Carbon brush holder tail plug assembling machine

Abstract

The invention relates to the technical field of electric brush assembling, in particular to a carbon brush holder tail plug assembling machine. Comprising a rack, a rotary dividing device and a plurality of workpiece carriers evenly distributed along the periphery of a rotary disc. The rotary dividing device comprises a fixed disc, a rotary disc and a driving assembly and drives the workpiece carrier to rotate intermittently. The function modules which are arranged in a surrounding mode are sequentially a feeding station, a discharging station, a feeding station, a discharging station and a control station. The feeding station is used for manually loading connector power supply terminal shells with piezoresistors. The bending forming module is used for carrying out plastic bending on the resistor pins; the resistance welding module is connected with the pin and the power supply terminal through resistance welding; the pin cutting module is used for cutting off redundant pins; the visual detection module is used for carrying out optical dimension detection; and the sorting and discharging module is used for sorting qualified and unqualified workpieces according to a detection result. The working process comprises the steps that after feeding, workpieces are bent, welded, cut, detected, sorted and discharged, automatic production is achieved, and the efficiency, the welding quality consistency and the product percent of pass are improved.

Description

Technical Field

[0001] This invention patent relates to the field of brush assembly technology, and in particular to a carbon brush holder tail plug assembly machine. Background Technology

[0002] As a core connection component in motor and electrical control systems, the manufacturing precision and assembly quality of the carbon brush holder directly determine the stability of circuit operation and the service life of the equipment. In traditional production models, the assembly of such components relies entirely on manual operation: operators must first manually pre-assemble the varistor and connector power terminal housing, and then use a soldering iron and solder wire to solder the varistor pins to the power terminals one by one. This manual operation method has several technical drawbacks: the production pace is slow, and the time spent on each piece is too long, severely restricting the overall production line capacity; the soldering quality is entirely dependent on the operator's technical experience and immediate condition, easily resulting in defects such as incomplete soldering, cold soldering, or irregular solder joint shapes, causing abnormal electrical connection impedance, which may lead to localized overheating or even circuit failure during long-term equipment operation; at the same time, manual soldering cannot apply uniform and quantifiable pressure to the solder joints, resulting in large pressure fluctuations, and lacks dynamic monitoring capabilities of the soldering process, making it impossible to identify soldering abnormalities and intervene in a timely manner.

[0003] To address these challenges, existing technologies attempt to incorporate some automation elements, such as using a basic rotary indexing table with simple pneumatic clamps to facilitate workpiece transfer, or configuring dedicated welding devices at a single workstation. However, these solutions have significant limitations: insufficient system integration, failing to construct a complete automated closed-loop process for lead plastic bending, resistance welding, post-weld finishing, and quality sorting; especially in the critical resistance welding stage, there is a general lack of real-time acquisition and closed-loop control mechanisms for core parameters such as welding pressure and electrode displacement, making it difficult to suppress weld quality fluctuations; furthermore, there is a lack of high-precision online visual inspection methods for key dimensional features after welding (such as total weld thickness, lead trimming residual length, power terminal spacing, etc.), making it impossible to achieve 100% finished product quality screening. Therefore, existing equipment cannot effectively improve production efficiency, nor can it guarantee a high degree of consistency in electrical performance and mechanical structure of products, failing to meet the stringent requirements of modern industry for highly reliable connection components.

[0004] To address the aforementioned issues, existing technologies urgently need improvement. Summary of the Invention

[0005] To address the aforementioned issues, the purpose of this invention is to provide a carbon brush holder tail plug assembly machine, which offers advantages such as improved production efficiency, consistent welding quality, automated closed-loop production, and enhanced product reliability and yield.

[0006] To achieve the above objectives, the present invention patent adopts the following technical solution:

[0007] This application provides a carbon brush holder tail plug assembly machine, the technical solution of which is as follows:

[0008] A carbon brush holder tail plug assembly machine, comprising:

[0009] frame;

[0010] A rotary indexing device, mounted on a frame, includes a fixed disk, a turntable rotatably disposed below the fixed disk, and a drive assembly for driving the turntable to perform intermittent indexing rotations.

[0011] Multiple workpiece carriers are evenly distributed along the periphery of the turntable and rotate with it;

[0012] The following functional modules are arranged around the rotary indexing device and sequentially on the frame:

[0013] The loading station is configured for operators to load the connector power terminal housings, which are assembled with varistor-to-be-welded, onto the workpiece carrier;

[0014] A bending and forming module is used to plastically bend the leads of a varistor.

[0015] Resistance welding module, used to connect bent pins to power terminals using resistance welding process;

[0016] Pin trimming module, used to remove excess pins after soldering;

[0017] The vision inspection module is used to perform optical dimension inspection on the workpieces after welding and cutting.

[0018] The sorting and unloading module is used to transfer qualified and unqualified workpieces separately according to the inspection results.

[0019] The assembly machine operates as follows: after the operator loads the workpiece onto the workpiece carrier at the loading station, the workpiece carrier carries the workpiece and rotates intermittently with the turntable, passing through each subsequent functional module in sequence; the bending and forming module bends the vertical pins into shape, the resistance welding module then welds the bent pins to the power terminal resistor as one piece, the pin trimming module then trims off the excessively long pins after welding, the vision inspection module performs imaging and dimensional analysis on the workpieces that have completed welding and trimming, and finally the sorting and unloading module sorts and unloads the workpieces according to the analysis results.

[0020] Furthermore, this application also proposes that a support component is provided below each functional module workstation on the edge of the turntable. The support component includes a support rod and a roller installed on its top. The roller makes rolling contact with the bottom surface of the turntable to provide auxiliary support. During the rotation and static load-bearing process of the turntable, the roller continuously contacts the bottom surface of the turntable to enhance the structural stability of the turntable edge at the workstation.

[0021] Furthermore, this application also proposes that the bending forming module includes:

[0022] The outer support mechanism is located on the radial outer side of the turntable and includes a radially movable first slide, a first linear driver that drives the first slide, a first clamping cylinder mounted on the first slide, and a pair of support jaws connected to the two output ends of the first clamping cylinder. The front working surface of the support jaws is arc-shaped.

[0023] The bending actuator is located on the radial inner side of the turntable and includes a column, a vertical slide mounted on the column, a second linear actuator that drives the vertical slide, a bending cylinder mounted on the vertical slide, and a pair of bending pressure heads connected to the output end of the bending cylinder.

[0024] Among them, an auxiliary positioning cylinder is also installed on the vertical slide, and the output end of the auxiliary positioning cylinder is connected to a pair of adjustable inner positioning grippers.

[0025] The working process is as follows: When the carrier carrying the workpiece stops at the bending station, the support jaws of the outer support mechanism first extend forward and abut against the outside of the pin; then the vertical slide of the bending execution mechanism drives the inner positioning jaws and bending pressure head downward, so that the inner positioning jaws move to the inner side between the two pins and are positioned, while the bending cylinder drives the bending pressure head forward to press the pins against the arc working surface of the support jaws, thereby completing the arc bending.

[0026] Furthermore, this application also proposes that the resistance welding module includes:

[0027] Welding frame;

[0028] A vertical adjustment mechanism, mounted on a welding frame, includes a first vertical slide rail and a first lifting cylinder that drives its movement;

[0029] A horizontal adjustment mechanism, mounted on the movable part of the vertical adjustment mechanism, includes a horizontal slide rail and an adjustment cylinder that drives its movement;

[0030] The welding execution assembly is fixed on the movable part of the horizontal adjustment mechanism. It includes a mounting bracket, a stationary electrode seat fixed on the mounting bracket, and a moving electrode seat that is opposite to the stationary electrode seat and can be driven to move closer or further away by a propulsion cylinder. The lower end of the stationary electrode seat is provided with a stationary electrode head, and the lower end of the moving electrode seat is provided with a moving electrode head.

[0031] The workpiece clamping mechanism is hinged to the frame and driven by a rotary drive, and has a clamping arm that can swing above the workpiece carrier and clamp the workpiece.

[0032] The working process is as follows: When the workpiece arrives at the welding station, the pressure arm of the workpiece clamping mechanism first swings down to clamp the workpiece; then the vertical adjustment mechanism drives the welding execution assembly to descend as a whole, so that the stationary electrode head and the moving electrode head are respectively aligned with the inside of the power terminal on the workpiece and the outside of the bent pin; the propulsion cylinder drives the moving electrode seat to move towards the stationary electrode seat, so that the moving electrode head presses the pin onto the power terminal, and then the two electrode heads are energized to perform resistance welding; after the welding is completed, the electrode head is reset and the pressure arm is raised.

[0033] Furthermore, this application also proposes that the pin trimming module includes:

[0034] Mounting base, fixed to the frame;

[0035] The clamping and transferring unit is mounted on a mounting base and includes a radially movable second slide, a third linear driver for driving the second slide, a second clamping cylinder mounted on the second slide, and a pair of cutting jaws connected to the output end of the second clamping cylinder for clamping the pin ends.

[0036] The shearing unit is located on the upper part of the mounting base and includes a second vertical slide rail, a second lifting cylinder that drives the second vertical slide rail, and a shear assembly driven by the shearing cylinder that is mounted on the movable part of the second vertical slide rail.

[0037] A waste collection device, located beside the turntable, is used to collect the cut-off leads;

[0038] The working process is as follows: the clamping and conveying unit first moves radially so that the cutting jaws clamp the end of the extended pin after welding; then the cutting unit descends and the scissor assembly cuts off the pin outside the clamping point; subsequently, the clamping and conveying unit retracts radially to above the waste collection device, the cutting jaws release, and the cut pin falls into the waste collection device.

[0039] Furthermore, this application also proposes that the sorting and unloading module is a three-axis Cartesian coordinate robot, which includes an X-axis linear module, a Y-axis linear module, and a Z-axis linear module that are orthogonally arranged and sequentially connected by transmission, as well as a pick-and-place end effector installed on the moving part of the Z-axis linear module; its working process is as follows: the three-axis Cartesian coordinate robot drives the pick-and-place end effector to move to the corresponding workpiece carrier to grab the workpiece according to the output signal of the vision detection module, and then transfers it to the qualified product assembly line or the unqualified product recycling position.

[0040] Furthermore, this application also proposes that the workpiece carrier has a positioning cavity for accommodating and positioning the portion of the power terminal block on which the varistor is mounted, as well as the main body of the varistor, and exposing the pins of the varistor and the portion of the power terminal block to be welded; during the loading station and subsequent station operations, the portion of the workpiece is constrained in the positioning cavity, exposing only the part to be processed.

[0041] Furthermore, this application also proposes that the resistance welding module integrates a displacement sensor and a pressure sensor to monitor and provide feedback on the displacement changes of the moving electrode head and the applied pressure during the welding process in real time. The working process is as follows: during the process of the propulsion cylinder driving the moving electrode head to press the workpiece, the displacement sensor and the pressure sensor collect data in real time and compare it with a preset threshold to monitor and ensure the stability and consistency of the welding pressure.

[0042] Furthermore, this application also proposes that the vision inspection module includes an industrial camera mounted vertically toward the workpiece, which is configured to acquire workpiece images and thereby detect the total thickness of the welding area, the residual length after pin trimming, and the spacing between the two power terminals; its working process is as follows: when the workpiece is stopped at the inspection station, the industrial camera takes a clear image of the top of the workpiece, the image processing system analyzes and measures the image, and compares the measurement results with a preset tolerance range to determine whether the workpiece is qualified.

[0043] As can be seen from the above, the carbon brush holder tail plug assembly machine provided in this application realizes automated assembly, welding, inspection and sorting by integrating a rotary indexing device and multiple functional modules. It has the advantages of improving production efficiency, ensuring consistent welding quality, realizing automated closed-loop production and improving product reliability and pass rate. Attached Figure Description

[0044] Figure 1 This is a top view of a carbon brush holder tail plug assembly machine provided in this application.

[0045] Figure 2 This is a three-dimensional schematic diagram of a carbon brush holder tail plug assembly machine provided in this application.

[0046] Figure 3 This is a structural schematic diagram of the outer support mechanism of a bending forming module provided in this application.

[0047] Figure 4 This application provides a schematic diagram of the bending actuator of a bending forming module.

[0048] Figure 5 This is a schematic diagram of the resistance welding module.

[0049] Figure 6This is a schematic diagram of the pin trimming module.

[0050] Figure 7 This is a structural diagram of the sorting and unloading module.

[0051] Figure 8 A schematic diagram showing the mounting of a workpiece on a workpiece carrier.

[0052] Figure 9 This is a schematic diagram showing the workpiece carrier separated from the workpiece. Detailed Implementation

[0053] The embodiments of this invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this invention, and should not be construed as limiting this invention.

[0054] In the description of this invention patent, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention patent 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 patent.

[0055] 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 one or more of that feature. In the description of this patent, unless otherwise stated, "a plurality of" means two or more, unless otherwise expressly defined.

[0056] In this invention patent, 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 connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention patent according to the specific circumstances.

[0057] In this invention patent, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0058] Traditional carbon brush holder assembly relies on manual operation, resulting in low production efficiency, unstable welding quality, and susceptibility to problems such as incomplete soldering and cold soldering, thus compromising product reliability. Existing automated systems lack high integration and a fully automated closed-loop process encompassing pin forming, precision soldering, post-soldering processing, and 100% inspection and sorting. Particularly in the resistance soldering stage, there is a lack of real-time monitoring and closed-loop control of key parameters such as welding pressure and electrode displacement, and 100% online visual inspection is also impossible, making it difficult to consistently guarantee high product consistency and reliability.

[0059] like Figure 1-9 As shown, this application proposes a carbon brush holder tail plug assembly machine. It achieves intermittent rotation and precise docking of workpieces by setting a rotary indexing device on the frame 1 and evenly distributing multiple workpiece carriers 6 around the circumference of the turntable 4. A loading station, bending and forming module 8, resistance welding module 9, lead trimming module 10, vision inspection module 11, and sorting and unloading module 12 are sequentially arranged around the rotary indexing device, thus constructing a fully automated assembly system from workpiece loading, lead plastic bending, resistance welding, lead trimming, optical dimension inspection, and sorting and unloading of qualified and unqualified products. In the working process of this assembly machine, the workpiece carriers 6 carry the workpieces, which rotate intermittently with the turntable 4, passing through each functional module sequentially. This achieves coordinated operation of each stage, effectively solving the technical bottlenecks of low efficiency, unstable quality, and lack of full-process automation and online quality inspection inherent in traditional manual methods and existing semi-automatic equipment.

[0060] For ease of understanding, the following explains some key terms in this embodiment:

[0061] The carbon brush holder tail plug assembly machine is a special equipment used to automate the production of carbon brush holder tail plug components. It integrates multiple functional modules to achieve fully automated operation from raw material loading to finished product sorting.

[0062] Frame 1 is the basic support structure of the assembly machine, used to install and fix all functional modules and transmission components, ensuring the overall stability and structural integrity of the equipment during operation.

[0063] The rotary indexing device is a mechanism for achieving intermittent and precise positional transfer of workpieces. It includes a fixed disk 3, which serves as the base of the device; a turntable 4, which is rotatably disposed below the fixed disk 3 to support the workpiece carrier 6 and rotate with it; and a drive assembly responsible for driving the turntable 4 to rotate intermittently at a preset angle, so that the workpiece can be precisely stopped between different workstations.

[0064] The workpiece carrier 6 is a clamp or pallet used to carry the workpiece to be processed. It is evenly distributed along the periphery of the turntable 4 and moves with the rotation of the turntable 4 to ensure stable transfer of the workpiece between each station.

[0065] The loading station is the starting point of the assembly machine. Here, the operator places the workpiece to be processed, namely the connector power terminal housing with varistors assembled, into the workpiece carrier 6.

[0066] The bending and forming module 8 is a mechanism for plastically deforming the pins of a varistor. Its purpose is to bend the pins into a preset shape to meet the requirements of subsequent welding processes.

[0067] The resistance welding module 9 is a device that uses the resistance heating effect to connect metal parts. It applies current and pressure to the bent pins and power terminals, causing them to generate high temperature and fuse at the contact surface, forming a strong electrical connection.

[0068] The pin trimming module 10 is a mechanism for cutting off excess parts of the varistor pins after soldering. It ensures that the pin length meets the product design specifications and avoids short circuits or other functional problems that may be caused by excessively long pins.

[0069] The vision inspection module 11 is a system that uses optical imaging technology to perform non-contact inspection of processed workpieces. It acquires and analyzes workpiece images to evaluate key parameters such as welding quality and dimensional accuracy.

[0070] The sorting and unloading module 12 is a mechanism that classifies workpieces according to the test results, and transfers qualified workpieces and unqualified workpieces to different collection areas or subsequent production lines respectively.

[0071] A varistor is a resistor with nonlinear current-voltage characteristics, often used in circuits for overvoltage protection.

[0072] A connector power terminal housing is an external structure used to house and protect the power terminals.

[0073] The pins are the conductive parts that extend from the varistor and are used to connect to other circuit components.

[0074] Power terminals are conductive components in connectors used to transmit electrical energy.

[0075] The carbon brush holder tail plug assembly machine of this embodiment includes a frame 1. The frame 1 can be constructed of welded steel structure, aluminum profile frame, or cast iron parts, and its main function is to provide a stable platform for installing all components of the assembly machine. For example, a closed frame can be welded from rectangular steel pipes, with mounting holes on its upper surface and sides to fix other modules. A rotary indexing device is installed on the assembly machine. This rotary indexing device can include a circular fixed disk 3 fixed to the frame 1, a turntable 4 rotatably disposed below the fixed disk 3, and a drive assembly for intermittently indexing the turntable 4. The drive assembly can be a stepper motor or servo motor, connected to the turntable 4 via gears, belts, or a cam mechanism to achieve precise intermittent rotation. For example, a gear ring can be provided at the bottom of the turntable 4, and the motor of the drive assembly drives a pinion to mesh with the gear ring, thereby driving the turntable 4 to rotate. Multiple workpiece carriers 6 are evenly distributed along the periphery of the turntable 4 and rotate with it. These carriers can be simple clamps, pallets, or molds, used to stably support workpieces during workpiece flow. For example, standardized workpiece fixtures can be drilled at equal intervals on the turntable 4, each fixture capable of holding one workpiece to be processed. A series of functional modules are arranged sequentially around the rotary indexing device and on the frame 1. These functional modules can be installed on the frame 1 in sequence around the turntable 4 of the rotary indexing device, according to the process flow. This layout ensures that the workpiece, driven by the turntable 4, can sequentially pass through each processing or inspection station. For example, multiple mounting platforms can be set around the frame 1 to fix the various modules.

[0076] The loading station is configured for operators to load connector power terminal housings, which are assembled with varistors to be soldered, onto workpiece carrier 6. The loading station can be a simple operating platform; for example, a workbench can be set up next to a stop position of turntable 4, where operators place the workpieces.

[0077] The bending and forming module 8 is used to plastically bend the leads of the varistor. This module may include a simple pneumatic or electric bending mechanism. For example, a pair of molds can be set up, and when the workpiece arrives at the station, the molds are driven by a cylinder to perform a mold closing action, bending the leads into a preset shape.

[0078] The resistance welding module 9 is used to connect bent leads to power terminals via resistance welding. This module may include a pair of electrodes that connect the bent leads to the power terminals by applying current and pressure. For example, a fixed electrode and a movable electrode may be provided. When the workpiece is in position, the movable electrode is pressed against the workpiece by a cylinder or motor, forming a circuit with the fixed electrode to complete the welding.

[0079] The lead trimming module 10 is used to remove excess lead portions after soldering. This module may include a cutting mechanism. For example, a pneumatic or electric shear can be used, which cuts off the excess lead portions when the workpiece is stationary.

[0080] The vision inspection module 11 is used to perform optical dimensional inspection on the welded and cut workpieces. This module may include a camera or image sensor to acquire images of the workpiece and perform optical dimensional inspection accordingly. For example, a regular camera can be placed above the workpiece to capture a top view of the workpiece, and then simple dimensional measurements can be performed using image processing software.

[0081] The sorting and unloading module 12 is used to transfer qualified and unqualified workpieces separately according to the inspection results. This module can be a simple pneumatic pusher or a robot. For example, two unloading ports can be set up, and a pusher pushes the workpiece into the qualified or unqualified channel according to the inspection signal.

[0082] The assembly machine operates as follows: Operators load workpieces onto workpiece carrier 6 at the loading station. Workpiece carrier 6, carrying the workpieces, rotates intermittently with turntable 4, passing through subsequent functional modules in sequence. Bending and forming module 8 bends the vertical leads into shape. Resistance welding module 9 then resistively welds the bent leads to the power terminals. Lead trimming module 10 then trims off any excessively long leads after welding. Vision inspection module 11 performs imaging and dimensional analysis on the welded and trimmed workpieces. Finally, sorting and unloading module 12 sorts and unloads the workpieces based on the analysis results. The entire process is coordinated and controlled by a central controller to ensure synchronous operation of all modules. This carbon brush holder tail plug assembly machine, by integrating a rotary indexing device and multiple automated functional modules, achieves fully automated production of carbon brush holder tail plugs from loading, lead forming, precision welding, post-weld processing to full inspection and sorting. This significantly improves production efficiency, reduces reliance on manual skills, and effectively avoids common quality problems in traditional manual welding, such as incomplete welding and cold welding. As a result, it consistently ensures high product consistency and reliability, and solves the technical bottlenecks of low efficiency, unstable quality, and lack of full-process automation and online quality inspection in existing technologies.

[0083] like Figure 2 and 6 As shown, a support component 13 is provided below each functional module workstation on the edge of the turntable 4. The support component 13 includes a support rod 14 and a roller 15 installed on its top. The roller 15 rolls in contact with the bottom surface of the turntable 4 to provide auxiliary support. During the rotation and static load-bearing process of the turntable 4, the roller 15 continuously contacts the bottom surface of the turntable 4 to enhance the structural stability of the edge of the turntable 4 at the workstation.

[0084] Specifically, the support assembly 13 is a mechanical device designed to provide structural reinforcement and stability to the turntable 4, especially under dynamic or static loads. This support assembly 13 effectively counteracts potential deflection or vibration of the turntable 4, ensuring its positional accuracy during operation. The support rod 14 is a rigid, slender member within the support assembly 13, primarily responsible for transmitting compressive force. The support rod 14 provides the main structural integrity and height adjustment capability of the support assembly 13. The roller 15 is a cylindrical or spherical rotating element within the support assembly 13, designed to achieve smooth contact and reduce friction between moving parts. The roller 15 rolls against the bottom surface of the turntable 4, providing support while allowing the turntable 4 to rotate freely. This rolling contact between the roller 15 and the bottom surface of the turntable 4 is a mechanical contact method, where the roller 15 rotates as the turntable 4 moves, thereby minimizing sliding friction. This rolling contact provides continuous, low-friction auxiliary support to the turntable 4, effectively preventing wear and ensuring smooth operation. During the rotation and stationary bearing processes of the turntable 4, the roller 15 continuously contacts the bottom surface of the turntable 4. This means that the support mechanism is designed to maintain uninterrupted contact with the turntable 4 throughout its entire operating cycle. This continuous contact ensures consistent structural stability and prevents momentary support interruptions that could lead to vibration or displacement, regardless of the state of the turntable 4. To achieve continuous contact, the support assembly 13 can include a pre-tensioned spring mechanism that biases the roller 15 upward, ensuring a constant contact pressure on the turntable 4; alternatively, the support assembly 13 can also be designed with a fixed and precise height adjustment to ensure that the roller 15 is always in contact with the bottom surface of the turntable 4, while the rotational freedom of the roller 15 adapts to the movement of the turntable 4. With the above technical solution, during the operation of the carbon brush holder tail plug assembly machine, the rotary indexing device carries the workpiece in intermittent rotation. When the workpiece carrier 6 is stationed at each functional module station for processing, the roller 15 of the support assembly 13 provides continuous rolling support below the edge of the turntable 4. This support acts directly on the processing area, effectively counteracting localized sinking or vibration that may be caused by changes in workpiece load, thereby significantly enhancing the structural stability of the turntable 4's edge. Because the rollers 15 use a rolling contact method, they provide support while minimizing frictional resistance during turntable 4 rotation, ensuring smooth indexing rotation. Furthermore, regardless of whether the turntable 4 is rotating or stationary, the rollers 15 maintain continuous contact with the bottom surface of the turntable 4, ensuring the continuity and consistency of the support and preventing instantaneous displacement due to support interruption.This stable support provides a solid foundation for subsequent precision machining processes such as bending, resistance welding, and pin trimming, effectively eliminating the problem of decreased machining accuracy caused by the instability of the turntable 4 edge, thus ensuring the high quality and consistency of the product.

[0085] like Figure 3 and 4 As shown, the bending forming module 8 includes: an outer support mechanism, located radially outer of the turntable 4, comprising a radially movable first slide 17, a first linear actuator 18 driving the first slide 17, a first clamping cylinder 19 mounted on the first slide 17, and a pair of support jaws 20 connected to the two output ends of the first clamping cylinder 19, wherein the front working surface of the support jaws 20 is arc-shaped. A bending execution mechanism, located radially inner of the turntable 4, includes a column 22, a vertical slide 23 mounted on the column 22, a second linear actuator 24 driving the vertical slide 23, a bending cylinder 25 mounted on the vertical slide 23, and a pair of bending pressure heads 26 connected to the output ends of the bending cylinder 25. An auxiliary positioning cylinder 27 is also mounted on the vertical slide 23, and the output end of the auxiliary positioning cylinder 27 is connected to a pair of adjustable-pitch inner positioning jaws 28. The working process is as follows: When the carrier carrying the workpiece stops at the bending station, the support jaw 20 of the outer support mechanism first extends forward and abuts against the outside of the pin; then the vertical slide 23 of the bending execution mechanism drives the inner positioning jaw 28 and the bending pressure head 26 to move downward, so that the inner positioning jaw 28 moves to the inner side between the two pins and is positioned, while the bending cylinder 25 drives the bending pressure head 26 to push forward, pressing the pin against the arc working surface of the support jaw 20, thereby completing the arc bending.

[0086] The outer support mechanism provides external support and positioning during pin bending. It can be implemented in various forms; for example, it can be a translation mechanism driven by a cylinder or motor to ensure the support gripper 20 moves precisely to a predetermined position. Another implementation is a cam mechanism, where the rotation of the cam drives the radial reciprocating motion of the support gripper 20. The first slide 17 is a movable component in the outer support mechanism, used to support the first clamping cylinder 19 and the support gripper 20, and to achieve precise radial displacement. The first linear actuator 18 drives the first slide 17 to move radially. It can use a stepper motor or servo motor in conjunction with a ball screw or rack and pinion mechanism to achieve precise position control. Another implementation is a pneumatic or hydraulic cylinder, where air or hydraulic pressure is controlled to drive the reciprocating motion of the first slide 17. The first clamping cylinder 19 is mounted on the first slide 17 and is used to drive the support gripper 20 to clamp or release. The cylinder can be a single-acting or double-acting cylinder, controlling the opening and closing of the grippers by controlling the on / off state or direction of the air supply. Alternatively, electric or hydraulic grippers can be used to provide greater clamping force or more precise control. The support gripper 20 is connected to the two output ends of the first clamping cylinder 19 and is used to abut against the outer side of the pin during bending. Its front working surface is constructed in an arc shape to provide uniform support for the pin and guide the pin into an arc shape. The support gripper 20 can be made of high-strength, wear-resistant materials, such as tool steel or cemented carbide, to ensure its service life and bending accuracy. Its arc-shaped working surface can be obtained through precision machining or die forming.

[0087] The bending actuator is used to perform the bending action of the pin. It can be driven pneumatically, hydraulically, or electrically to provide sufficient bending force. For example, a cylinder-driven pressure head or a cam mechanism controlled by a servo motor can be used to complete the bending. The column 22 is a structural support component of the bending actuator and is used to mount the vertical slide 23. The vertical slide 23 is mounted on the column 22 and is used to support the bending cylinder 25, the bending pressure head 26, and the auxiliary positioning cylinder 27, and to achieve precise vertical displacement. The second linear actuator 24 is used to drive the vertical slide 23 to move vertically.

[0088] The bending cylinder 25 is mounted on the vertical slide table 23 and is used to drive the bending head 26 to perform bending actions. This cylinder can be a single-acting or double-acting cylinder, and the extension and retraction of the bending head 26 are controlled by controlling the on / off state or direction of the air supply. Alternatively, an electric actuator or hydraulic cylinder can be used to provide greater bending force or more precise control. The bending head 26 is connected to the output end of the bending cylinder 25 and acts directly on the lead, pressing it against the arc-shaped working surface of the supporting jaws 20.

[0089] The auxiliary positioning cylinder 27 is mounted on the vertical slide 23 and is used to drive the inner positioning gripper 28 for positioning. This cylinder can be a miniature or thin cylinder to adapt to compact installation spaces. Its function is to provide precise positioning force, ensuring that the inner positioning gripper 28 can be accurately inserted between the pins. The inner positioning gripper 28 is connected to the output end of the auxiliary positioning cylinder 27, and its spacing is adjustable, used for inner positioning of the pins before bending. This adjustable gripper spacing design can be achieved through the auxiliary positioning cylinder 27, or through a threaded adjustment mechanism, wedge mechanism, or elastic mechanism to accommodate the spacing of pins of different specifications. The gripper material is typically a wear-resistant material, such as engineering plastic or surface-treated metal, to avoid damaging the pins.

[0090] Through the above technical solution, when the carrier carrying the workpiece stops at the bending station, the support jaws 20 of the outer support mechanism first extend forward and abut against the outside of the pin, providing stable external support for the pin. Subsequently, the vertical slide 23 of the bending execution mechanism drives the inner positioning jaws 28 and the bending pressure head 26 downward. The inner positioning jaws 28 first move to the inner side between the two pins and perform precise positioning, effectively preventing the pins from shifting or misaligning during the bending process. At the same time, the bending cylinder 25 drives the bending pressure head 26 forward, precisely pressing the pins against the arc working surface of the support jaws 20, thereby achieving an arc-shaped bend of the pins. This collaborative working method, through the combination of outer support, inner positioning, and precise pressure, ensures the shape consistency and positional accuracy of the bent pins, significantly improving bending accuracy and laying a solid foundation for the subsequent resistance welding process. This effectively solves the problem of insufficient pin bending accuracy and consistency, ensuring the stability of product quality.

[0091] like Figure 5 As shown, the resistance welding module 9 includes a welding frame 29, a vertical adjustment mechanism, a horizontal adjustment mechanism, welding execution components, and a workpiece clamping mechanism. The welding frame 29 is the basic support structure of the resistance welding module 9, used to support and fix all components within the module, providing a stable mounting platform, ensuring the structural rigidity and stability of the entire welding module, and preventing component displacement due to vibration or stress during welding, thereby ensuring welding accuracy. The welding frame 29 can be constructed by welding or bolting high-strength steel or aluminum alloy profiles to form a robust frame structure; alternatively, it can be manufactured by casting or integral molding to achieve higher overall rigidity.

[0092] A vertical adjustment mechanism is mounted on the welding frame 29, comprising a first vertical slide rail 31 and a first lifting cylinder 32 that drives its movement. This vertical adjustment mechanism enables precise vertical movement of the welding actuator, allowing the welding electrode to accurately approach or move vertically away from the workpiece, compensating for height differences in the workpiece carrier 6, and providing a suitable initial height for subsequent horizontal alignment. The first vertical slide rail 31 can be a linear guide pair, such as a ball linear guide or a dovetail guide, providing a smooth vertical movement path; the first lifting cylinder 32 can be a double-acting cylinder, achieving precise up-and-down stroke control by controlling air pressure. Furthermore, in addition to cylinder drive, a servo motor combined with a ball screw or rack and pinion mechanism can also be used to achieve more precise vertical position control.

[0093] A horizontal adjustment mechanism is mounted on the movable part of the vertical adjustment mechanism, and includes a horizontal slide rail 34 and an adjustment cylinder 35 that drives its movement. This horizontal adjustment mechanism is used for fine-tuning the position of the welding execution component in the horizontal direction. After the vertical adjustment mechanism roughly positions the electrode, the horizontal adjustment mechanism can perform horizontal offset correction on the electrode, ensuring that the stationary electrode head 41 and the moving electrode head 42 are precisely aligned with the specific welding points on the inner side of the power terminal and the outer side of the bent pin on the workpiece, eliminating alignment deviations caused by workpiece or carrier manufacturing tolerances, assembly errors, etc. This horizontal adjustment mechanism is mainly used for adjustment and positioning during equipment setup. The horizontal slide rail 34 can be a crossed roller guide or a linear bearing guide, providing high-precision horizontal movement; the adjustment cylinder 35 can be a short-stroke, high-precision pneumatic slide or a proportional control cylinder, achieving fine horizontal displacement. Alternatively, a miniature ball screw module driven by a stepper motor or servo motor can be used to achieve more precise and programmable horizontal adjustment.

[0094] The welding execution assembly is fixed to the movable part of the horizontal adjustment mechanism. It includes a mounting bracket 37, a stationary electrode seat 38 fixed to the mounting bracket 37, and a moving electrode seat 39 opposite to the stationary electrode seat 38 and driven closer to or further away by a propulsion cylinder 40. A stationary electrode head 41 is located at the lower end of the stationary electrode seat 38, and a moving electrode head 42 is located at the lower end of the moving electrode seat 39. This welding execution assembly is the core component that directly completes the resistance welding operation. It includes the electrode mounting, positioning, and driving mechanisms, responsible for precisely positioning the stationary electrode head 41 and the moving electrode head 42 to the welding point, applying controllable welding pressure, and finally completing the welding by applying electricity. The propulsion cylinder 40 can be a short-stroke, high-thrust cylinder for quickly applying and releasing welding pressure. The stationary electrode seat 38 and the moving electrode seat 39 can be made of a highly conductive, high-strength copper alloy to ensure good conductivity and wear resistance. The electrode heads can be selected from different materials and geometries according to the shape and material of the workpiece being welded, such as chromium-zirconium copper electrode heads.

[0095] The workpiece clamping mechanism is hinged to the frame 1 and driven by a rotary drive 44. It has a pressure arm 45 that can swing above the workpiece carrier 6 and clamp the workpiece. This workpiece clamping mechanism is used to firmly fix the workpiece in the workpiece carrier 6 before welding operations, preventing displacement of the workpiece during welding due to electrode contact, pressure application, or vibration, thereby ensuring the accuracy of the welding position and the stability of the welding quality. The rotary drive 44 can be a rotary cylinder or a small servo motor, driving the pressure arm 45 to swing via a linkage mechanism. The end of the pressure arm 45 can be equipped with an elastic pressure block or a positioning block to adapt to the shape of the workpiece and provide uniform clamping force. Alternatively, the clamping mechanism can use a vertically lifting cylinder to drive the pressure block to directly press down on the workpiece, or a side-clamping cylinder to clamp the workpiece from the side.

[0096] The working process of the resistance welding module 9 is as follows: When the workpiece arrives at the welding station, the pressure arm 45 of the workpiece clamping mechanism first swings down to clamp the workpiece; then the vertical adjustment mechanism drives the welding execution assembly to descend as a whole, so that the stationary electrode head 41 and the moving electrode head 42 are respectively aligned with the inner side of the power terminal and the outer side of the bent pin on the workpiece; the propulsion cylinder 40 drives the moving electrode seat 39 to move towards the stationary electrode seat 38, so that the moving electrode head 42 presses the pin onto the power terminal, and then the two electrode heads are energized for resistance welding; after welding is completed, the electrode heads are reset and the pressure arm 45 is raised. The entire process is precisely timed and positioned by a controller (such as a PLC). Through the above technical solution, the resistance welding module 9 effectively solves the problems of inaccurate electrode position and unstable pressure during resistance welding through a multi-level adjustment and collaborative control mechanism. The welding frame 29 provides a stable foundation, and the combination of the vertical adjustment mechanism and the horizontal adjustment mechanism realizes precise control of the electrode from coarse positioning to fine alignment, ensuring that the electrode can be accurately aligned with the specific welding point on the workpiece. Meanwhile, the propulsion cylinder 40 in the welding execution assembly can apply controllable and stable welding pressure, while the workpiece clamping mechanism firmly fixes the workpiece before welding to prevent displacement. This precise positioning and pressure control mechanism significantly reduces the occurrence of incomplete welds, cold welds, and uneven weld quality, thereby greatly improving the reliability and consistency of the product's electrical connections and ensuring the production quality of the carbon brush holder tail plug.

[0097] like Figure 6As shown, the pin trimming module 10 includes: a mounting base 46, a clamping and transferring unit, a cutting unit, and a waste collection device 57. The mounting base 46 is fixed to the frame 1, providing a stable support platform for the entire pin trimming module 10 and ensuring its structural rigidity and positioning accuracy during operation. The clamping and transferring unit is disposed on the mounting base 46 and includes a radially movable second slide 48, a third linear actuator 49 driving the second slide 48, a second clamping cylinder 50 mounted on the second slide 48, and a pair of cutting jaws 51 connected to the output end of the second clamping cylinder 50 for clamping the pin ends. The second slide 48 can be a linear guide module driven by a ball screw, and the third linear actuator 49 can be a servo motor, achieving high-precision positioning through an encoder; alternatively, the second slide 48 can also be a pneumatic slide, and the third linear actuator 49 can be a cylinder, with position control through a limit switch. The second clamping cylinder 50 can be a small precision pneumatic gripper, and the cutting gripper 51 can be made of wear-resistant alloy steel with an anti-slip texture on the inner surface; alternatively, the second clamping cylinder 50 can be a parallel opening and closing pneumatic gripper, and the cutting gripper 51 can have a clamping surface with rubber or polyurethane padding to increase friction and protect the pin surface. The shearing unit is located on the upper part of the mounting base 46, and includes a second vertical slide rail 53, a second lifting cylinder 54 that drives the second vertical slide rail 53, and a scissor assembly 55 driven by the shearing cylinder 56 and mounted on the moving part of the second vertical slide rail 53. The second vertical slide rail 53 can be a precision linear guide rail, the second lifting cylinder 54 is a cylinder with a buffer, the scissor assembly 55 can be a shear-type blade made of high-hardness alloy steel, and the shearing cylinder 56 is a small double-acting cylinder; alternatively, the second vertical slide rail 53 can be a dovetail slide rail, the second lifting cylinder 54 is an electric push rod, the scissor assembly 55 can be a punch shear blade, and the shearing cylinder 56 is a hydraulic cylinder, providing greater shearing force. The waste collection device 57 is located beside the turntable 4 and is used to receive the cut-off leads. The waste collection device 57 can be designed as a collection box with an inclined guide plate, made of stainless steel or anti-static plastic, with a waste pipe connected to the bottom, which can automatically transport the waste to a central waste bin; alternatively, it can be a detachable drawer-type collection box made of transparent plastic, which is easy to observe the amount of waste and can be manually emptied periodically.

[0098] In actual operation, the clamping and transferring unit first moves radially, causing the cutting jaws 51 to clamp the protruding pin ends after welding. Specifically, the third linear actuator 49 drives the second slide table 48 to move precisely to a preset position, aligning the opening of the cutting jaws 51 with the pin ends. Then, the second clamping cylinder 50 actuates, closing the cutting jaws 51 and firmly clamping the pin. Next, the cutting unit descends, and the scissor assembly 55 actuates to cut the pin outside the clamping point. During this process, the second lifting cylinder 54 drives the second vertical slide rail 53 to descend, aligning the blade of the scissor assembly 55 with the cutting point of the clamped pin. Subsequently, the cutting cylinder 56 drives the scissor assembly 55 to close, completing the cutting. Afterward, the clamping and transferring unit retracts radially above the waste collection device 57, the cutting jaws 51 release, and the cut pin falls into the waste collection device 57. Specifically, the third linear actuator 49 drives the second slide 48 in the reverse direction, causing it to move radially to directly above the waste collection device 57. Then, the second clamping cylinder 50 releases the clamping force, the cutting jaws 51 open, and the lead waste falls into the waste collection device 57 under the action of gravity.

[0099] Through the above technical solution, the pin trimming module 10 of this application effectively solves the problems of low pin trimming accuracy and improper waste disposal by working in concert with a precision clamping and transfer unit and a cutting unit. The second slide 48 and the third linear driver 49 of the clamping and transfer unit can achieve precise radial positioning of the pin end. Together with the cutting jaw 51 driven by the second clamping cylinder 50, the pin can be firmly and accurately clamped, thereby fixing the cutting point, avoiding pin shaking during the cutting process, and ensuring the consistency of the pin residual length. The second vertical slide rail 53 and the second lifting cylinder 54 of the cutting unit drive the scissor assembly 55 to descend vertically. After the pin is precisely clamped and positioned, the cutting action can be completed stably and controllably, further ensuring the cutting accuracy. In addition, the cooperation between the waste collection device 57 and the clamping and transfer unit allows the cut pin to be radially transferred and oriented, effectively preventing waste from scattering, maintaining a clean working environment, and simplifying the centralized treatment of waste. The entire work process is automated, which significantly improves the efficiency and quality stability of cutting, and avoids the cutting deviations and environmental pollution problems caused by improper operation in traditional methods.

[0100] like Figure 7As shown, the sorting and unloading module 12 is a three-axis Cartesian coordinate robot, which includes an X-axis linear module 59, a Y-axis linear module 60 and a Z-axis linear module 61 that are orthogonally arranged and sequentially connected by transmission, and a pick-and-place end effector 62 installed on the moving part of the Z-axis linear module 61; its working process is as follows: the three-axis Cartesian coordinate robot drives the pick-and-place end effector 62 to move to the corresponding workpiece carrier 6 to grab the workpiece according to the output signal of the vision detection module 11, and then transfers it to the qualified product assembly line or the unqualified product recycling position.

[0101] Specifically, the sorting and unloading module 12 employs a three-axis Cartesian coordinate robot. A three-axis Cartesian coordinate robot is an automated device based on the Cartesian coordinate system, achieving precise movement in three-dimensional space through three mutually perpendicular linear motion axes (X, Y, Z). This robot provides high-precision, high-repeatability three-dimensional spatial positioning capabilities to achieve precise workpiece gripping and placement. In practical applications, the robot can employ various driving methods. For example, it can use a servo motor-driven ball screw or rack and pinion mechanism, combined with a high-precision linear guide, to achieve high-precision, high-speed, and high-repeatability movement; alternatively, it can use a stepper motor-driven synchronous belt transmission system, combined with a linear guide, suitable for scenarios where cost and speed requirements are certain but precision requirements are relatively relaxed. The three-axis Cartesian coordinate robot includes an X-axis linear module 59, a Y-axis linear module 60, and a Z-axis linear module 61, which are orthogonally arranged and sequentially connected in transmission. Among them, the X-axis linear module 59 is usually the main motion axis on the robot base, responsible for providing the main working range in the horizontal direction; the Y-axis linear module 60 is installed on the moving part of the X-axis module, responsible for providing motion in the horizontal direction perpendicular to the X-axis; and the Z-axis linear module 61 is installed on the moving part of the Y-axis module, responsible for providing lifting motion in the vertical direction.

[0102] An end effector 62 is mounted on the moving part of the Z-axis linear module 61. This end effector is the part that directly contacts the robot and the workpiece, and is used to perform operations such as gripping and placing. It can be implemented in various ways; for example, a vacuum suction cup can be used to adsorb the workpiece surface through negative pressure, suitable for workpieces with flat surfaces and light weight; or a pneumatic or electric gripper can be used to grasp the workpiece through mechanical clamping force, suitable for workpieces with irregular shapes or requiring greater gripping force. This end effector serves as the interface between the robot and the workpiece, enabling reliable gripping and release of the workpiece.

[0103] The working process of the three-axis Cartesian coordinate robot is as follows: Based on the output signal of the vision inspection module 11, it drives the pick-and-place end effector 62 to move to the corresponding workpiece carrier 6 to grasp the workpiece, and then transfers it to the qualified product production line or the unqualified product recycling location. After completing the inspection of the workpiece, the vision inspection module 11 outputs information such as the workpiece's qualification and position. After receiving these signals, the three-axis Cartesian coordinate robot can accurately position the pick-and-place end effector 62 above the workpiece to be grasped and perform the grasping action. Subsequently, based on the vision inspection results, the robot accurately transfers qualified products to the qualified product production line for subsequent processes or packaging, and transfers unqualified products to the unqualified product recycling location for disposal or rework.

[0104] By employing a three-axis Cartesian coordinate robot as the sorting and unloading module 12, the accuracy and efficiency of workpiece sorting are significantly improved. This robot, with its orthogonally arranged and sequentially connected X-axis linear module 59, Y-axis linear module 60, and Z-axis linear module 61, can achieve high-precision positioning and movement in three-dimensional space, ensuring that the end effector 62 can accurately grasp the workpiece. Simultaneously, its close linkage with the vision inspection module 11 enables the sorting process to make intelligent decisions and automate execution based on real-time inspection results, avoiding errors and inefficiencies that may occur with manual sorting. In the entire automated production process of the carbon brush holder tail assembly machine, this high-precision, high-efficiency sorting and unloading module 12, as the final stage, ensures that the results of all preceding processes, such as bending, welding, cutting, and vision inspection, are effectively classified and processed. This improves the automation level of the entire assembly machine and the consistency of product quality, preventing inefficiencies or errors in the sorting stage from negating the advantages brought by the preceding automation.

[0105] like Figure 8 and 9 As shown, the workpiece carrier 6 has a positioning cavity 63 for accommodating and positioning the part of the power terminal block on which the varistor is installed, as well as the main body of the varistor, and exposing the pins and the part of the power terminal to be soldered. During the loading station and subsequent station operations, the part of the workpiece is constrained in the positioning cavity 63, and only the part to be processed is exposed.

[0106] Specifically, the workpiece carrier 6 has a positioning cavity 63. This positioning cavity 63 is a groove or space on the workpiece carrier 6 designed to accommodate and position a specific part of the workpiece. Its shape and size precisely match the outline of the power terminal block portion on the workpiece where the varistor is mounted and the varistor body. The positioning cavity 63 can be formed directly on the workpiece carrier 6 body through precision machining (e.g., milling, EDM), or manufactured by injection molding. Alternatively, a replaceable insert design can be used, where a universal mounting slot is provided on the workpiece carrier 6, and prefabricated positioning inserts of different shapes are installed onto the carrier according to the shape of this part of different workpieces, achieving compatibility with various workpieces. This design aims to provide robust physical constraints and precise initial positioning for critical parts of the workpiece.

[0107] The positioning cavity 63 is used to accommodate and position the portion of the power terminal block on which the varistor is mounted, as well as the body of the varistor. The function of the positioning cavity 63 is to securely support and fix these two key components of the workpiece. This means that the internal structure of the cavity can fit and support the corresponding portion of the power terminal block and the body of the varistor, ensuring they maintain their correct relative positions within the carrier. For example, the cavity can be designed with a contour that matches the shape of that portion of the power terminal block and provides a stable placement space for the body of the varistor. In this way, the key assembly parts of the workpiece can be integrated into a stable whole after being placed on the carrier.

[0108] Simultaneously, the positioning cavity 63 exposes the pins and power terminals to be soldered. The geometry of the positioning cavity 63 is optimized so that specific areas of the varistor pins and power terminals requiring soldering (e.g., the contact surface between the pins and the power terminals) can extend out of the cavity or be flush with the cavity surface, thus being fully exposed to the outside. This can be achieved by controlling the cavity depth, edge shape, and openings of specific shapes in the cavity walls. For example, the cavity depth can ensure that the varistor body and power terminal base are fixed, while the free ends of the pins extend out of the cavity, and the soldering area of ​​the power terminals may be designed to be flush with the top surface of the cavity so that the electrode head can make direct contact. This is intended to ensure that subsequent functional modules (such as bending and forming module 8 and resistance welding module 9) can operate on the target area without obstruction.

[0109] Furthermore, during the loading station and subsequent station operations, the aforementioned portion of the workpiece is constrained within the positioning cavity 63. This means that from the moment the operator loads the workpiece onto the initial loading station of the workpiece carrier 6 until the workpiece completes all processing steps and is sorted and unloaded, this critical portion of the workpiece remains firmly held within the positioning cavity 63 without relative displacement. In addition to the tight fit of the cavity itself, the constraint on the workpiece can be further enhanced by integrating simple elastic clamping mechanisms (e.g., spring sheets, elastic clips) onto the workpiece carrier 6 or by providing auxiliary clamping devices (e.g., pneumatic pressure plates) at each functional station to counteract the inertial forces during the intermittent rotation of the turntable 4 or the reaction forces generated during processing. This continuous constraint ensures the positional stability of the critical portion of the workpiece throughout the automated assembly process.

[0110] Ultimately, the positioning cavity 63 exposes only the areas to be machined. This is a further emphasis and summary of "exposing the solderable portions of the pins and power terminals." It means that the design of the positioning cavity 63 not only exposes the areas to be machined but also effectively shields or protects areas of the workpiece that do not require machining. This selective exposure ensures machining accuracy and protects the overall integrity and appearance quality of the workpiece.

[0111] Through the above technical solution, the positioning cavity 63 on the workpiece carrier 6 can provide customized physical constraints for the key parts of the workpiece, effectively solving the problem of workpiece movement or offset caused by inaccurate positioning during automated assembly. This precise positioning ensures that when subsequent functional modules such as the bending and forming module 8, resistance welding module 9, and lead trimming module 10 are operated, the tools can accurately act on the parts to be processed of the leads and power terminals, avoiding the problem of inaccurate exposure of the operating parts. At the same time, the design of exposing only the parts to be processed not only improves processing efficiency but also protects the non-processed areas of the workpiece from damage or contamination, thereby significantly improving processing accuracy and consistency and fundamentally guaranteeing product quality.

[0112] In some of the solutions described above in this application, a resistance welding module 9 is proposed to connect the bent pins to the power terminals through a resistance welding process. However, in this process, due to the lack of real-time monitoring of welding pressure and electrode displacement, the welding quality may be unstable, resulting in inconsistent welding pressure and affecting the consistency and reliability of the product.

[0113] In a further embodiment, the resistance welding module 9 integrates a displacement sensor and a pressure sensor to monitor and provide feedback on the displacement changes and applied pressure of the moving electrode head 42 during the welding process in real time. The working process is as follows: during the process of the propulsion cylinder 40 driving the moving electrode head 42 to press the workpiece, the displacement sensor and the pressure sensor collect data in real time and compare it with a preset threshold to monitor and ensure the stability and consistency of the welding pressure.

[0114] Specifically, the displacement sensor is a device that converts mechanical displacement into an electrical signal output. It can employ a linear variable differential transformer (LVDT) sensor, which accurately detects the linear displacement of the moving electrode head 42 by measuring changes in coil inductance; alternatively, it can use a grating ruler sensor, which uses optical principles to measure the moving distance of the moving electrode head 42 with high precision. This displacement sensor is used to accurately capture the positional changes of the moving electrode head 42 during the welding process, ensuring that it moves according to a preset trajectory and stroke, avoiding welding defects caused by displacement deviations. The pressure sensor is a device that can sense pressure signals and convert them into usable output signals. It can employ a piezoresistive pressure sensor, which reflects the magnitude of the pressure applied by the moving electrode head 42 to the workpiece by measuring changes in resistance; alternatively, it can use a piezoelectric pressure sensor, which uses the piezoelectric effect to convert pressure into an electrical charge signal, thereby achieving real-time monitoring of welding pressure. This pressure sensor is used to monitor the force applied by the moving electrode head 42 when pressing against the workpiece in real time, ensuring that the welding pressure is within the set optimal range, preventing excessive or insufficient pressure from affecting welding strength and quality.

[0115] With the above configuration, the resistance welding module 9 can monitor and provide feedback on the displacement changes of the moving electrode head 42 and the applied pressure in real time during the welding process. The analog signals collected by the sensors are converted into digital signals by an A / D converter and transmitted to the controller. The controller processes and analyzes the data and can display the results on the human-machine interface or use them for subsequent closed-loop control. This real-time monitoring mechanism ensures that key physical parameters during the welding process can be continuously and instantly acquired, providing a basis for subsequent judgment and adjustment. During the process of the propulsion cylinder 40 driving the moving electrode head 42 to press the workpiece, the control system is programmed to simultaneously start the data acquisition program of the displacement sensor and pressure sensor after the propulsion cylinder 40's action command is issued, and continuously record until the pressing action is completed or the welding ends. This ensures that the most accurate and direct welding parameter data can be obtained at the critical moment when the welding force is applied and the electrode contacts.

[0116] The collected data is compared with preset thresholds. Upper and lower limits for displacement and pressure are preset in the control system, and the real-time data collected by the sensors is compared point-by-point or interval-by-interval with these thresholds; alternatively, an ideal displacement-pressure curve or range can be set, and the real-time data is analyzed for matching with this curve or range. Through comparison, it can be quickly determined whether the current welding parameters are within the process requirements, providing a basis for subsequent quality control. Ultimately, this monitoring mechanism ensures the stability and consistency of welding pressure. When real-time data exceeds the preset threshold, the control system can issue an alarm, automatically adjust the drive parameters of the propulsion cylinder 40, or even stop the welding process to correct the deviation. This ability to proactively intervene and adjust the welding process ensures that the welding quality of each product meets high standards, significantly improving product consistency and reliability. By integrating displacement and pressure sensors into the resistance welding module 9, this application can acquire real-time and accurate data on the displacement changes and applied pressure of the moving electrode head 42 during the welding process. When the propulsion cylinder 40 drives the moving electrode head 42 to press against the workpiece, these sensors synchronously collect data and compare it with preset thresholds. This real-time monitoring mechanism enables the system to dynamically grasp key parameters during the welding process. If displacement or pressure deviates from the preset range, it can be detected and intervened promptly. This effectively solves the problems of unstable welding pressure and inaccurate electrode displacement caused by the lack of real-time monitoring in traditional resistance welding, thus significantly improving the stability of welding quality and product consistency. Through precise control of welding pressure and real-time feedback of displacement, defects such as incomplete welds and cold welds can be effectively avoided, ensuring that each weld point achieves the expected strength and reliability, thereby improving the overall production quality and efficiency of the carbon brush holder tail assembly machine.

[0117] Furthermore, the vision inspection module 11 includes an industrial camera mounted vertically towards the workpiece. This camera is configured to acquire images of the workpiece and thereby detect the total thickness of the welded area, the residual length of the leads after trimming, and the spacing between the two power terminals. Its operation is as follows: when the workpiece is stationary at the inspection station, the industrial camera captures a clear image of the top of the workpiece. The image processing system analyzes and measures the image, comparing the measurement results with a preset tolerance range to determine whether the workpiece is qualified. Specifically, the industrial camera is an image acquisition device designed specifically for industrial automation and machine vision applications, characterized by high resolution, high frame rate, high stability, and adaptability to harsh industrial environments. For example, a CCD camera with a global shutter function can be used, which can effectively avoid motion blur and ensure clear image capture when the workpiece is quickly stationary; alternatively, a CMOS camera can be selected, which has advantages in data transmission speed and integration, suitable for scenarios requiring high-speed image processing. As the core component of the vision inspection module 11, the industrial camera is responsible for converting the physical image of the workpiece into a digital signal that can be processed by a computer, serving as the basic data source for all subsequent inspection and analysis. The "vertical workpiece mounting" refers to setting the optical axis of the industrial camera's lens perpendicular to the surface of the workpiece to be inspected. This mounting method can be achieved in several ways. For example, a precision mechanical adjustment mechanism, such as a universal bracket with an adjustment screw, can be used in conjunction with a laser alignment instrument for precise calibration to ensure that the camera's optical axis is strictly perpendicular to the workpiece's inspection plane. Alternatively, an electrically operated adjustment platform with integrated encoder feedback can be used, with software control to achieve precise attitude adjustment of the camera in three-dimensional space to meet the vertical mounting requirements. This mounting method aims to eliminate perspective distortion and ensure a linear correspondence between the object's size in the image and its actual size, thus providing a reliable image basis for accurate dimensional measurement. The "acquiring workpiece images" refers to the industrial camera capturing and digitizing the visual information of the workpiece at a specific moment. Specifically, when the workpiece carrier 6, carrying the workpiece, is stationed at the inspection station, an industrial camera can be controlled by an external trigger signal (e.g., issued by a station sensor or PLC controller) to perform a precise exposure, thereby acquiring a clear and stable image of the workpiece. Alternatively, the industrial camera can be configured to operate in continuous mode, and combined with Region of Interest (ROI) detection or motion state judgment in the image processing system, the required image frames can be automatically captured after the workpiece enters the preset inspection area and stabilizes. This step is the starting point of the visual inspection process, providing raw data for subsequent image analysis and dimensional measurement. The "total thickness of the welded area, the residual length after pin trimming, and the spacing between the two power terminals" refers to the precise quantification of these three key dimensional parameters from the acquired workpiece image using a specific image processing algorithm.For example, the total thickness of the welding area can be determined by analyzing the grayscale gradient changes in the image or by combining structured light projection technology to identify the contour and height information of the welding area, and then calculated according to a pre-calibrated scale. For the residual length after pin trimming, edge detection algorithms (such as the Canny or Sobel operators) can be used to identify the trimmed endpoints of the pins and their connection points with the power terminals, then the pixel distance between the two points can be calculated and converted into the actual length. For the spacing between two power terminals, template matching or feature point recognition algorithms can be used to accurately locate the center point or specific edge point of the two power terminals, and then the distance between them can be calculated. These parameters are core indicators for evaluating the quality and functional reliability of carbon brush holder tail plug products, directly reflecting the stability of the welding process and the compatibility of product assembly. The image processing system is an integrated hardware and software platform used to analyze, measure, and judge digital images acquired by industrial cameras. At the hardware level, a high-performance industrial-grade computer (IPC) paired with a professional image acquisition card can be used to provide powerful computing capabilities and data transmission bandwidth. At the software level, professional machine vision software libraries (such as Halcon, OpenCV, or VisionPro) can be run. These libraries provide rich image processing algorithms, including image enhancement, filtering, edge detection, feature extraction, dimensional measurement, and pattern recognition. This system is key to achieving automated and intelligent inspection, as it can transform raw image data into meaningful dimensional information and pass / fail judgment results. The "preset tolerance range" refers to the allowable variation range set for each dimensional parameter to be inspected according to product design specifications, engineering requirements, and quality standards. For example, the nominal values ​​and upper and lower tolerance values ​​of the total thickness of the welding area, the residual length of the pins, and the spacing between power terminals can be entered in the user interface of the image processing software; alternatively, these tolerance data can be stored in an external database or configuration file for dynamic reading and comparison by the image processing system during runtime. This tolerance range is the objective basis for determining whether a workpiece is qualified, ensuring the consistency and controllability of product quality and avoiding the subjectivity of human judgment.

[0118] Through the above technical solution, this application effectively solves the problem of the lack of specificity and standardization in the inspection content of the existing visual inspection module 11, and significantly improves the reliability of workpiece qualification judgment and the consistency of product quality. Specifically, the industrial camera installed vertically towards the workpiece ensures that the acquired workpiece image is free of perspective distortion, providing a reliable image basis for accurate dimensional measurement and avoiding measurement errors caused by viewing angle deviation. The industrial camera is configured to specifically detect the total thickness of the welding area, the residual length after pin trimming, and the spacing between the two power terminals. These parameters directly correspond to the key quality indicators of the carbon brush holder tail plug product, such as the reliability of electrical connection, pin safety and appearance, and terminal assembly compatibility, thereby achieving comprehensive and accurate monitoring of core quality parameters. When the workpiece is stationed at the inspection station, the industrial camera captures a clear image of the top of the workpiece, ensuring the stability and clarity of image acquisition and providing high-quality input for subsequent image processing. The image processing system analyzes and measures the image, automatically and objectively extracting the required dimensional information, avoiding the subjectivity and inefficiency of manual inspection. Finally, the measurement results were compared with the preset tolerance range, achieving automated conformity judgment based on a unified standard, ensuring the standardization and consistency of product quality assessment. Through this series of meticulous inspection steps, this application can promptly identify and reject unqualified products, fundamentally guaranteeing the production quality of carbon brush holder tail plugs and improving the automation level and product reliability of the overall assembly machine.

[0119] The following example will provide a more detailed explanation of the above technical solution:

[0120] An electronics manufacturing base faced problems such as low assembly efficiency and poor product quality consistency in brush holder assembly. Traditional manual assembly methods resulted in inconsistent soldering quality and made online inspection impossible. To solve these technical challenges, the production base introduced an automated assembly system.

[0121] The core of this equipment is a carbon brush holder tail assembly machine. This assembly machine first includes a robust frame 1, which serves as the mounting base for all functional modules. A rotary indexing device is mounted on the frame 1, consisting of a fixed disk 3, a turntable 4 rotatably positioned below the fixed disk 3, and a drive assembly that drives the turntable 4 to perform intermittent indexing rotation. Multiple workpiece carriers 6 are evenly distributed along the periphery of the turntable 4, and these carriers rotate synchronously with the turntable 4.

[0122] The assembly process is as follows:

[0123] First, at the loading station, the operator loads the pre-assembled connector power terminal housing (containing the varistor to be soldered) onto the workpiece carrier 6. The workpiece carrier 6 has a positioning cavity 63 that matches the shape of the workpiece, precisely accommodating the power terminal housing and varistor, while exposing the pins and the solderable portion of the power terminals. This design ensures that the workpiece is stably constrained within the positioning cavity 63 during all subsequent station operations, exposing only the parts to be processed, thus guaranteeing processing accuracy and consistency and avoiding errors caused by inaccurate positioning during manual operation.

[0124] After the workpiece is loaded, the workpiece carrier 6 carries the workpiece and rotates intermittently with the turntable 4, passing through each subsequent functional module in sequence. During the rotation and stationary loading of the turntable 4, a support component 13 is provided below the edge of the turntable 4 corresponding to each functional module station. This support component 13 includes a support rod 14 and a roller 15 mounted on its top. The roller 15 continuously rolls in contact with the bottom surface of the turntable 4, providing auxiliary support for the edge of the turntable 4 at the station, enhancing the structural stability of the turntable 4 when carrying the workpiece, effectively avoiding the shaking that may occur under heavy load or impact of a traditional simple indexing plate, and ensuring the accuracy of operation at each station.

[0125] When the workpiece-carrying carrier stops at the bending station, the bending forming module 8 begins operation. This module includes an outer support mechanism and a bending execution mechanism. The support gripper 20 of the outer support mechanism first extends forward and abuts against the outside of the pin, with its front working surface being arc-shaped. Subsequently, the vertical slide 23 of the bending execution mechanism drives the inner positioning gripper 28 and the bending pressure head 26 downward, causing the inner positioning gripper 28 to move to the inner side between the two pins and perform positioning. At the same time, the bending cylinder 25 drives the bending pressure head 26 forward, precisely pressing the pin against the arc-shaped working surface of the support gripper 20, thereby completing the arc-shaped bend. This automated bending process ensures that the bending angle and shape height of each pin are consistent, overcoming the problems of inconsistent angles and shape deviations commonly found in manual bending.

[0126] After bending and forming, the workpiece rotates with the turntable 4 to the resistance welding module 9. When the workpiece reaches the welding station, the pressure arm 45 of the workpiece clamping mechanism first swings down to clamp the workpiece, ensuring its stability during the welding process. Subsequently, the vertical adjustment mechanism drives the welding execution assembly to descend as a whole, aligning the stationary electrode head 41 and the moving electrode head 42 with the inner side of the power terminal and the outer side of the bent pin on the workpiece, respectively. The horizontal adjustment mechanism then makes fine adjustments to ensure precise alignment between the electrode and the workpiece. Next, the propulsion cylinder 40 drives the moving electrode seat 39 towards the stationary electrode seat 38, causing the moving electrode head 42 to firmly press the pin onto the power terminal. During this clamping process, the displacement sensor and pressure sensor integrated into the resistance welding module 9 monitor and feedback the displacement change of the moving electrode head 42 and the applied pressure in real time, comparing them with preset thresholds to monitor and ensure the stability and consistency of the welding pressure. Subsequently, the two electrode heads are energized for resistance welding. After welding is completed, the electrode heads reset, and the pressure arm 45 is raised. This automated resistance welding, combined with real-time parameter monitoring, completely solves the quality problems of traditional manual soldering, such as cold solder joints, uneven solder joints, and lack of precise welding pressure control, significantly improving welding quality and the reliability of electrical connections.

[0127] After welding, the workpiece enters the lead trimming module 10. The clamping and conveying unit first moves radially, causing the cutting jaws 51 to clamp the extended lead ends after welding. Next, the cutting unit descends, and the shear assembly 55 actuates to cut off the lead outside the clamping point. Subsequently, the clamping and conveying unit retracts radially above the waste collection device 57, the cutting jaws 51 release, and the cut lead falls into the waste collection device 57. This process achieves precise lead length trimming, avoiding the problems of inconsistent lengths and waste scattering associated with manual trimming.

[0128] The cut workpiece is then sent to the vision inspection module 11. This module includes an industrial camera mounted vertically towards the workpiece. While the workpiece is stationary at the inspection station, the camera captures a clear image of the top of the workpiece. The image processing system analyzes and measures the image, detecting the total thickness of the welded area, the residual length of the leads after cutting, and the spacing between the two power terminals. The measurement results are compared with preset tolerance ranges to determine whether the workpiece is qualified. This 100% online optical dimensional inspection fills the gap in effective quality monitoring in traditional production, ensuring that every workpiece leaving the factory meets stringent quality standards.

[0129] Finally, the workpiece arrives at the sorting and unloading module 12. This module is a three-axis Cartesian robot, which includes an X-axis linear module 59, a Y-axis linear module 60, and a Z-axis linear module 61, which are orthogonally arranged and sequentially connected by transmission, as well as a pick-and-place end effector 62 mounted on the moving parts of the Z-axis linear module 61. Based on the output signal from the vision detection module 11, the three-axis Cartesian robot drives the pick-and-place end effector 62 to move to the corresponding workpiece carrier 6 to grasp the workpiece, and then transfers it to the qualified product assembly line or the unqualified product recycling location. This automated sorting process is based on objective detection results, avoiding the errors and inefficiencies of manual sorting, and achieving precise separation of qualified and unqualified products.

[0130] Through the aforementioned integrated automated assembly machines, the production base has achieved fully automated closed-loop production of carbon brush holder tail plugs, from pin forming, precision welding, post-weld processing to full inspection and sorting. This not only significantly improves production efficiency but also fundamentally ensures the welding quality and consistency of products through high-precision process control and comprehensive end-point testing, solving the technical bottlenecks of low efficiency, unstable quality, and lack of online monitoring inherent in traditional manual methods and existing semi-automated equipment.

[0131] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0132] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention.

Claims

1. A carbon brush holder tail plug assembly machine, characterized in that, include: Rack (1); A rotary indexing device is installed on the frame (1), which includes a fixed disk (3), a turntable (4) rotatably disposed below the fixed disk (3), and a drive assembly for driving the turntable (4) to perform intermittent indexing rotation; Multiple workpiece carriers (6) are evenly distributed along the periphery of the turntable (4) and rotate with it; The following functional modules are arranged around the rotary indexing device and sequentially on the frame (1): The loading station is configured to allow operators to load the connector power terminal housings assembled with the varistor to be welded onto the workpiece carrier (6); A bending and forming module (8) is used to plastically bend the pins of the varistor; Resistance welding module (9) is used to connect the bent pins to the power terminals by resistance welding process; The pin trimming module (10) is used to cut off the excess pin portion after soldering; The vision inspection module (11) is used to perform optical dimension inspection on the welded and cut workpieces; The sorting and unloading module (12) is used to transfer qualified and unqualified workpieces separately according to the test results; The assembly machine operates as follows: after the operator loads the workpiece onto the workpiece carrier (6) at the loading station, the workpiece carrier (6) carries the workpiece and rotates intermittently with the turntable (4), passing through each subsequent functional module in sequence; the bending and forming module (8) bends the vertical pins into shape, the resistance welding module (9) then welds the bent pins to the power terminal resistor as one piece, the pin trimming module (10) then trims the excessively long pins after welding, the vision inspection module (11) performs imaging and size analysis on the workpieces that have completed welding and trimming, and finally the sorting and unloading module (12) sorts and unloads the workpieces according to the analysis results.

2. The carbon brush holder tail plug assembly machine according to claim 1, characterized in that, The turntable (4) is provided with a support component (13) below each functional module station on its edge. The support component (13) includes a support rod (14) and a roller (15) installed on its top. The roller (15) rolls in contact with the bottom surface of the turntable (4) to provide auxiliary support. During the rotation and static load-bearing process of the turntable (4), the roller (15) continuously contacts the bottom surface of the turntable (4) to enhance the structural stability of the edge of the turntable (4) at the station.

3. The carbon brush holder tail plug assembly machine according to claim 1, characterized in that, The bending and forming module (8) includes: The outer support mechanism is located on the radial outer side of the turntable (4), including a radially movable first slide (17), a first linear driver (18) that drives the first slide (17), a first clamping cylinder (19) mounted on the first slide (17), and a pair of support claws (20) connected to the two output ends of the first clamping cylinder (19). The front working surface of the support claws (20) is constructed in an arc shape. The bending actuator is located on the radial inner side of the turntable (4) and includes a column (22), a vertical slide (23) mounted on the column (22), a second linear actuator (24) driving the vertical slide (23), a bending cylinder (25) mounted on the vertical slide (23), and a pair of bending pressure heads (26) connected to the output end of the bending cylinder (25). Among them, an auxiliary positioning cylinder (27) is also installed on the vertical slide (23), and the output end of the auxiliary positioning cylinder (27) is connected to a pair of adjustable inner positioning grippers (28); The working process is as follows: when the carrier carrying the workpiece stops at the bending station, the support jaw (20) of the outer support mechanism first extends forward and abuts against the outside of the pin; then the vertical slide (23) of the bending execution mechanism drives the inner positioning jaw (28) and the bending pressure head (26) to move downward, so that the inner positioning jaw (28) moves to the inner side between the two pins and is positioned, while the bending cylinder (25) drives the bending pressure head (26) to push forward, pressing the pin against the arc working surface of the support jaw (20), thereby completing the arc bending.

4. The carbon brush holder tail plug assembly machine according to claim 1, characterized in that, The resistance welding module (9) includes: Welding frame (29); The vertical adjustment mechanism is installed on the welding frame (29) and includes a first vertical slide rail (31) and a first lifting cylinder (32) that drives its movement. A horizontal adjustment mechanism is installed on the movable part of the vertical adjustment mechanism, including a horizontal slide rail (34) and an adjustment cylinder (35) that drives its movement; The welding execution assembly is fixed on the movable part of the horizontal adjustment mechanism. It includes a mounting bracket (37), a static electrode seat (38) fixed on the mounting bracket (37), and a moving electrode seat (39) opposite to the static electrode seat (38) and which can be driven to move closer or further away by a propulsion cylinder (40). The static electrode seat (38) is provided with a static electrode head (41) at its lower end, and the moving electrode seat (39) is provided with a moving electrode head (42) at its lower end. The workpiece clamping mechanism is hinged to the frame (1) and driven by a rotary drive (44), and has a clamping arm (45) that can swing above the workpiece carrier (6) and clamp the workpiece. The working process is as follows: when the workpiece arrives at the welding station, the pressure arm (45) of the workpiece clamping mechanism first swings down to clamp the workpiece; then the vertical adjustment mechanism drives the welding execution assembly to descend as a whole, so that the stationary electrode head (41) and the moving electrode head (42) are respectively aligned with the inner side of the power terminal on the workpiece and the outer side of the bent pin; the propulsion cylinder (40) drives the moving electrode seat (39) to move towards the stationary electrode seat (38), so that the moving electrode head (42) presses the pin on the power terminal, and then the two electrode heads are energized to perform resistance welding; after the welding is completed, the electrode head is reset and the pressure arm (45) is raised.

5. The carbon brush holder tail plug assembly machine according to claim 1, characterized in that, The pin trimming module (10) includes: Mounting base (46) is fixed to the frame (1); The clamping and transferring unit is disposed on the mounting base (46) and includes a radially movable second slide (48), a third linear driver (49) for driving the second slide (48), a second clamping cylinder (50) mounted on the second slide (48), and a pair of cutting claws (51) connected to the output end of the second clamping cylinder (50) for clamping the pin ends; The shearing unit is disposed on the upper part of the mounting base (46) and includes a second vertical slide rail (53), a second lifting cylinder (54) that drives the second vertical slide rail (53), and a shear assembly (55) driven by the shearing cylinder (56) mounted on the movable part of the second vertical slide rail (53). Waste collection device (57) is located on the side of the turntable (4) and is used to receive the cut-off pins; The working process is as follows: the clamping and transferring unit first moves radially so that the cutting jaw (51) clamps the end of the extended pin after welding; then the cutting unit descends and the scissor assembly (55) cuts off the pin outside the clamping point; subsequently, the clamping and transferring unit moves radially back to above the waste collection device (57), the cutting jaw (51) releases, and the cut pin falls into the waste collection device (57).

6. The carbon brush holder tail plug assembly machine according to claim 1, characterized in that, The sorting and unloading module (12) is a three-axis Cartesian coordinate robot, which includes an X-axis linear module (59), a Y-axis linear module (60) and a Z-axis linear module (61) that are orthogonally arranged and connected in sequence, as well as a pick-and-place end effector (62) installed on the moving part of the Z-axis linear module (61); Its working process is as follows: the three-axis rectangular coordinate robot drives the pick-and-place end effector (62) to move to the corresponding workpiece carrier (6) to grab the workpiece according to the output signal of the vision detection module (11), and then transfers it to the qualified product production line or the unqualified product recycling position.

7. The carbon brush holder tail plug assembly machine according to claim 1, characterized in that, The workpiece carrier (6) has a positioning cavity (63) for accommodating and positioning the part of the power terminal block on which the varistor is installed, as well as the main body of the varistor, and exposing the pins of the varistor and the part of the power terminal block to be welded to the outside; during the loading station and subsequent station operations, the part of the workpiece is constrained in the positioning cavity (63), and only the part to be processed is exposed.

8. The carbon brush holder tail plug assembly machine according to claim 4, characterized in that, The resistance welding module (9) integrates a displacement sensor and a pressure sensor, which are used to monitor and provide feedback on the displacement change of the moving electrode head (42) and the applied pressure during the welding process in real time. Its working process is as follows: during the process of the propulsion cylinder (40) driving the moving electrode head (42) to press the workpiece, the displacement sensor and pressure sensor collect data in real time and compare it with the preset threshold to monitor and ensure the stability and consistency of the welding pressure.

9. The carbon brush holder tail plug assembly machine according to claim 1, characterized in that, The vision inspection module (11) includes an industrial camera mounted vertically toward the workpiece, which is configured to acquire images of the workpiece and thereby detect the total thickness of the welded area, the residual length after pin trimming, and the spacing between the two power terminals. The working process is as follows: when the workpiece is stopped at the inspection station, the industrial camera takes a clear image of the top of the workpiece, the image processing system analyzes and measures the image, and compares the measurement results with the preset tolerance range to determine whether the workpiece is qualified.

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