An automated packaging method, system, and packaging device for a gas sensor.

Abstract

This application relates to the field of gas sensor packaging technology, specifically to an automated packaging method, system, and packaging device for gas sensors. The method includes: pre-establishing a packaging process parameter-gas-sensitive channel adaptation model; calculating the actual coaxiality deviation and correcting the sealing pressure reference value based on the gas-sensitive channel aperture; starting the integrated packaging unit, applying pre-pressure according to the corrected sealing pressure, and simultaneously collecting the temperature of the sealing area through an infrared temperature measurement module to determine whether dynamic adjustment of the welding temperature is needed; after welding, maintaining the corrected sealing pressure, and dynamically adjusting the pressure holding time based on the gas-sensitive channel length and the creep coefficient of the sealing material to complete the sealing process. This application achieves a precise balance between sealing performance and conduction efficiency by establishing a dynamic adaptation model of process parameters and gas-sensitive channel structure, overcoming the coupling imbalance bottleneck of existing technologies.

Description

Technical Field

[0001] This application relates to the field of gas sensor packaging technology, specifically to an automated packaging method, system, and packaging device for a gas sensor. Background Technology

[0002] Gas sensors, as core components for gas detection and monitoring, are widely used in industrial safety, environmental monitoring, smart homes, and other fields. Their packaging quality directly determines the sensor's detection accuracy, response speed, and lifespan. The core technical challenge in the packaging process lies in achieving a dynamic balance between "gas-sensitive channel conduction" and "packaging sealing"—ensuring efficient contact between the gas-sensitive material and the gas to be measured while simultaneously isolating external interference factors such as dust and moisture through a sealed structure.

[0003] Existing automated packaging technologies commonly suffer from a "sealing-conduction coupling imbalance": key process parameters such as sealing pressure and welding temperature are fixed, lacking a dynamic adaptation mechanism with the structural parameters (aperture and length) of the gas-sensitive channel. Specifically, the sealing pressure is preset solely based on the hardness of the packaging material, without considering the nonlinear effects of the gas-sensitive channel aperture. When the aperture is small, a fixed sealing pressure easily leads to channel compression and deformation, reducing the conduction cross-sectional area and decreasing the sensor's response speed. When the aperture is large, a fixed sealing pressure fails to create an effective seal, allowing external interference to easily penetrate the sensor and causing drift in detection accuracy. Simultaneously, heat conduction during welding alters the elastic modulus of the sealing material, further exacerbating the coupling imbalance between sealing pressure and gas-sensitive channel conduction. This results in significant fluctuations in response speed and decreased detection accuracy during mass production, leading to poor gas sensor manufacturing performance. Summary of the Invention

[0004] To address the aforementioned technical problems, the purpose of this application is to provide an automated packaging method, system, and packaging device for gas sensors. The specific technical solution adopted is as follows: In a first aspect, embodiments of this application provide an automated packaging method for a gas sensor, the method comprising the following steps: Pre-establish packaging process parameters - gas-sensitive channel adaptation model. Input the core parameters of the gas sensor to be packaged, including the gas-sensitive channel aperture d, gas-sensitive channel length L, and sealing material elastic modulus E. Output the corresponding packaging process parameters, including the sealing pressure reference value. Welding temperature range, initial holding time ; The spatial distance between the gas-sensitive channel and the packaging base is collected by a combination of an industrial camera and a laser rangefinder, and the actual coaxiality deviation is calculated. And the sealing pressure reference value is corrected by combining the gas-sensitive channel orifice diameter d; Start the integrated packaging unit, apply pre-pressure according to the corrected sealing pressure, and simultaneously collect the temperature of the sealing area through the infrared temperature measurement module to determine whether the welding temperature needs to be dynamically adjusted. After welding is completed, maintain the corrected sealing pressure and dynamically adjust the pressure holding time according to the length L of the gas-sensitive channel and the creep coefficient of the sealing material to complete the sealing process.

[0005] Preferably, the method for correcting the sealing pressure reference value is as follows: based on the sealing pressure reference value, the corrected sealing pressure is obtained by coupling calculation of the gas-sensitive channel aperture adaptation coefficient and the coaxiality deviation compensation coefficient, which is used to achieve dynamic matching between the sealing pressure and the gas-sensitive channel specifications and assembly accuracy.

[0006] Preferably, the welding temperature range is determined according to the type of sealing material: when the sealing material is silicone rubber, the temperature range is 120~150℃; when the sealing material is polytetrafluoroethylene, the temperature range is 200~230℃.

[0007] Preferably, the method for determining whether dynamic adjustment of the welding temperature is needed is as follows: when the measured temperature of the sealing area deviates from the specified value... The welding temperature is dynamically adjusted when a preset fluctuation threshold is reached. This is the preset thermal stability temperature of the sealing material.

[0008] Preferably, the method for dynamically adjusting the welding temperature is as follows: by combining the thermoelastic properties of the sealing material, the welding temperature is dynamically calibrated according to the deviation between the real-time welding temperature and the thermal stability temperature of the sealing material to maintain the stability of the sealing material performance.

[0009] Preferably, the dynamic adjustment method for the pressure holding time is as follows: based on the initial pressure holding time... Based on this, the adjusted pressure holding time is obtained through the linkage calculation of the gas-sensitive channel length adaptation coefficient and the material creep coefficient, which is used to achieve dynamic adaptation between the pressure holding time and the gas-sensitive channel structure and sealing material characteristics.

[0010] Preferably, after the sealing process is completed, the process further includes airtightness testing and electrical performance testing of the packaged sensor, and feeding the test results back to the adaptation model for parameter optimization so as to update the adaptation model in real time.

[0011] Preferably, the airtightness test adopts the differential pressure method, and the electrical performance test includes response speed and detection accuracy tests. The response speed test adopts the standard gas concentration step method, and the detection accuracy test adopts the multi-point calibration method.

[0012] Secondly, embodiments of this application provide an automated packaging system for a gas sensor, implementing the automated packaging method described above. The system includes: The parameter modeling module is used to pre-establish the packaging process parameters-gas-sensitive channel adaptation model. It takes the core parameters of the gas sensor to be packaged as input and outputs the corresponding packaging process parameters. The collaborative positioning and parameter correction module is used to collaboratively acquire the spatial distance between the gas-sensitive channel and the packaging base through an industrial camera and a laser rangefinder, and to calculate the actual coaxiality deviation. And the sealing pressure reference value is corrected by combining the gas-sensitive channel orifice diameter d; The thermal-mechanical coordinated control module is used to start the integrated packaging unit, apply pre-pressure according to the corrected sealing pressure, and simultaneously collect the temperature of the sealing area through the infrared temperature measurement module to determine whether the welding temperature needs to be dynamically adjusted. After welding is completed, the corrected sealing pressure is maintained, and the pressure holding time is dynamically adjusted according to the gas-sensitive channel length L and the creep coefficient of the sealing material to complete the sealing process. The detection and optimization module is used to perform airtightness detection and electrical performance testing on the packaged sensor, and feed the detection results back to the adaptation model for parameter optimization, so as to update the adaptation model in real time. The central control module coordinates the workflow of each module, stores process parameters, test data and adaptation models, and realizes full-process automated control.

[0013] Thirdly, embodiments of this application also provide an automated packaging apparatus for a gas sensor. The system includes a memory, a processor, and a computer program stored in the memory and running on the processor. When the processor executes the computer program, it implements the steps of any one of the above-described automated packaging methods for a gas sensor.

[0014] As can be seen from the above embodiments, the automated packaging method, system, and packaging device for a gas sensor provided in this application have at least the following beneficial effects: 1. This application establishes a packaging process parameter-gas-sensitive channel adaptation model to achieve accurate mapping between the core parameters of the sensor and the initial process parameter set, providing an adaptability benchmark for subsequent full-process dynamic packaging, avoiding the problem of mismatch between general fixed parameters and specific sensors from the source, and laying the foundation for the balance between sealing and conduction.

[0015] 2. This application uses visual positioning and laser ranging to collect data and correct sealing pressure, thereby achieving dynamic adaptation between sealing pressure and gas-sensitive channel specifications and assembly precision. This effectively avoids packaging defects caused by channel deformation or uneven stress on the sealing surface, and improves packaging precision and stability.

[0016] 3. This application dynamically adjusts the welding temperature based on the thermoelastic properties of the sealing material, which can compensate for temperature interference during the welding process, maintain the stability of the sealing material performance, and form a synergistic control with the corrected sealing pressure, further optimizing the sealing-conduction balance effect and ensuring the compatibility of welding and sealing processes.

[0017] 4. This application combines the length of the gas-sensitive channel with the creep characteristics of the sealing material to dynamically adjust the pressure holding time, which can be specifically adapted to the sealing requirements of different structures and materials, avoiding seal loosening or channel deformation caused by improper pressure holding, and consolidating the reliability of the packaging structure.

[0018] 5. This application optimizes the adaptation model through feedback of test results, realizes continuous iterative updates of process parameters, and improves the model adaptation accuracy. It can not only adapt to the packaging requirements of gas sensors of different specifications, but also steadily improve the packaging consistency and overall efficiency of mass production. Attached Figure Description

[0019] To more clearly illustrate the technical solutions and advantages in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a flowchart illustrating the steps of an automated packaging method for a gas sensor, as provided in one embodiment of this application. Detailed Implementation

[0021] To further illustrate the technical means and effects adopted by this application to achieve the intended inventive purpose, the following, in conjunction with the accompanying drawings and preferred embodiments, details the specific implementation, structure, features, and effects of an automated packaging method, system, and packaging device for a gas sensor according to this application. In the following description, different "one embodiment" or "another embodiment" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0022] Unless otherwise specified and limited, terms such as “comprising,” “including,” or any other variations thereof are intended to cover a non-exclusive inclusion, such that a circuit structure, article, or device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such an article or device. Without further limitation, an element defined by the phrase “comprising one…” does not exclude the presence of other identical elements in the article or device that includes said element. Furthermore, the term “and / or” as used herein includes any and all combinations of one or more of the associated listed items. All technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0023] The following description, in conjunction with the accompanying drawings, details the specific scheme of the automated packaging method, system, and packaging device for a gas sensor provided in this application.

[0024] Example 1: This example uses the automated packaging of an MQ-135 gas sensor (gas-sensitive channel aperture d=2mm, gas-sensitive channel length L=5mm, sealing material is silicone rubber, elastic modulus E=0.8MPa) as an example to illustrate the specific implementation process of an automated packaging method for a gas sensor.

[0025] Please see Figure 1 The diagram illustrates a flowchart of an automated packaging method for a gas sensor provided in this embodiment. The method includes the following steps: 1.1. Pre-establish packaging process parameters - gas-sensitive channel adaptation model. Input the core parameters of the gas sensor to be packaged, including the gas-sensitive channel aperture d, channel length L, and elastic modulus E of the sealing material. Output the corresponding packaging process parameters, including the sealing pressure reference value. Welding temperature range, initial holding time .

[0026] The pre-established adaptation model is constructed in the following way: First, core parameters (gas-sensitive channel aperture, channel length, elastic modulus of sealing material, etc.) of gas sensors of different specifications are collected along with corresponding packaging process parameters and sensor performance test data to establish a multi-dimensional sample database; then, based on the sample data, a machine learning algorithm (in this embodiment, a gradient descent optimized neural network is used, which is a well-known technology and will not be described in detail) is used to train the model, fit the mapping relationship between the core parameters and the corresponding packaging process parameters, and embed sealing-conduction balance constraints to iteratively optimize the model parameters to reduce prediction errors; finally, the model accuracy is calibrated through multiple sets of verification experiments to ensure that the output corresponding packaging process parameters can adapt to the packaging requirements of the corresponding sensor.

[0027] It should be noted that the welding temperature range is determined according to the type of sealing material: when the sealing material is silicone rubber, the temperature range is 120~150℃; when the sealing material is polytetrafluoroethylene, the temperature range is 200~230℃. The sealing material used in this embodiment is silicone rubber.

[0028] 1.2. The spatial distance between the gas-sensitive channel and the packaging base is collected by a combination of an industrial camera and a laser rangefinder to calculate the actual coaxiality deviation. The sealing pressure reference value is corrected by combining the gas-sensitive channel orifice diameter d.

[0029] It should be noted that the spatial distance refers to the distance between the center coordinates of the gas-sensitive channel and the reference coordinates of the encapsulation sealing surface. The reference coordinates of the encapsulation sealing surface are the spatial coordinates of a preset reference positioning point on the sealing contact surface of the encapsulation base. These coordinates serve as a reference for the positioning calibration of the gas-sensitive channel, and are primarily used to quantify the spatial positional deviation between the center of the gas-sensitive channel and the sealing surface, ensuring precise alignment between the sealing surface and the gas-sensitive channel when sealing pressure is applied. These reference coordinates correspond to the core positioning area of ​​the sealing surface, and are typically formed by fitting a pair of preset reference points on the encapsulation base to create a spatial reference coordinate system for the sealing surface, ensuring positioning accuracy and encapsulation consistency.

[0030] Furthermore, this application uses the sealing pressure reference value as a basis and calculates the corrected sealing pressure by coupling the gas-sensitive channel aperture adaptation coefficient and the coaxiality deviation compensation coefficient, which is used to achieve dynamic matching between the sealing pressure and the gas-sensitive channel specifications and assembly accuracy.

[0031] Specifically, in this embodiment, according to the correction formula (Where P is the corrected sealing pressure,) For standard gas-sensitive channel aperture, To determine the maximum permissible coaxiality deviation, this embodiment sets the maximum permissible coaxiality deviation. For the sealing pressure reference value Perform dynamic corrections.

[0032] It should be noted that this correction method, on the one hand, involves... The coefficient adapts to the differences in orifice diameter of different gas-sensitive channels. When the orifice diameter is small, the pressure is reduced to avoid channel compression and deformation, and reduction of the conduction cross-sectional area. When the orifice diameter is large, the pressure is appropriately increased to ensure tight sealing, thus solving the problem that a fixed pressure cannot adapt to multiple channel specifications. On the other hand, through... The coefficient compensates for coaxiality assembly deviations, avoiding uneven stress on the sealing surface caused by deviations. This prevents excessive local pressure from squeezing the channel and insufficient local pressure from causing sealing gaps. At the same time, it avoids thermal-mechanical coupling interference for subsequent welding processes, reduces the impact of welding heat conduction on the elastic modulus of the sealing material, and reduces the risk of sealing-conduction coupling imbalance from the source.

[0033] In this embodiment, when the actual coaxiality deviation Exceeding the maximum permissible coaxiality deviation At that time, the piezoelectric ceramic fine-tuning mechanism automatically corrects the error. Less than the maximum permissible coaxiality deviation Then, substitute the values ​​into the formula to calculate the corrected sealing pressure.

[0034] 1.3 Start the integrated packaging unit, apply pre-pressure according to the corrected sealing pressure, and simultaneously collect the temperature of the sealing area through the infrared temperature measurement module to determine whether the welding temperature needs to be dynamically adjusted.

[0035] It should be noted that the infrared temperature measurement module is a non-contact temperature detection component in the integrated packaging assembly of this application. Its core function is to collect real-time temperature data from the sealing and welding areas, providing accurate feedback for dynamic adjustment of the welding temperature and meeting the requirements for non-contact temperature measurement and rapid response during the packaging process. Its core components include an infrared detector, an optical focusing assembly, and a signal processing unit. Its working principle is based on the blackbody radiation law, capturing the infrared radiation energy emitted by the sealing material and welding area, converting it into a corresponding temperature electrical signal, and outputting an accurate temperature value after calibration by the signal processing unit. It does not require direct contact with the object being measured, thus avoiding physical interference or contamination to the sealing surface and welding area.

[0036] Furthermore, the method used in this application to determine whether dynamic adjustment of the welding temperature is necessary is as follows: When the measured temperature of the sealed area deviates When a preset fluctuation threshold is reached, this application dynamically calibrates the welding temperature based on the deviation between the real-time welding temperature and the thermal stability temperature of the sealing material, taking into account the thermoelastic properties of the sealing material, to maintain the stability of the sealing material's performance; wherein, This is the preset thermal stability temperature of the sealing material.

[0037] The preset fluctuation threshold is a range of allowable temperature fluctuations set based on the thermal stability of the sealing material and the precision requirements of the welding process. There is no fixed, uniform value; it needs to be set appropriately for the type of sealing material. Its core function is to trigger dynamic adjustments to the welding temperature. In this embodiment, the preset fluctuation threshold is obtained manually by the operator based on the specific sealing material model, and is ultimately incorporated into the initial process parameter set and synchronously sent to the thermo-mechanical co-control module.

[0038] Specifically, in this embodiment, the infrared temperature measurement module collects the temperature of the sealing area in real time. The initial welding temperature is set to a preset thermal stability temperature T0 of the sealing material. When the measured temperature of the sealing area deviates from the preset temperature, the module will automatically adjust the temperature accordingly. When the preset fluctuation threshold is reached, based on the formula (in The calibrated welding temperature is T, where T is the real-time temperature measurement of the welding sealing area, and k is the thermoelastic coefficient of the sealing material. In this embodiment, the thermoelastic coefficient of the sealing material is... , The welding temperature is dynamically adjusted based on the preset thermal stability temperature of the sealing material.

[0039] It should be noted that this parameter adjustment step can effectively compensate for heat conduction loss and ambient temperature disturbance during the welding process, and precisely control the welding temperature within the preset range. This avoids both excessively high temperatures that could cause aging of the sealing material and a sharp drop in elastic modulus, and excessively low temperatures that could lead to insufficient welding strength and loose sealing surfaces. On the other hand, by establishing a linkage mechanism between temperature and sealing material performance through the thermoelastic coefficient k, it ensures that the rate of change of the elastic modulus of the sealing material during the welding process is controlled within the preset range. This works in conjunction with the previously corrected sealing pressure to further mitigate the risk of sealing-conduction coupling imbalance and ensure the stability of the sensor's sealing performance and gas-sensitive channel conduction efficiency after packaging.

[0040] 1.4 After welding, maintain the corrected sealing pressure and dynamically adjust the pressure holding time according to the length L of the gas-sensitive channel and the creep coefficient of the sealing material to complete the sealing process; In this application, the dynamic adjustment method for the holding time is as follows: based on the initial holding time... Based on this, the adjusted pressure holding time is obtained through the linkage calculation of the gas-sensitive channel length adaptation coefficient and the material creep coefficient, which is used to achieve dynamic adaptation between the pressure holding time and the gas-sensitive channel structure and sealing material characteristics.

[0041] Specifically, in this embodiment, the adjustment formula for the pressure holding time is used. (where t is the adjusted holding time,) The initial pressure holding time is L, and the length of the gas-sensitive channel is L. For standard gas-sensitive channel length, The pressure holding time compensation coefficient ranges from 0.2 to 0.5. Its purpose is to ensure that changes in the gas-sensitive channel length L significantly affect the pressure holding time. This embodiment sets... Dynamically adjust the pressure holding time.

[0042] It should be noted that this adjustment step can specifically compensate for the creep differences of sealing materials under different gas-sensitive channel lengths, avoid insufficient pressure holding leading to loosening of the sealing structure, or excessive pressure holding causing channel deformation, further consolidate the sealing-conduction balance effect, and maintain constant pressure until the adjusted duration to complete the sealing process.

[0043] 1.5 After completing the sealing process, the airtightness and electrical performance of the encapsulated sensor are tested. The test results are fed back to the adaptation model for parameter optimization, so as to update the adaptation model in real time.

[0044] The airtightness test adopts the differential pressure method. The packaged sensor is tested according to the preset test pressure and preset pressure holding time. After the test, the pressure leakage is within the allowable range, which meets the airtightness requirements.

[0045] The specific operation procedure for testing the airtightness of the packaged sensor using the differential pressure method is as follows: First, gas is filled into the sealed cavity of the packaged sensor to the preset test pressure using the differential pressure airtightness tester of the integrated testing component. Then, the gas filling circuit is closed and the pressure holding time is started. During the preset pressure holding time, the pressure change in the cavity is monitored in real time. If the pressure leakage is controlled within the allowable range after the test, the airtightness requirement is met. The preset detection pressure and preset holding time are both retrieved from the initial process parameter set (the adaptation model is based on the sensor specification output), and can also be fine-tuned according to the characteristics of the sealing material and the requirements for packaging accuracy to ensure that the detection standard and packaging process are compatible. The determination of the allowable pressure leakage range is based on a comprehensive setting of the sensor application scenario, the characteristics of the sealing material, and the requirements for detection accuracy: First, the basic range is initially defined by combining the sealing level requirements of the actual application environment of the sensor; then, the range boundary is calibrated through thermo-mechanical coupling analysis based on the air permeability coefficient of the sealing material and the sealing area of ​​the packaging structure; finally, through multiple sets of packaging verification experiments, the final allowable range that can both ensure the long-term stability of the sensor and be compatible with batch detection efficiency is determined. The specific parameter settings are set by the implementer according to the actual situation, and will not be elaborated further.

[0046] Furthermore, the electrical performance testing includes response speed and detection accuracy testing: the response speed test uses the standard gas concentration step method, and the detection accuracy test uses the multi-point calibration method. The response speed is tested using the standard gas concentration step method, and the detection accuracy is tested using the multi-point calibration method; both meet the preset performance standards.

[0047] The test results are input into the adaptation model, and the process parameter set is optimized through the gradient descent algorithm to update the corresponding sealing pressure benchmark value, which is then used for the subsequent packaging production of the same model of sensor, continuously improving the consistency of batch packaging.

[0048] Example 2: Based on the same inventive concept as the above method, this application also provides an automated packaging system for a gas sensor. This automated packaging system is used in conjunction with the above method and includes: The parameter modeling module is used to pre-establish the packaging process parameters-gas-sensitive channel adaptation model. It takes the core parameters of the gas sensor to be packaged as input and outputs the corresponding packaging process parameters.

[0049] The collaborative positioning and parameter correction module is used to collaboratively acquire the spatial distance between the gas-sensitive channel and the packaging base through an industrial camera and a laser rangefinder, and to calculate the actual coaxiality deviation. The sealing pressure reference value is corrected by combining the gas-sensitive channel orifice diameter d.

[0050] The thermal-mechanical coordinated control module is used to start the integrated packaging unit, apply pre-pressure according to the corrected sealing pressure, and simultaneously collect the temperature of the sealing area through the infrared temperature measurement module to determine whether the welding temperature needs to be dynamically adjusted. After welding is completed, the corrected sealing pressure is maintained, and the pressure holding time is dynamically adjusted according to the gas-sensitive channel length L and the creep coefficient of the sealing material to complete the sealing process.

[0051] The integrated packaging unit combines a welding unit and a sealing unit, and has built-in pressure and temperature sensors to perform welding and sealing operations and provide real-time feedback on process parameters.

[0052] The detection and optimization module is used to perform airtightness testing and electrical performance testing on the packaged sensor, and feeds the detection results back to the adaptation model for parameter optimization, so as to update the adaptation model in real time.

[0053] The central control module coordinates the workflow of each module, stores process parameters, test data and adaptation models, and realizes full-process automated control.

[0054] The system's workflow is as follows: The parameter modeling module receives core sensor parameters via industrial Ethernet, calls the built-in process parameter-gas-sensitive channel adaptation model to output an initial set of process parameters, and transmits it to the central control module; the collaborative positioning and parameter correction module collects spatial position data in real time, calculates coaxiality deviation, and corrects process parameters; the thermo-mechanical collaborative control module dynamically adjusts the welding temperature using infrared temperature measurement data to ensure stable performance of the sealing material; the integrated packaging module, under the coordination of the central control module, performs welding and sealing operations and collects pressure and temperature feedback data in real time; after completing airtightness and electrical performance testing, the detection and optimization module generates a test report and feeds it back to the parameter modeling module to drive model parameter optimization.

[0055] Example 3: Based on the same inventive concept as the above method, this application embodiment also provides an automated packaging device for a gas sensor, including a memory, a processor, and a computer program stored in the memory and running on the processor. When the processor executes the computer program, it implements the automated packaging method for a gas sensor described above.

[0056] The various embodiments in this application are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.

[0057] It should be noted that, unless otherwise specified and limited, terms such as “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a circuit structure, article, or device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such article or device. Without further limitations, an element defined by the phrase “comprising one…” does not exclude the presence of other identical elements in the article or device that includes said element. Furthermore, the term “and / or” as used herein includes any and all combinations of one or more of the associated listed items.

[0058] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the invention herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not invented in this application.

[0059] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope.

Claims

1. An automated packaging method for a gas sensor, characterized in that, The method includes the following steps: Pre-establish packaging process parameters - gas-sensitive channel adaptation model. Input the core parameters of the gas sensor to be packaged, including the gas-sensitive channel aperture d, gas-sensitive channel length L, and sealing material elastic modulus E. Output the corresponding packaging process parameters, including the sealing pressure reference value. Welding temperature range, initial holding time ; The spatial distance between the gas-sensitive channel and the packaging base is collected by a combination of an industrial camera and a laser rangefinder, and the actual coaxiality deviation is calculated. And the sealing pressure reference value is corrected by combining the gas-sensitive channel orifice diameter d; Start the integrated packaging unit, apply pre-pressure according to the corrected sealing pressure, and simultaneously collect the temperature of the sealing area through the infrared temperature measurement module to determine whether the welding temperature needs to be dynamically adjusted. After welding is completed, maintain the corrected sealing pressure and dynamically adjust the pressure holding time according to the length L of the gas-sensitive channel and the creep coefficient of the sealing material to complete the sealing process.

2. The automated packaging method for a gas sensor as described in claim 1, characterized in that, The method for correcting the sealing pressure reference value is as follows: based on the sealing pressure reference value, the corrected sealing pressure is obtained by coupling calculation of the gas-sensitive channel orifice diameter adaptation coefficient and the coaxiality deviation compensation coefficient, which is used to achieve dynamic matching between the sealing pressure and the gas-sensitive channel specifications and assembly accuracy.

3. The automated packaging method for a gas sensor as described in claim 1, characterized in that, The welding temperature range is determined according to the type of sealing material: when the sealing material is silicone rubber, the temperature range is 120~150℃; when the sealing material is polytetrafluoroethylene, the temperature range is 200~230℃.

4. The automated packaging method for a gas sensor as described in claim 1, characterized in that, The method for determining whether dynamic adjustment of the welding temperature is needed is as follows: when the measured temperature of the sealing area deviates from... The welding temperature is dynamically adjusted when a preset fluctuation threshold is reached. This is the preset thermal stability temperature of the sealing material.

5. The automated packaging method for a gas sensor as described in claim 4, characterized in that, The method for dynamically adjusting the welding temperature is as follows: by combining the thermoelastic properties of the sealing material, the welding temperature is dynamically calibrated according to the deviation between the real-time welding temperature and the thermal stability temperature of the sealing material in order to maintain the stability of the sealing material performance.

6. The automated packaging method for a gas sensor as described in claim 1, characterized in that, The dynamic adjustment method for the pressure holding time is as follows: based on the initial pressure holding time... Based on this, the adjusted pressure holding time is obtained through the linkage calculation of the gas-sensitive channel length adaptation coefficient and the material creep coefficient, which is used to achieve dynamic adaptation between the pressure holding time and the gas-sensitive channel structure and sealing material characteristics.

7. The automated packaging method for a gas sensor as described in claim 1, characterized in that, After the sealing process is completed, the airtightness and electrical performance of the encapsulated sensor are tested. The test results are fed back to the adaptation model for parameter optimization, so as to update the adaptation model in real time.

8. The automated packaging method for a gas sensor as described in claim 7, characterized in that, The airtightness test uses the differential pressure method, and the electrical performance test includes response speed and detection accuracy tests. The response speed test uses the standard gas concentration step method, and the detection accuracy test uses the multi-point calibration method.

9. An automated packaging system for a gas sensor, characterized in that, The system for implementing the automated packaging method as described in any one of claims 1-8 includes: The parameter modeling module is used to pre-establish the packaging process parameters-gas-sensitive channel adaptation model. It takes the core parameters of the gas sensor to be packaged as input and outputs the corresponding packaging process parameters. The collaborative positioning and parameter correction module is used to collaboratively acquire the spatial distance between the gas-sensitive channel and the packaging base through an industrial camera and a laser rangefinder, and to calculate the actual coaxiality deviation. And the sealing pressure reference value is corrected by combining the gas-sensitive channel orifice diameter d; The thermal-mechanical coordinated control module is used to start the integrated packaging unit, apply pre-pressure according to the corrected sealing pressure, and simultaneously collect the temperature of the sealing area through the infrared temperature measurement module to determine whether the welding temperature needs to be dynamically adjusted. After welding is completed, the corrected sealing pressure is maintained, and the pressure holding time is dynamically adjusted according to the gas-sensitive channel length L and the creep coefficient of the sealing material to complete the sealing process. The detection and optimization module is used to perform airtightness detection and electrical performance testing on the packaged sensor, and feed the detection results back to the adaptation model for parameter optimization, so as to update the adaptation model in real time. The central control module coordinates the workflow of each module, stores process parameters, test data and adaptation models, and realizes full-process automated control.

10. An automated packaging apparatus for a gas sensor, comprising a memory, a processor, and a computer program stored in the memory and running on the processor, characterized in that, When the processor executes the computer program, it implements an automated packaging method for a gas sensor as described in any one of claims 1-8.

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