the horizontal direction. The cable management module (60) includes two sets of cable management adjustment parts (623) corresponding to the two vertical limiting parts (6241) respectively.

8. The coil winding device according to claim 6, characterized in that, The pressure plate (624) is electrically connected to the control module and is movably disposed on the cable management base (621) in the vertical direction.

9. The coil winding device according to claim 4, characterized in that, The positioning adjustment part (622) has a positioning groove (6221) on its side along the horizontal direction. The positioning groove (6221) passes through the positioning adjustment part (622) in the vertical direction to form a first side wall (6222) and a second side wall (6223) that are perpendicular to each other and parallel to the vertical direction. The positioning adjustment surface includes the first side wall (6222) and the second side wall (6223).

10. The coil winding device according to claim 2, characterized in that, The cable management module (60) has the cable management adjustment surface and the positioning adjustment surface, and the material handling module (30) includes the first component, and the first component is movable relative to the cable management adjustment surface and the positioning adjustment surface.

11. The coil winding device according to claim 1, characterized in that, The material handling module (30) includes a first suction nozzle (32) capable of picking up the coil to be processed.

12. The coil winding device according to claim 11, characterized in that, The material handling module (30) also includes a first vacuum sensor connected to the first suction nozzle (32). The first vacuum sensor is electrically connected to the control module and is used to detect the negative pressure value between the first suction nozzle (32) and the coil to be processed.

13. The coil winding device according to claim 11, characterized in that, The first suction nozzle (32) has a plurality of vacuum holes (321) in the horizontal direction, and the diameter of the vacuum hole (321) on the outer side is smaller than the diameter of the vacuum hole (321) on the inner side.

14. A coil assembly device, characterized in that, Includes a coil management device as described in any one of claims 1 to 13 and an attachment module (90), wherein the attachment module (90) is disposed on the base (10) and is at least partially located within the working area, and the material picking module (30) is also capable of picking up and placing the substrate to be assembled; The attachment module (90) includes an attachment fixture and a dispensing module. The material handling module (30) can place the substrate to be assembled on the attachment fixture. The dispensing module is used to apply adhesive to the substrate to be assembled. The material handling module (30) can also attach the coil to be assembled to the substrate to be assembled with the adhesive, so that the lead wire of the coil to be assembled contacts the pad of the substrate to be assembled. The coil to be assembled is the coil to be arranged after the lead wire is deformed.

15. A method for managing coil wires, characterized in that, A coil management device applicable to any one of claims 1 to 13, comprising the steps of: a. The upper vision module acquires the upper vision image of the coil to be processed. b. The lower vision module acquires the lower vision image of the coil of wire to be processed; c. The control module obtains the first feature parameters of the coil to be processed based on the upper visual image and the lower visual image; d. The control module compares the reference parameters of the preset coil template with the first feature parameters, and outputs the first correction command; e. The first component moves the coil to be managed relative to the management surface based on the first calibration command, so as to deform the lead wire to the shape corresponding to the reference parameter by having the lead wire of the coil to be managed abut against the management surface.

16. The coil winding method according to claim 15, characterized in that, Between step b and step c, the following step is also included: f. The control module further obtains a second feature parameter of the coil to be processed based on the upper visual image and the lower visual image; wherein, the second feature parameter includes the relative offset and relative offset angle of the coil to be processed relative to the first component in the carrying state; g. The control module compares the reference parameters of the preset coil template with the second feature parameters and outputs a second correction command; Between step d and step e, the following step is also included: h. The first component moves the coil to be managed relative to the positioning adjustment surface of the cable management module based on the second calibration command, so as to adjust the coil to be managed relative to the first component to the position corresponding to the reference parameter by the coil to be managed abutting against the positioning adjustment surface.

17. The coil winding method according to claim 15, characterized in that, The first feature parameter also includes a model parameter, which includes the outer contour parameter, inner contour parameter and / or pad coordinates of the coil to be processed; the control module stores a plurality of the preset coil templates, each preset coil template corresponding to a coil parameter range, which includes the outer contour parameter range, inner contour parameter range and / or pad coordinate range of the coil; Between step c and step d, there is an additional step: i. The control module compares the model parameter with the range of coil parameters of each preset coil template. If the model parameter is within one of the ranges of coil parameters, the corresponding preset coil template is selected. If the model parameter exceeds the range of each coil parameter, the model parameter of the coil to be processed is recorded and the coil to be processed is discarded.

18. The coil winding method according to claim 15, characterized in that, Step c includes the following steps: c1. Preprocessing the upper visual image and the lower visual image; wherein, the preprocessing includes classifying and storing the upper visual image and the lower visual image according to the acquisition angle, performing non-local mean denoising on the upper visual image and the lower visual image, and / or cropping the upper visual image and the lower visual image based on the preset coil template and retaining the local image of the position of the coil lead to be processed.

19. The coil winding method according to claim 18, characterized in that, Step c further includes the following step: c2. The control module binarizes the contour coordinates of the leader line in the local image; c3. The control module refines the contour coordinates to obtain the centerline coordinates of the lead wire; c4. The control module detects and locates the coordinates of the two endpoints of the centerline coordinates.

20. The coil winding method according to claim 15, characterized in that, Step d includes the following steps: d1. The control module compares the first feature parameters detected in the upper visual image and the lower visual image with the reference parameters of the preset coil template to obtain the deflection direction and deflection value of the lead wire relative to the lead wire position in the preset coil template from the upper and lower perspectives respectively. d2. The control module fuses the deflection direction and the deflection value for the upper and lower viewpoints respectively; d3. The control module outputs the first correction command based on the fused deflection direction and the deflection value. The first correction command includes the rotation angle and movement stroke of the first component.

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