Visual laser welding equipment for vertically wound flat wire PFC (power factor correction) inductor

Abstract

The invention discloses visual laser welding equipment for a flat wire vertically-wound PFC inductor. Comprising a main control box, a control machine body, a mounting part, a laser welding mechanism, a first linear walking module, a second linear walking module, an assembling part, a first driving part, a first transmission part, a second driving part, a second transmission part, a supporting part, a bearing part, a clamp, a laser generator, a visual detection assembly and a welding quality detection module. The main control box provides mounting support for all the components, and a central control module is arranged in a control machine body on the side face of the main control box, plays a global regulation and control function and is matched with adjustment and correction of workpiece positions; a laser generator supplies energy, a laser welding head acts on a welding area, and a visual detection assembly accurately recognizes the position of a workpiece; the welding quality detection module monitors soldering tin flow, welding appearance and defects. The position of the workpiece can be automatically adjusted, the welding efficiency and the quality stability are improved, and the welding defect rate is reduced.

Description

Technical Field

[0001] This invention relates to the field of magnetic material processing equipment, and in particular to a flat wire vertical winding PFC inductor vision laser welding equipment. Background Technology

[0002] In the inductor manufacturing industry, the soldering of inductor coils to terminals is a critical process. Traditional methods of soldering inductor coils to terminals, such as manual soldering or some simple automated soldering equipment, have many problems.

[0003] In terms of positioning, common laser welding equipment mainly relies on the experience and operating skills of workers to align the lead wire of the inductor coil with the terminal. It is difficult to guarantee that the lead wire of the inductor coil will be accurately located in the middle of the terminal every time welding. Positional deviation will affect the performance consistency of the inductor and is prone to inaccurate positioning.

[0004] Furthermore, for laser welding, the energy and speed of the laser have a significant impact on the welding quality. Traditional equipment often cannot track the energy and speed of the laser in real time, leading to fluctuations in welding quality and an inability to guarantee the consistency of weld point quality. This fails to meet the working requirements of magnetic material processing equipment. Therefore, a flat wire vertical winding PFC inductor vision laser welding device is proposed. Summary of the Invention

[0005] This invention provides the following technical solution: a flat wire vertical winding PFC inductor vision laser welding device, comprising:

[0006] The main control box has a control body mounted on its side and a mounting component connected to its top rear side. A laser welding mechanism is mounted on the outside of the mounting component. A central control module is installed inside the control body. The main control box serves as the core installation and support carrier of the equipment, providing a stable installation foundation for each component. The control body and its internal central control module undertake the global control function, integrating feedback information from each component and issuing commands to ensure the coordinated operation of each system of the equipment. This avoids action delays or incoordination caused by decentralized component control, providing a stable control foundation for the subsequent precise welding process and reducing welding failures caused by control disorder.

[0007] The first linear travel module is installed on the top of the main control box. The output component of the first linear travel module is equipped with a second linear travel module. The top of the second linear travel module is equipped with an assembly. The first linear travel module and the second linear travel module form a multi-dimensional moving structure, which can drive the assembly to achieve multi-directional position adjustment, breaking through the limitation of traditional single-direction movement. It can flexibly adjust the position of the assembly according to the welding requirements of the workpiece, thereby driving the subsequent drive components, transmission components and other components to adapt to the welding position requirements of different specifications of workpieces, improving the equipment's adaptability to flat wire vertical winding PFC inductors of different sizes, and reducing the time and cost of replacing special tooling due to insufficient equipment adaptability.

[0008] A first driving component is connected to the front side of the assembly, and a second driving component is installed on the side of the assembly. The output end of the first driving component is connected to a first transmission component, and the output shaft of the second driving component is equipped with a second transmission component. The first driving component and the second driving component transmit power through the first transmission component and the second transmission component respectively, forming an independent and coordinated power transmission path. This allows for precise control of the intensity and speed of power output, avoiding the problem of insufficient or excessive power transmission from a single driving component. It provides a stable and controllable power source for the tilt adjustment of subsequent support components and load-bearing components, ensuring a smooth and precise adjustment process and reducing position adjustment deviations caused by unstable power.

[0009] A support component is inserted in the middle of the first and second transmission components. A load-bearing component is installed at the top of the support component, and a clamp is provided at the top of the load-bearing component. As a key component connecting the transmission component and the load-bearing component, the support component can stably transmit the power of the transmission component to the load-bearing component, ensuring that the load-bearing component maintains structural stability during adjustment. The clamp at the top of the load-bearing component can firmly clamp the workpiece, preventing workpiece displacement during welding. Combined with the coordinated adjustment of the support component and the load-bearing component, when the visual inspection component detects a positional deviation, the support component and the load-bearing component can be adjusted by the transmission component, thereby correcting the workpiece position. This provides a stable guarantee for workpiece fixation and position adjustment for precise welding, reducing welding deviations caused by insecure workpiece fixation or inability to adjust the position.

[0010] A laser generator is installed outside the laser welding mechanism. A laser welding head is installed at the lower part of the laser welding mechanism. A vision inspection component is installed on the outer side of the laser welding mechanism. The vision inspection component integrates an industrial camera, an image acquisition card, a light source module, and an image analysis and processing unit. The laser generator provides the energy source for laser welding, and the laser welding head precisely applies the laser energy to the welding area to ensure efficient welding. The vision inspection component acquires workpiece images through the industrial camera, the image acquisition card quickly transmits image data, the light source module optimizes the imaging environment, and the image analysis and processing unit accurately identifies the positions of terminals and inductor coil leads, forming a complete vision inspection closed loop. It can capture workpiece position information in real time, providing an accurate basis for subsequent position adjustments, avoiding welding misalignment caused by inaccurate position identification, and improving welding position accuracy. The vision inspection component also integrates an image enhancement module. The image enhancement module is a software algorithm module and has built-in adaptive histogram equalization algorithm and wavelet transform denoising algorithm. The image enhancement function is realized through the hardware carrier mounted on the image analysis and processing unit.

[0011] The welding quality inspection module is integrated inside the laser welding mechanism. This module integrates a solder flow monitoring unit, a visual inspection unit, and a defect identification unit. The solder flow monitoring unit tracks the solder flow in real time to prevent solder from flowing into the terminal threaded holes and affecting subsequent assembly. The visual inspection unit checks whether the weld appearance meets standards, and the defect identification unit promptly detects welding cracks, porosity, and other problems. This comprehensive welding quality monitoring system prevents defective products from flowing into subsequent processes, reduces rework and scrap due to welding quality issues, improves product pass rate, and provides data support for welding process optimization, thus contributing to continuous improvement of welding quality.

[0012] Preferably, the outer ends of the first and second transmission components are connected to the corresponding inner positions of the assembly via bearings, and the interiors of the first and second transmission components are provided with through slots. The second transmission component is located below the first transmission component and is arranged in a cross shape.

[0013] Preferably, a ball head is inserted into the inner side of the second transmission member, and a first locking groove is formed inside the ball head at a position corresponding to the first transmission member, and a second locking groove is formed inside the ball head at a position corresponding to the second transmission member.

[0014] Preferably, a first locking block is inserted inside the first locking slot, and the bottom end of the first locking block is connected to the corresponding position on the surface of the assembly. A second locking block is inserted inside the second locking slot, and the top end of the second locking block is connected to the bottom end of the support member.

[0015] Preferably, the visual detection component also integrates an image enhancement module, which is equipped with an adaptive histogram equalization algorithm and a wavelet transform denoising algorithm. The image analysis and processing unit has a built-in deep learning-based image recognition algorithm.

[0016] Preferably, the bottom of the laser welding mechanism is equipped with a parameter monitoring and feedback module, which includes a laser energy sensor, a laser movement speed sensor, a temperature sensor, and a data processing and feedback unit. The laser movement speed sensor is equipped with laser Doppler velocimetry technology.

[0017] Preferably, the welding quality inspection module also integrates a data preprocessing unit. The data preprocessing unit establishes data connections with the solder flow monitoring unit, appearance inspection unit, and defect identification unit through data cables. The data preprocessing unit is used to process the collected raw data, filter out interfering data, and then standardize and integrate the data to convert different heterogeneous data into a unified format.

[0018] Preferably, the defect classification and grade determination subunit has 30 sets of welding defect feature models and corresponding quality grade standards under the flat wire vertical winding PFC inductive laser welding process pre-stored internally, and the defect identification unit is connected to the data transmission terminal of the vision inspection component through a data cable.

[0019] Preferably, the central control module adopts an embedded industrial computer architecture. The motherboard of the central control module integrates 5-10 I / O interfaces and analog input channels. The software system of the central control module is developed based on a real-time operating system and is equipped with a task scheduling function. The control program of the central control module includes a parameter configuration interface, a manual debugging interface, and an automatic operation interface. The interface interaction logic of the central control module adopts a state machine design pattern.

[0020] Preferably, the light source module includes a light source controller and a ring-shaped shadowless LED light source array. The control terminal of the ring-shaped shadowless LED light source array adopts a regional dimming design. The light source controller has a built-in light intensity feedback adjustment circuit. The light intensity feedback adjustment circuit monitors the emitted light intensity in real time through a photodiode. The lens of the industrial camera is equipped with an electric zoom mechanism.

[0021] In summary, compared with the prior art, the present invention provides a flat wire vertical winding PFC inductive vision laser welding device, which has the following beneficial effects:

[0022] 1. This invention drives the movement of the first transmission component through the first driving component and the movement of the second transmission component through the second driving component, thereby enabling the tilt adjustment of the support component and the load-bearing component in the left-right and front-back directions. In turn, it can automatically adjust the position of the workpiece terminals and inductor coil lead wires after the workpiece is clamped by the fixture and the visual inspection component detects that the position of the workpiece terminals and inductor coil lead wires is incorrect, ensuring that the inductor coil lead wires are accurately located in the middle position of the terminals. This avoids the operational errors and inefficiencies of manual adjustment, reduces production interruptions caused by manual intervention, and improves the overall welding operation efficiency.

[0023] 2. The present invention, through the welding quality detection module, can track and monitor the laser parameters in real time during the laser welding process, thereby improving the stability of welding quality and making up for the shortcomings of traditional laser welding equipment caused by parameter fluctuations. Furthermore, under the control of the central control module, it can work with relevant detection components to track the energy and movement of the laser in real time, avoiding problems such as insufficient welding strength and uneven weld due to unstable laser parameters, and reducing the probability of welding defects. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the present invention.

[0025] Figure 2 This is a schematic diagram of the top structure of the main control box of the present invention.

[0026] Figure 3 This is a schematic diagram of the second linear walking module structure of the present invention.

[0027] Figure 4 This is a schematic diagram of the assembly structure of the present invention.

[0028] Figure 5 This is a schematic diagram of the structure of the first and second transmission components of the present invention.

[0029] Figure 6 This is a schematic diagram of the ball head structure of the present invention.

[0030] Figure 7 This is a schematic diagram of the laser welding mechanism of the present invention.

[0031] Explanation of reference numerals in the attached figures:

[0032] 1. Main control box; 2. Control body; 3. Mounting components; 4. Laser welding mechanism; 5. First linear walking module; 6. Second linear walking module; 7. Assembly parts; 8. First drive component; 81. First transmission component; 9. Second drive component; 91. Second transmission component; 10. Support component; 11. Bearing component; 12. Fixture; 13. Ball head; 14. First locking slot; 141. First locking block; 15. Second locking slot; 151. Second locking block; 16. Laser generator; 17. Laser welding head; 18. Vision inspection component. Detailed Implementation

[0033] This invention provides a technical solution: a flat wire vertical winding PFC inductive vision laser welding device, comprising a main control box 1, a control body 2, a mounting component 3, a laser welding mechanism 4, a first linear walking module 5, a second linear walking module 6, an assembly 7, a first driving component 8, a first transmission component 81, a second driving component 9, a second transmission component 91, a support component 10, a load-bearing component 11, a clamp 12, a ball head 13, a first locking groove 14, a first locking block 141, a second locking groove 15, a second locking block 151, a laser generator 16, a laser welding head 17, and a vision inspection component 18.

[0034] Please see Figure 1 The main control box 1 is equipped with a control body 2 on its side, and a mounting part 3 is connected to the top rear side of the main control box 1. A laser welding mechanism 4 is installed on the outside of the mounting part 3, and a central control module is installed inside the control body 2.

[0035] Please see Figure 2 The first linear motion module 5 is mounted on the top of the main control box 1. A second linear motion module 6 is mounted externally on the output component of the first linear motion module 5. (See also...) Figure 3 The top of the second linear walking module 6 is equipped with a mounting accessory 7. Both the first linear walking module 5 and the second linear walking module 6 are drive structures in which the motor drives the lead screw to rotate to control the movement of the slider.

[0036] Please see Figure 4 The first drive component 8 is connected to the front side of the assembly 7, and the second drive component 9 is mounted on the side of the assembly 7. Please refer to [link / reference]. Figure 5 The output end of the first driving component 8 is connected to the first transmission component 81, and the output shaft of the second driving component 9 is equipped with the second transmission component 91. Both the first driving component 8 and the second driving component 9 are stepper motors.

[0037] A support member 10 is inserted into the middle of the first transmission member 81 and the second transmission member 91. The support member 10 is a shaft structure, and a bearing member 11 is installed at the top of the support member 10. The bearing member 11 is a flat plate structure, and a clamp 12 is provided on the top of the bearing member 11. The combined design of the first linear walking module 5 and the second linear walking module 6 breaks the limitation of traditional single-direction movement and forms a multi-dimensional movement adjustment structure. The first linear walking module 5 is installed on the top of the main control box 1, providing a stable support foundation for the entire movement adjustment system. Its output component drives the second linear walking module 6 to move in one direction, while the second linear walking module 6 can drive the top mounting part 7 to move in another direction. The two work together to enable the mounting part 7 to achieve flexible multi-directional position adjustment on the horizontal plane. This multi-dimensional adjustment capability allows assembly 7 to precisely adjust to the appropriate working position according to the welding requirements of flat wire vertically wound PFC inductors of different specifications. This, in turn, drives subsequent connected components such as the first drive component 8 and the second drive component 9 to synchronously adapt to the workpiece position, effectively improving the equipment's adaptability to inductor workpieces of different sizes and models. In actual production, when it is necessary to switch to welding inductors of different specifications, there is no need to change special tooling or significantly adjust the overall structure of the equipment. Position adaptation can be completed simply by controlling the first linear walking module 5 and the second linear walking module 6. This significantly reduces tooling change and equipment debugging time, lowers production switchover costs, and also avoids installation errors that may be introduced by frequent tooling changes, ensuring the consistency of welding quality for workpieces of different specifications.

[0038] Please see Figure 5 and Figure 6 The outer ends of the first transmission component 81 and the second transmission component 91 are connected to the corresponding positions of the inner side of the assembly 7 through bearings. The first transmission component 81 and the second transmission component 91 are both provided with through grooves. The second transmission component 91 is located below the first transmission component 81, and the first transmission component 81 and the second transmission component 91 are arranged in a cross shape. A ball head 13 is inserted into the inner side of the second transmission component 91. A first locking groove 14 is provided in the inner side of the ball head 13 at the position corresponding to the first transmission component 81. A second locking groove 15 is provided in the inner side of the ball head 13 at the position corresponding to the second transmission component 91. A first locking block 141 is inserted into the inner side of the first locking groove 14. The bottom end of the first locking block 141 is connected to the corresponding position of the surface of the assembly 7. A second locking block 151 is inserted into the inner side of the second locking groove 15. The top end of the second locking block 151 is connected to the bottom end of the support component 10.

[0039] Please see Figure 7A laser generator 16 is installed on the outside of the laser welding mechanism 4. A laser welding head 17 is installed on the lower part of the laser welding mechanism 4. A vision inspection component 18 is installed on the outer side of the laser welding mechanism 4. The vision inspection component 18 integrates an industrial camera, an image acquisition card, a light source module, and an image analysis and processing unit. The vision inspection component 18 also integrates an image enhancement module. The image enhancement module is equipped with an adaptive histogram equalization algorithm and a wavelet transform denoising algorithm. The image analysis and processing unit has a built-in deep learning-based image recognition algorithm.

[0040] The laser generator 16 provides a stable energy source for laser welding, ensuring that the laser welding head 17 can output laser energy that meets welding requirements. The laser welding head 17, as the laser energy output terminal, can precisely focus the laser on the welding area, achieving efficient welding of the inductor coil and terminal. The two work together to provide core energy support for the welding process, ensuring smooth welding operations. The vision inspection component 18, mounted on the side of the laser welding mechanism 4, acquires image information of the welding area and workpiece through an industrial camera. The image acquisition card quickly transmits image data, avoiding detection lag caused by data transmission delays. The light source module provides a uniform and stable lighting environment for image acquisition, reducing image quality degradation caused by uneven lighting. The image enhancement module integrated within the vision inspection component 18 improves image contrast through an adaptive histogram equalization algorithm, making workpiece details clearer. It then removes interference noise from the image through a wavelet transform denoising algorithm, further improving image quality and laying a good foundation for subsequent image analysis and processing. The image analysis and processing unit incorporates a deep learning-based image recognition algorithm with powerful feature recognition capabilities. It can accurately identify the positional features of terminals and inductor coil leads, precisely determining their relative positional relationship. Even with minor stains or scratches on the workpiece surface, it can effectively avoid interference, ensuring accurate position detection. This complete visual inspection process of "image acquisition, transmission, enhancement, and recognition" enables precise detection of the workpiece position, providing a reliable basis for subsequent position adjustments. It avoids welding deviations caused by inaccurate position detection, significantly improving welding position accuracy and product quality consistency.

[0041] The welding quality inspection module is integrated inside the laser welding mechanism 4. The welding quality inspection module integrates a solder flow monitoring unit, an appearance inspection unit, and a defect identification unit. The bottom of the laser welding mechanism 4 is equipped with a parameter monitoring and feedback module, which includes a laser energy sensor, a laser movement speed sensor, a temperature sensor, and a data processing and feedback unit. The laser movement speed sensor is equipped with laser Doppler velocimetry technology.

[0042] The welding quality inspection module integrated into the laser welding mechanism 4 tracks the flow of solder in real time during the welding process through the solder flow monitoring unit. It can promptly detect whether the solder is flowing into the terminal threaded hole, avoiding the problem of solder flowing into the threaded hole and causing blockage, which affects subsequent assembly, as is common in traditional welding. The appearance inspection unit inspects the appearance of the weld after welding to determine whether there are appearance defects such as uneven width or uneven surface, ensuring that the weld appearance meets quality standards. The defect identification unit can further identify hidden defects such as cracks and porosity that may exist inside the weld, realizing comprehensive monitoring of welding quality, preventing unqualified products from flowing into subsequent processes, and significantly improving the product qualification rate. The parameter monitoring and feedback module at the bottom of the laser welding mechanism 4 monitors the laser output energy in real time through a laser energy sensor, ensuring that the laser energy is always within a preset reasonable range. This prevents overheating of the welding area due to excessive energy, which could damage the workpiece, or insufficient energy, which could result in a weak weld. The laser movement speed sensor uses laser Doppler velocimetry technology to accurately measure the movement speed of the laser welding head 17, ensuring stable welding speed and preventing uneven weld quality due to speed fluctuations. The temperature sensor monitors the temperature of the welding area and key components of the equipment, preventing overheating that could cause equipment failure or affect welding quality. The data processing and feedback unit analyzes the data collected by each sensor. If any parameter deviation is detected, a feedback signal is immediately sent to the central control module, which then adjusts the laser welding parameters in a timely manner. This forms a closed-loop control system of "parameter monitoring, analysis, feedback, and adjustment," ensuring that laser welding is always performed under optimal parameter conditions. This effectively improves the stability of welding quality and reduces welding defects caused by parameter fluctuations.

[0043] The welding quality inspection module also integrates a data preprocessing unit. This unit connects to the solder flow monitoring unit, appearance inspection unit, and defect identification unit via data cables. The data preprocessing unit processes the collected raw data, filters out interfering data, and standardizes and integrates the data, converting heterogeneous data into a unified format. The defect identification unit includes a defect classification and grading subunit. This subunit pre-stores 30 sets of welding defect feature models and corresponding quality grade standards. The quality grade standards are determined based on process test data from flat wire vertical winding PFC inductive laser welding. Cluster analysis extracts 30 typical welding defect features, covering all common defect types in this process, such as solder overflow, porosity, cracks, cold solder joints, and uneven weld seams. If a standard lower than 30 is used... The number of models in a set will not be able to fully encompass the typical welding defects of the process, leading to missed defects in the identification. Using 30 models can achieve accurate identification of welding defects in the process without the need for more models, thus avoiding data redundancy that affects the identification efficiency. The defect identification unit is connected to the data transmission end of the vision inspection component 18 via a data cable.

[0044] The data preprocessing unit within the welding quality inspection module establishes data connections with various inspection units, centrally receiving raw data collected by the solder flow monitoring unit, appearance inspection unit, and defect identification unit. During actual inspection, raw data may be affected by factors such as equipment vibration and environmental electromagnetic interference, resulting in some interfering data. The data preprocessing unit effectively filters this interfering data, ensuring the authenticity and accuracy of the data. Simultaneously, the data formats output by different inspection units may differ. The data preprocessing unit standardizes and integrates heterogeneous data into a unified format, facilitating unified analysis and retrieval of data by the subsequent defect identification unit and central control module, avoiding low data processing efficiency or analysis errors caused by inconsistent data formats. The defect classification and grading subunit within the defect identification unit pre-stores multiple sets of common welding defect feature models and quality grade standards. When the defect identification unit detects a welding defect, it compares the defect features with the pre-stored models to quickly determine the defect type, such as cracks, porosity, or incomplete soldering. Simultaneously, it determines the severity of the defect based on the quality grade standards, providing clear defect information to the staff. Furthermore, the data connection between the defect identification unit and the visual inspection component 18 allows the acquisition of image data collected by the visual inspection component 18 as an auxiliary basis for judgment, further improving the accuracy of defect identification and avoiding misjudgments caused by a single data source. This design of data preprocessing and precise defect classification not only improves the data processing efficiency and accuracy of welding quality inspection, but also provides detailed defect data support for subsequent quality control and process optimization. Staff can formulate targeted improvement measures based on defect type and level to continuously improve welding process level and product quality.

[0045] The central control module adopts an embedded industrial computer architecture. The motherboard of the central control module integrates 5-10 IO interfaces and analog input channels. The software system of the central control module is developed based on a real-time operating system and is equipped with a task scheduling function. The control program of the central control module includes a parameter configuration interface, a manual debugging interface, and an automatic operation interface. The interface interaction logic of the central control module adopts a state machine design pattern. The light source module includes a light source controller and a ring shadowless LED light source array. The control terminal of the ring shadowless LED light source array adopts a regional dimming design. The light source controller has a built-in light intensity feedback adjustment circuit. The light intensity feedback adjustment circuit monitors the emitted light intensity in real time through photodiodes. The lens of the industrial camera is equipped with an electric zoom mechanism.

[0046] The central control module adopts an embedded industrial computer architecture, boasting advantages such as small size, high stability, and fast processing speed. It can adapt to complex working conditions in industrial production environments, ensuring long-term stable operation and providing a reliable hardware foundation for the coordinated control of various modules. The motherboard integrates multiple I / O interfaces and analog input channels, allowing simultaneous connection to multiple components such as the laser welding mechanism 4, vision inspection component 18, and welding quality inspection module. This enables simultaneous data acquisition and command issuance from multiple modules, avoiding limitations on module connectivity due to insufficient interfaces and improving the equipment's scalability and compatibility. The software system and task scheduling function, developed based on a real-time operating system, can rationally schedule various tasks of the equipment. Tasks such as welding operations, position detection, and parameter monitoring can be executed in parallel, avoiding equipment lag or response delays caused by task conflicts and ensuring smooth and efficient equipment operation. The control program includes a parameter configuration interface for easy adjustment of welding and inspection parameters according to different workpiece welding requirements; a manual debugging interface for manual operation during equipment installation and debugging or in case of abnormalities; and an automatic operation interface supporting fully automated welding operations in mass production, meeting operational needs in different scenarios. The user interface logic employs a state machine design pattern, ensuring clear operation and stable state transitions, thus improving the operator experience and reducing equipment malfunctions caused by operational errors. The light source module's light source controller works in conjunction with a ring-shaped shadowless LED light source array to provide uniform illumination for visual inspection. The zoned dimming design adjusts the light intensity of different areas within the welding zone according to their illumination requirements, ensuring uniform illumination. The light intensity feedback adjustment circuit monitors the light intensity in real time via photodiodes; if the light intensity deviates from the preset value, it promptly adjusts the light source output to maintain stable illumination and prevent light variations from affecting image acquisition quality. The industrial camera lens's motorized zoom mechanism allows for flexible adjustment of the lens focal length based on workpiece distance or inspection requirements, clearly capturing workpiece details at different distances without requiring manual focus adjustment. This enhances the flexibility and efficiency of visual inspection, further ensuring image clarity and inspection accuracy.

[0047] This solution uses the first driving component 8 to drive the movement of the first transmission component 81 and the second driving component 9 to drive the movement of the second transmission component 91, thereby enabling the support component 10 and the load-bearing component 11 to tilt in the left-right and front-back directions. This allows for automatic adjustment when the workpiece is clamped by the fixture 12 and the visual inspection component 18 detects that the position of the workpiece's terminals and the inductor coil lead wire is incorrect. This ensures that the inductor coil lead wire is accurately positioned in the middle of the terminal, avoiding the operational errors and inefficiencies of manual adjustment, reducing production interruptions caused by manual intervention, and improving the overall welding operation efficiency.

[0048] This solution, through its welding quality detection module, can track and monitor laser parameters in real time during the laser welding process, improving the stability of welding quality and compensating for the shortcomings of traditional laser welding equipment caused by parameter fluctuations. Furthermore, under the control of the central control module, it can work with relevant detection components to track the energy and movement of the laser in real time, avoiding problems such as insufficient welding strength and uneven welds caused by unstable laser parameters, and reducing the probability of welding defects.

Claims

1. A flat wire vertical winding PFC inductive vision laser welding equipment, characterized in that, include: The main control box (1) is equipped with a control body (2) on its side. The main control box (1) is equipped with a laser welding mechanism (4) on its exterior. The control body (2) is equipped with a central control module inside. The central control module adopts an embedded industrial control computer architecture. The first linear walking module (5) is installed on the top of the main control box (1). The output component of the first linear walking module (5) is equipped with a second linear walking module (6). The top of the second linear walking module (6) is equipped with a mounting part (7). The first drive member (8) is connected to the front side of the assembly (7), and the second drive member (9) is installed on the side of the assembly (7). The output end of the first drive member (8) is connected to the first transmission member (81), and the output shaft of the second drive member (9) is equipped with the second transmission member (91). A support member (10) is inserted in the middle of the first transmission member (81) and the second transmission member (91), and a clamp (12) is provided on the top of the support member (10). A laser generator (16) is installed on the outside of the laser welding mechanism (4). The laser welding mechanism (4) is equipped with a vision inspection component (18). The vision inspection component (18) integrates an industrial camera, an image acquisition card, a light source module, and an image analysis and processing unit. The vision inspection component (18) also integrates an image enhancement module. The image enhancement module is a software algorithm module and has built-in adaptive histogram equalization algorithm and wavelet transform denoising algorithm. The image enhancement function is realized by mounting it on the hardware carrier of the image analysis and processing unit. The welding quality inspection module is integrated inside the laser welding mechanism (4). The welding quality inspection module integrates a solder flow monitoring unit, an appearance inspection unit, and a defect identification unit. The defect identification unit is equipped with a defect classification and grade determination subunit. The defect classification and grade determination subunit achieves grade determination by matching the collected welding defect features with the pre-stored defect feature model. The welding quality inspection module also integrates a data preprocessing unit. The welding quality inspection module and the vision inspection component (18) establish a bidirectional data connection through a data cable. The two share the image data collected by the vision inspection component (18). The inspection data of the welding quality inspection module is synchronously transmitted to the image analysis and processing unit of the vision inspection component (18). The bottom of the laser welding mechanism (4) is equipped with a parameter monitoring and feedback module. The parameter monitoring and feedback module includes a laser energy sensor, a laser moving speed sensor, a temperature sensor, and a data processing and feedback unit. The parameter monitoring and feedback module is used to monitor the laser output energy, the laser welding head moving speed, and the temperature parameters of the welding area in real time. The data processing and feedback unit establishes a one-way data transmission connection with the central control module through a data line. It is used to feed back the monitored parameter data to the central control module, and the central control module issues instructions to adjust the working parameters of the laser welding mechanism (4).

2. The flat wire vertical winding PFC inductive vision laser welding equipment according to claim 1, characterized in that: The outer ends of the first transmission component (81) and the second transmission component (91) are connected to the corresponding positions on the inner side of the assembly (7) through bearings. The first transmission component (81) and the second transmission component (91) are both provided with through slots. The second transmission component (91) is located below the first transmission component (81) and is arranged in a cross shape.

3. The flat wire vertical winding PFC inductive vision laser welding equipment according to claim 1, characterized in that: A ball head (13) is inserted into the inner side of the second transmission member (91). A first locking groove (14) is opened in the inner side of the ball head (13) at a position corresponding to the first transmission member (81). A second locking groove (15) is opened in the inner side of the ball head (13) at a position corresponding to the second transmission member (91).

4. The flat wire vertical winding PFC inductive vision laser welding equipment according to claim 3, characterized in that: The first snap-fit ​​groove (14) is provided with a first snap-fit ​​block (141) inserted inside. The bottom end of the first snap-fit ​​block (141) is connected to the corresponding position on the surface of the assembly (7). The second snap-fit ​​groove (15) is provided with a second snap-fit ​​block (151) inserted inside. The top end of the second snap-fit ​​block (151) is connected to the bottom end of the support member (10).

5. The flat wire vertical winding PFC inductive vision laser welding equipment according to claim 1, characterized in that: The image enhancement module is equipped with an adaptive histogram equalization algorithm and a wavelet transform denoising algorithm, and the image analysis and processing unit has a built-in deep learning-based image recognition algorithm.

6. The flat wire vertical winding PFC inductive vision laser welding equipment according to claim 1, characterized in that: The parameter monitoring and feedback module includes a laser energy sensor, a laser motion speed sensor, a temperature sensor, and a data processing and feedback unit. The laser motion speed sensor is equipped with laser Doppler velocimetry technology.

7. The flat wire vertical winding PFC inductive vision laser welding equipment according to claim 1, characterized in that: The data preprocessing unit establishes data connections with the solder flow monitoring unit, appearance inspection unit, and defect identification unit via data cables. The data preprocessing unit is used to process the collected raw data, filter out interfering data, and then standardize and integrate the data to convert different heterogeneous data into a unified format.

8. The flat wire vertical winding PFC inductive vision laser welding equipment according to claim 1, characterized in that: The defect classification and grade determination subunit has 30 sets of welding defect feature models and corresponding quality grade standards under the flat wire vertical winding PFC inductive laser welding process in advance. The defect identification unit is connected to the data transmission end of the vision inspection component (18) through a data line.

9. The flat wire vertical winding PFC inductive vision laser welding equipment according to claim 1, characterized in that: The central control module's motherboard integrates 5-10 I / O interfaces and analog input channels. The software system of the central control module is developed based on a real-time operating system and has a task scheduling function. The control program of the central control module includes a parameter configuration interface, a manual debugging interface, and an automatic operation interface. The interface interaction logic of the central control module adopts a state machine design pattern.

10. A flat wire vertical winding PFC inductive vision laser welding equipment according to claim 1, characterized in that: The light source module includes a light source controller and a ring-shaped shadowless LED light source array. The control terminal of the ring-shaped shadowless LED light source array adopts a regional dimming design. The light source controller has a built-in light intensity feedback adjustment circuit, which monitors the emitted light intensity in real time through a photodiode. The lens of the industrial camera is equipped with an electric zoom mechanism.

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