A fully automated assembly equipment for air duct sensors

Abstract

This invention discloses a fully automatic assembly equipment for air duct sensors, aiming to provide an efficient and fully automatic assembly equipment for air duct sensors. The key technical features are: a frame with a feeding device on it; a glue welding device on one side of the feeding device; a transmission device on one side of the glue welding device; an ultrasonic welding device on one side of the transmission device; a pre-discharge inspection device on one side of the ultrasonic welding device; and a discharge device on one side of the pre-discharge inspection device.

Description

Technical Field

[0001] This invention relates to the field of automated assembly equipment, and more specifically to a fully automated assembly equipment for air duct sensors. Background Technology

[0002] With the development of the automotive industry and the increasing demands of users for in-vehicle comfort, automatic air conditioning systems have become standard equipment in modern vehicles. To achieve precise and constant in-vehicle temperature, the air conditioning system needs to acquire environmental parameters from multiple dimensions in real time, among which the in-vehicle air duct sensor is the core component for realizing closed-loop logic control.

[0003] Traditional duct sensor production relies heavily on semi-automatic equipment or manual assembly, resulting in several significant technical drawbacks: 1. Complex and time-consuming integration: The manufacturing process of duct sensors involves more than ten steps, including automatic wire gripping, precision welding, injection molding (or grouting), glue application, curing and aging, and final testing. Existing equipment often only automates a single workstation, requiring manual intervention or slow conveyor transport between workstations, hindering overall production rhythm and increasing the risk of secondary damage to precision components during transport. 2. Low precision in minute spaces: The thermistor core inside the duct sensor is tiny with extremely fine pins, requiring extremely high precision from the vision alignment and motion control systems during assembly. Existing equipment often suffers from insufficient mechanical repetitive positioning accuracy when handling processes such as outdoor pin bending and micro-contact welding, leading to incomplete solder joints or core misalignment, affecting the consistency of the product's thermal response. 3. Lack of real-time online closed-loop detection: Traditional production lines typically employ a finished product sampling inspection mode. Because environmental factors during the production of air duct sensors (such as changes in adhesive viscosity and dynamic compensation of glue volume) are dynamic, existing equipment cannot monitor the process parameters of each step (such as welding pressure curves and dynamic compensation of glue volume) in real time during production. This leads to defective products being transferred to the final stage of production, increasing the company's production costs. 4. Conflict between high cleanliness and environmental enclosure: Due to the sensor's enclosure and sensitivity to static electricity, the accumulation of micro-dust and static electricity generated during high-speed operation of enclosed devices is often difficult to control effectively. Existing enclosed solutions present a contradiction between ease of maintenance and optimized space layout. Furthermore, different types of vehicles require different air duct sensors due to their different structures.

[0004] Currently, Chinese patent CN221454917U discloses an assembly device for sealing rings of vehicle-mounted air duct temperature sensors, including a material discharge mechanism consisting of a vibrating disc and a transmission track disposed at the discharge end of the vibrating disc; a material transfer mechanism including a receiving mechanism disposed at the discharge end of the transmission track and a transmission cylinder disposed on one side of the receiving mechanism, with a material transfer cylinder connected above the transmission cylinder, and a material transfer rod connected to the cylinder shaft of the material transfer cylinder, the material transfer rod being disposed above the transmission track; a material lifting mechanism including a transfer cylinder disposed at the rear end of the receiving mechanism, with a gripper assembly connected to the cylinder shaft of the transfer cylinder; a material picking mechanism disposed on the other side of the transmission track and a receiving mechanism disposed on one side of the material picking mechanism.

[0005] While this vehicle-mounted air duct temperature sensor sealing ring assembly equipment can quickly assemble and connect the sealing ring and the vehicle-mounted air duct temperature sensor body, saving labor and greatly improving assembly efficiency with a high degree of automation, the entire process of the air duct sensor includes automatic housing feeding, QR code printing and reading on the housing (generating a unique identification number), CCD pre-soldering inspection AOI (to prevent misalignment of the NTC inside the housing with the corresponding position of the housing), fully automatic soldering, post-soldering quality inspection AOI (to prevent missing solder, cold solder, insufficient solder, etc.), and UV glue application (to evenly coat the NTC inside the ordinary housing with UV glue). The process involves a series of steps, including TC (moisture and vibration protection), glue path inspection (preventing glue leakage, insufficient glue, excessive glue, etc.), material transfer, UV curing, shell assembly, ultrasonic welding (ultrasonic welding of the upper and lower shells), repeated code reading (preventing manual intervention to remove or disrupt the product order), resistance testing, pin AOI inspection (detecting the relative dimensions of the pins to the shell), pin height testing, and automatic material unloading and tray placement. Therefore, it is necessary to develop a fully automated process from raw material input to finished product, with precise deviation correction capabilities and an integrated digital quality monitoring system. Figure 1 Specialized equipment for producing air duct sensors. Summary of the Invention

[0006] The purpose of this invention is to provide a fully automated assembly equipment for air duct sensors. It features a fully automated assembly process specifically designed for air duct sensors, realizing fully automated operation from housing loading, laser marking, code reading, pre-soldering AOI inspection, automatic soldering, post-soldering AOI inspection, UV dispensing, adhesive path inspection, UV curing, upper and lower housing assembly, ultrasonic welding, secondary code reading, resistance testing, pin size detection, pin height detection to automatic unloading and tray placement. It has advantages such as high precision, high efficiency, full inspection, and traceability, effectively solving the problems of high reliance on manual labor, poor accuracy, lack of traceability, and incomplete inspection in traditional processes.

[0007] The above-mentioned technical objective of the present invention is achieved through the following technical solution: A fully automatic assembly equipment for air duct sensors includes a frame, characterized in that: a feeding device is provided on the frame, a glue welding device is provided on one side of the feeding device, a transmission device is provided on one side of the glue welding device, an ultrasonic welding device is provided on one side of the transmission device, a pre-discharge detection device is provided on one side of the ultrasonic welding device, and a discharging device is provided on one side of the pre-discharge detection device. The adhesive soldering device includes a first rotating motor located inside the frame, the outlet of the first rotating motor being a first rotating disk located on the frame, and a plurality of first workstation blocks being provided on the first rotating disk; the first rotating disk is also provided with a laser marking station, a first code reading station, a pre-soldering inspection station, an automatic soldering head connected to the pre-soldering inspection station, a post-soldering inspection station, a dispensing device, a glue path inspection station, and a material unloading and gripping device arranged in sequence around its circumference. The transmission device is also equipped with a curing station, and the ultrasonic welding device is located on a frame on one side of the transmission device; an upper and lower shell assembly device is also provided between the ultrasonic welding device and the transmission device. The pre-unloading inspection device includes a second rotating motor located inside the frame. The outlet of the second rotating motor is located on a second rotating disk on the frame. The second rotating disk is provided with several second workstation blocks. The second rotating disk is provided with a second code reading station, a resistance test station, a pin size detection station, and a pin height detection station arranged in a circular pattern. The unloading device is located on one side of the pin height detection station.

[0008] The above solution, through a composite layout of dual turntables and linear transmission, highly integrates multiple processes such as marking, inspection, welding, dispensing, curing, shell assembly, ultrasonic welding, electrical testing, and material unloading, achieving fully automated operation. This solves the problems of dispersed processes, slow cycle time, and high labor costs in traditional manual or semi-automatic lines. The first turntable enables synchronous processing at multiple stations in a circular manner, with high space utilization, high positioning accuracy, and stable operation. The second turntable enables full-dimensional inspection after welding to ensure the quality of products leaving the factory. The transmission device connects smoothly with the curing station and ultrasonic welding device, realizing continuous automation of assembly, curing, welding, and inspection, significantly improving production efficiency and product consistency.

[0009] Further configuration: A first housing visual shape locator is provided between the feeding device and the first rotating disk, facing the direction of the first rotating disk; a second housing visual shape locator is also provided on one side of the upper and lower housing assembly device.

[0010] The above solution, by setting CCD vision shape positioners at key positions during material loading and housing assembly, enables automatic correction of housing loading posture and precise alignment of housing assembly position. This solves the problems of easy misalignment and low assembly accuracy of small-sized sensor housings, significantly improves the positional accuracy of welding and housing placement, and increases product yield, while avoiding manual alignment errors.

[0011] Further configuration: The transmission device includes a driven roller located on one side of the material gripping device, a transmission motor located on one side of the ultrasonic welding detection device, an active roller located at the outlet of the transmission motor, and a transmission belt sleeved on the active roller and the driven roller, wherein the transmission belt passes through the curing station.

[0012] The above solution, which uses a motor-driven belt conveyor, is simple in structure, stable in operation, and reliable in positioning. It can achieve smooth, continuous, and low-vibration conveying of workpieces. The conveyor belt runs through the curing station, allowing the UV adhesive to be cured synchronously during the conveying process. This does not occupy an independent workstation or increase the cycle time, thereby improving the overall efficiency of the equipment and solving the defects of traditional curing equipment that require separate stops and have longer cycle times.

[0013] Further configuration: The feeding device includes a placement box located on the frame, feeding linear modules are provided on both sides of the placement box, and a feeding transverse linear module is provided between the feeding linear modules. The feeding transverse linear module is provided with a feeding mechanical gripper.

[0014] The above solution utilizes a dual linear module and a mechanical gripper to achieve automatic feeding of the casing. The gripping is stable, the action is fast, and the positioning is accurate. It can realize automatic feeding of batch silos without frequent manual feeding, reducing human intervention, improving the continuous production capacity of the equipment, and meeting the needs of large-scale automated production.

[0015] Further configuration: The dispensing device includes a dispensing frame located on the frame, a dispensing linear module on the dispensing frame, and an online vision dispensing machine on the dispensing linear module.

[0016] The above solution, using an online vision dispensing machine, can identify the workpiece position in real time and automatically compensate for the dispensing path, achieving precise dispensing of NTC components and uniform and controllable dispensing volume. It solves the problems of easy leakage, insufficient dispensing, excessive dispensing, and positional deviation in traditional dispensing, improves the moisture-proof and vibration-resistant protection effect, and ensures the long-term reliability of the sensor.

[0017] Further configuration: The material feeding gripping device includes a material feeding gripping bracket located on one side of the transmission belt, a material feeding gripping linear module on the material feeding gripping bracket, and a material feeding gripping mechanical gripper on the material feeding gripping linear module.

[0018] The above solution uses a linear module to drive a mechanical gripper, enabling high-speed, stable, and precise transfer of the workpiece from the first rotating disk to the transfer device. This results in fast action response, high repeatability, and avoids damage to the workpiece during transfer, ensuring smooth process connections and improving overall cycle time.

[0019] Further configuration: The upper and lower shell assembly device includes support rods located on both sides of the transmission belt near the ultrasonic welding device. The support rods are equipped with upper and lower shell linear modules. The upper and lower shell linear modules are also equipped with upper and lower shell transverse linear modules. The upper shell gripping robot is also equipped with a storage box for the upper shell on one side of the transmission belt. The upper shell storage box is equipped with a downward-sloping slide rail on one side. The frame is also equipped with a placement platform connected to the slide rail. The frame below the placement platform is also equipped with a vibrator connected to the placement platform. A first vision locator for controlling and positioning the upper shell gripping robot is provided above the placement platform. A second vision locator for controlling the position of the upper shell and the position of the workpiece on the transmission belt after gripping is also provided on one side of the placement platform.

[0020] Through the above solution, vibration feeding, dual vision positioning, and dual linear module robotic arms, the upper shell can be automatically sorted, positioned, gripped, and assembled, solving the problems of low efficiency, high deviation rate, and poor consistency of manual capping. The vibrator ensures orderly feeding of the shell, and the dual vision ensures double precision in gripping and capping, meeting the high assembly precision requirements of automotive-grade sensors.

[0021] Further configuration: The ultrasonic welding device includes a bracket located between the transmission belt and the second rotating disk, a cam-type pick-and-place robot arm on the bracket, and an ultrasonic welding head on one side of the bracket.

[0022] The above solution utilizes a cam-type pick-and-place robot and an ultrasonic welding head to achieve high-speed, high-precision workpiece transfer and instantaneous welding. The PPU robot is fast, accurate, long-lasting, and easy to maintain. Combined with the ultrasonic welding head, it achieves a firm and sealed weld on the upper and lower shells, solving the problems of slow transfer, low precision, and unstable welding of traditional cylinders, and significantly improving welding efficiency and sealing performance.

[0023] Further configuration: The feeding device includes a storage box located on the frame, feeding linear modules are provided on both sides of the storage box, and a feeding transverse linear module is provided between the feeding linear modules. The feeding transverse linear module is provided with a feeding mechanical gripper.

[0024] The above solution uses a dual-linear module-driven mechanical gripper to achieve automatic material feeding and neat tray placement. Finished products can be placed in an orderly manner according to the tray rules, eliminating the need for manual collection and tray placement, reducing labor costs, avoiding damage to finished products, and realizing full automation from production to packaging.

[0025] Further configuration: Several third workstation blocks are also fixedly installed on the transmission belt.

[0026] By implementing the above solution, a dedicated third workstation block is installed on the conveyor belt, ensuring that the workpiece is stably positioned, without shifting or shaking, during the conveying, curing, waiting for assembly and welding processes. This guarantees the foundation for high-precision operations in subsequent visual inspection, shell assembly, and ultrasonic welding, thereby improving the overall stability and product qualification rate.

[0027] In summary, the integrated structural design, featuring dual-turntable multi-station integration, full-process visual positioning, high-speed PPU transfer, ultrasonic precision welding, multi-AOI online inspection, and QR code full-chain traceability, significantly improves efficiency compared to traditional manual and semi-automatic assembly equipment. 1. Fully automated process, significantly reducing reliance on manual labor and production costs. The fully automated closed-loop operation from material loading to adhesive bonding, curing, assembly, welding, inspection and unloading reduces the traditional 7-person operation to 1 person on duty, completely eliminating human operation errors and efficiency fluctuations, significantly increasing production capacity and reducing unit manufacturing costs, and has outstanding economic innovation.

[0028] 2. The dual-turntable and linear transmission composite layout achieves high precision and fast cycle time. The first turntable completes coding, pre-soldering inspection, automatic soldering, post-soldering AOI, visual dispensing, and glue path inspection; the second turntable completes secondary coding, resistance testing, and full inspection of pin size / height; combined with belt conveyor and UV online curing, there is no waiting time in the process, the space is highly compact, and the repeatability and production cycle time are far superior to traditional distributed equipment, forming a structural layout advantage.

[0029] 3. Multi-vision, PPU robotic arm, and ultrasonic welding ensure welding precision. Dual-vision positioning and posture correction during material feeding and assembly; cam-type PPU robotic arm enables high-speed and high-precision transfer; ultrasonic welding head ensures a firm seal on the shell; online vision dispensing ensures uniform glue path; multiple precision mechanisms work together to fundamentally solve common industry problems such as incomplete welding, misalignment, glue leakage, and shell misalignment, resulting in good stability of assembly and welding quality.

[0030] 4. Full-process online AOI inspection enables real-time interception of defective products. It integrates pre-soldering AOI, post-soldering AOI, glue circuit inspection, pin size inspection, pin height inspection, and resistance testing. The entire process is 100% inspected rather than sampled, effectively preventing defective products from flowing into the next process, greatly improving the first pass rate, reducing rework and scrap costs, and forming full-process control of quality.

[0031] 5. QR code full-link binding enables automotive-grade data traceability through laser coding and front and rear dual-reading. It binds and stores the product's unique identifier with inspection images, welding parameters, dispensing data, and electrical test results throughout the entire process, supporting after-sales reverse traceability. This meets the quality control requirements of automotive-grade sensors, fills the technological gap of traditional equipment lacking digital traceability, and avoids asymmetry caused by manual intervention. Attached Figure Description

[0032] The invention will be further described below with reference to the accompanying drawings.

[0033] Figure 1 This is a schematic diagram of the air duct sensor structure; Figure 2 This is a schematic diagram of the overall structure of the fully automated assembly and welding equipment for air duct sensors; Figure 3 This is an enlarged structural diagram of the fully automated assembly and welding equipment for air duct sensors used to display the feeding device. Figure 4 This is an enlarged structural diagram of the fully automated assembly and welding equipment for air duct sensors used to display the adhesive welding device. Figure 5 This is an enlarged structural diagram of a fully automated assembly and welding equipment for air duct sensors used to display a dispensing device. Figure 6 This is a magnified structural diagram of an ultrasonic welding device used in a fully automated assembly and welding equipment for air duct sensors. Figure 7 This is an enlarged structural diagram of the second rotating disk displayed by the fully automated assembly and welding equipment for air duct sensors. Figure 8 This is an enlarged structural diagram of the upper and lower housing assembly device, displayed by the fully automated assembly and welding equipment for air duct sensors.

[0034] In the diagram, 1. Frame; 2. Feeding device; 21. Placement box; 22. Feeding linear module; 23. Feeding transverse linear module; 24. Feeding mechanical gripper; 3. Adhesive welding device; 31. First rotating motor; 32. First rotating disk; 33. First workstation block; 34. Laser marking station; 35. First code reading station; 36. Pre-soldering inspection station; 37. Automatic soldering head; 38. Post-soldering inspection station; 39. Dispensing device; 391 392. Dispensing rack; 393. Linear dispensing module; 394. Inline vision dispensing machine; 315. Glue path inspection station; 316. Material feeding gripper; 317. Material feeding gripper bracket; 318. Linear dispensing module; 319. Material feeding gripper mechanical gripper; 4. Conveying device; 41. Driven roller; 42. Conveying motor; 43. Driven roller; 44. Conveying belt; 5. Ultrasonic welding device; 51. Bracket; 52. Cam-type pickup 53. Robotic arm; 6. Ultrasonic welding head; 7. Pre-unloading inspection device; 8. Second rotating motor; 9. Second rotating disk; 10. Second workstation block; 11. Second code reading station; 12. Resistance test station; 13. Pin size detection station; 14. Pin height detection station; 15. Unloading device; 16. Storage box; 17. Unloading linear module; 18. Unloading transverse linear module; 19. Unloading mechanical gripper; 20. Curing station; 21. Upper and lower shell assembly device; 22. Support rod; 33. Upper and lower shell linear module; 44. Upper shell gripping robot; 55. Upper shell storage box; 66. Slide rail; 77. Placement platform; 88. Vibrator; 99. First vision locator; 910. Second vision locator; 10. First shell vision shape locator; 11. Second shell vision shape locator; 12. Third workstation block. Detailed Implementation

[0036] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings.

[0037] The technical solution adopted in this invention is: a fully automatic assembly and welding equipment for air duct sensors, such as... Figure 2 The diagram shows a frame 1, which serves as the overall installation base. The frame 1 adopts a closed dustproof frame structure to meet the electrostatic protection and cleanliness requirements for automotive-grade product manufacturing. During operation, the frame 1 will be enclosed by dustproof plates and dustproof doors on all sides.

[0038] like Figure 3As shown, the feeding device 2 is fixedly installed at the input end of the frame 1. The feeding device 2 includes a placement box 21, which is fixedly connected to the table surface of the frame 1; feeding linear modules 22 are fixedly installed on both sides of the placement box 21, the base of the feeding linear modules 22 is fixedly connected to the frame 1, and its slider moves in the vertical direction; a feeding transverse linear module 23 is fixedly connected between the two sets of feeding linear modules 22, and the feeding transverse linear module 23 is set in the horizontal direction; a feeding mechanical gripper 24 is fixedly installed on the slider of the feeding transverse linear module 23, and the gripper moves in conjunction with the module.

[0039] On one side of the output end of the feeding device 2, a first housing visual shape locator 10 is fixedly installed. The locator bracket 51 is fixedly connected to the frame 1. The lens is set towards the first rotating disk 32 and is used to place the housing in the correct position by the feeding mechanical gripper 24 before the housing is fed.

[0040] like Figure 4 As shown, the adhesive welding device 3 is fixedly installed on the downstream side of the feeding device 2, and is arranged in a straight line with the feeding device 2. The first rotating motor 31 of the adhesive welding device 3 is fixedly installed below the table inside the frame 1. Its output axis passes through the table of the frame 1 and is fixedly connected to the center of the first rotating disk 32, driving the first rotating disk 32 to perform indexing rotation. Several first workstation blocks 33 are evenly fixed on the first rotating disk 32. The first workstation blocks 33 are bolted to the first rotating disk 32 and rotate synchronously with the disk. Along the circumference of the first rotating disk 32, each workstation mechanism is fixedly arranged with the frame 1 as the installation reference: the laser marking station 34 is fixedly installed on the frame 1 and located outside the first rotating disk 32; the first code reading station 35, the pre-soldering inspection station 36, the automatic soldering head 37, the post-soldering inspection station 38, and the adhesive path inspection station 310 are all fixedly installed on the frame 1 in sequence and distributed on the outer periphery of the first rotating disk 32, wherein the automatic soldering head 37 is fixedly connected to one side of the pre-soldering inspection station 36.

[0041] like Figure 5 As shown, the dispensing device 39 is fixedly installed on the frame 1, and its dispensing frame 391 is fixedly connected to the frame 1. The dispensing linear module 392 is vertically installed on the dispensing frame 391. The online vision dispensing machine 393 is fixed on the slider of the dispensing linear module 392 and can move up and down to dispense glue to the workpiece.

[0042] like Figure 6 , Figure 7 and Figure 8 As shown, the feeding gripping device 311 is fixedly installed on the frame 1, located between the first rotating disk 32 and the transmission device 4. Its feeding gripping bracket 312 is fixedly connected to the frame 1. The feeding gripping linear module 313 is horizontally fixed on the bracket 51. The feeding gripping mechanical gripper 314 is fixed on the module slider to realize the gripping and transfer of the first rotating disk 32 to the transmission device 4.

[0043] The conveying device 4 is fixedly installed on the frame 1, located downstream of the adhesive welding device 3, and connected to the unloading gripping device 311. The conveying device 4 includes: a driven roller 41 fixedly installed on the frame 1 via a bearing seat; a conveying motor 42 fixedly installed on the frame 1, with its output shaft fixedly connected to the driving roller 43; a conveying belt 44 is fitted onto the driving roller 43 and the driven roller 41, and is driven by the conveying motor 42 for closed-loop conveying; several third station blocks 12 are fixedly connected to the conveying belt 44 for positioning and supporting workpieces.

[0044] The curing station 8 is a cover structure, which is fixedly connected above the conveyor belt 44 and fixedly connected to the frame 1 at the bottom. The conveyor belt 44 passes through the center of the inside of the curing station 8, so that the workpiece can be UV cured during the conveying process.

[0045] The upper and lower housing assembly device 9 is fixedly mounted on the frame 1, located on one side of the transmission device 4 and at the front end of the ultrasonic welding device 5, with the three connected in sequence. The upper and lower housing assembly device 9 includes: The support rod 91 is vertically fixed to the frame 1; the upper and lower housing linear modules 92 are horizontally fixed to the top of the support rod 91; the upper and lower housing transverse linear modules 93 are fixedly connected to the slider of the upper and lower housing linear modules 92; the upper housing gripping robot 94 is fixedly installed on the slider of the upper and lower housing transverse linear modules 93 to realize the gripping action.

[0046] The upper housing storage box 95 is fixedly installed on the frame 1, and its outlet is connected to the slide rail 96. The slide rail 96 is inclined downwards and connected to the placement platform 97. The placement platform 97 is fixedly installed on the frame 1, and its bottom is fixedly connected to the vibrator 98. The base of the vibrator 98 is fixedly fixed to the frame 1. The first vision locator 99 is fixedly installed above the placement platform 97, and its bracket 51 is connected to the frame 1. The second vision locator 910 is fixedly installed on one side of the transmission belt 44, with its lens facing the workpiece and the upper housing gripping robot 94 to achieve dual positioning. The second housing vision shape locator 11 is fixedly installed on the side of the upper and lower housing assembly device 9 and fixed to the frame 1.

[0047] The ultrasonic welding device 5 is fixedly installed on the frame 1, located between the transmission device 4 and the pre-unloading inspection device 6. The ultrasonic welding device 5 includes: a bracket 51 fixedly connected to the frame 1; and a cam-type pick-and-place robot 52 fixedly installed on the bracket 51, with its input end facing the transmission belt 44 and its output end facing the second rotating disk 62. The ultrasonic welding head 53 is fixedly mounted on the bracket 51, located beside the cam-type pick-and-place robot 52, and works with the robot to complete the welding. The pre-discharge inspection device 6 is fixedly mounted on the frame 1, located downstream of the ultrasonic welding device 5. The pre-discharge inspection device 6 includes: a second rotary motor 61 fixedly mounted inside the frame 1, with its output axis axially fixedly connected to the center of the second rotating disk 62, driving the second rotating disk 62 to rotate; several second workstation blocks 63 are evenly fixedly arranged on the second rotating disk 62; a second code reading station 64, a resistance testing station 65, a pin size detection station 66, and a pin height detection station 67 are all fixedly mounted on the frame 1, distributed sequentially along the outer periphery of the second rotating disk 62. The unloading device 7 is fixedly mounted on the output end of the frame 1, connected to the pre-discharge inspection device 6. The unloading device 7 includes: a storage box 71 fixedly mounted on the frame 1; and unloading linear modules 72 fixedly mounted on both sides of the storage box 71 on the frame 1. The material feeding linear modules 72 are fixedly connected to the material feeding horizontal linear modules 73; the material feeding mechanical gripper 74 is fixedly installed on the slider of the material feeding horizontal linear module 73 to complete the finished product gripping and tray placement.

[0048] Its main working principle is as follows: After the equipment is powered on, the system performs a self-check, each mechanism returns to its origin, and enters a fully automatic cyclic working state. The entire process from workpiece feeding to discharging requires no manual intervention. The action sequence and working principle are as follows: 1. Automatic Housing Loading and Visual Positioning: Driven by the loading linear module 22 and the loading transverse linear module 23, the loading mechanical gripper 24 picks up the sensor-equipped lower housing from the placement box 21 and moves it above the first housing visual shape locator 10. The first housing visual shape locator 10 captures the housing shape, identifies the housing angle and offset, and sends the coordinate compensation signal to the control system. The control system controls the gripper to fine-tune the angle and position, accurately placing the housing into the first workstation block 33 of the first rotating disk 32, completing the loading and initial positioning.

[0049] 2. First rotating disk 32: Full-process adhesive welding. The first rotating motor 31 drives the first rotating disk 32 to rotate at equal angles, and the workpiece enters each process sequentially with the workstation block: Laser marking station 34: engraves a unique QR code on the surface of the shell as a traceability ID for the whole process; First code reading station 35: reads the QR code and binds it to the production process to establish a data archive; Pre-soldering inspection station 36: uses AOI vision to inspect the position of NTC components, judges whether they are misaligned or misassembled, and directly marks and removes defective products; Automatic soldering head 37: performs fully automatic constant temperature precision soldering on NTC pins to ensure full solder joints and no cold solder joints; Post-soldering inspection station 38: AOI captures images of solder joints to detect missing solder joints, cold solder joints, insufficient solder joints, and bridging, intercepting defects in real time; Dispensing device 39: The online vision dispensing machine 393 first captures the workpiece position and automatically compensates for the path, then accurately dispenses UV glue onto the NTC components to achieve moisture-proof, shock-proof, and fixed protection; Glue path inspection station 310: Visually inspects whether the glue path is complete, uniform, and correctly positioned, judging whether there is missing glue, insufficient glue, or excessive glue; Unloading gripper 311: The unloading gripper mechanical gripper 314 takes the workpiece that has completed the glue welding process from the first station block 33 and smoothly transfers it to the third station block 12 of the conveyor belt 44.

[0050] 3. Transfer and UV online curing The transmission motor 42 drives the drive roller 43 to rotate, which in turn drives the transmission belt 44 and the third station block 12 to be conveyed forward at a uniform speed. The workpiece passes through the curing station 8 with the transmission belt 44. The UV lamp continuously irradiates the UV adhesive during the conveying process, realizing online synchronous curing without occupying an independent station or extending the cycle time, thus improving overall efficiency.

[0051] 4. Automatic assembly of upper and lower housings The upper housing in the upper housing storage box 95 slides into the placement platform 97 via the slide rail 96. The vibrator 98 vibrates at a low frequency, causing the upper housing to flip over so that its back is facing up. The first vision locator 99 captures and positions the upper housing and sends the coordinates of the flipped upper housing to the control system. The upper and lower housing linear module 92 and the upper and lower housing transverse linear module 93 drive the upper housing gripping robot 94 to move and accurately grip the upper housing. The second vision locator 910 simultaneously captures the position of the lower housing on the conveyor belt 44 and performs secondary position compensation. The control system drives the robot to accurately close the upper housing onto the lower housing, completing the closing assembly and ensuring uniform assembly gaps, no misalignment, and no pressure damage.

[0052] 5. Ultrasonic welding The cam-type pick-and-place robot 52 moves quickly to transfer the closed workpiece from the third station block 12 to the area below the ultrasonic welding head 53 at high speed and with high precision. The ultrasonic welding head 53 moves downward and applies high-frequency vibration and pressure to the joint surface of the upper and lower shells, causing the contact surface materials to melt and bond together, achieving a sealed and firm weld. After welding is completed, the robot transfers the workpiece to the second station block 63 of the second rotating disk 62 for the final inspection stage.

[0053] 6. Second rotating disk 62: Comprehensive finished product inspection The second rotating motor 61 drives the second rotating disk 62 to rotate in increments, and the workpieces complete the following steps in sequence: The second code reading station 64 reads the QR code again to confirm that the product sequence has not been manually disrupted, ensuring the integrity of the traceability chain; Resistance testing station 65: Probes contact sensor pins to automatically test NTC resistance and determine if it is within the acceptable range; Pin size inspection station 66: AOI visually inspects the position, spacing, and deformation of the pins relative to the housing; Pin height inspection station 67: Inspects whether the pin extension height meets automotive-grade standards. All inspection data, AOI images, welding parameters, and dispensing data are linked to QR codes for storage, enabling full-process traceability.

[0054] 7. Automatic feeding and good / defective product classification Qualified finished products: Driven by the feeding linear module 72 and the feeding transverse linear module 73, the feeding machine gripper 74 picks up the finished products from the second workstation block 63 and neatly arranges them into the storage box 71 according to the material tray rules. Unqualified products: The control system marks them as NG, and the feeding mechanism places them in the unqualified product storage area, preventing them from being mixed with good products.

[0055] The entire device solves the problems of poor soldering of tiny pins, uneven dispensing of adhesive in micro-gap areas, easy misalignment of the housing, and the lack of manual labor and full inspection in traditional lines. Through the composite layout of dual turntables and linear conveyor, it achieves the organic synergy of high-precision processing, continuous curing, and full-dimensional inspection.

[0056] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall fall within the scope of the invention.

Claims

1. A fully automatic assembly apparatus for air duct sensors, comprising a frame (1), characterized in that: The frame (1) is provided with a feeding device (2), a glue welding device (3) is provided on one side of the feeding device (2), a transmission device (4) is provided on one side of the glue welding device (3), an ultrasonic welding device (5) is provided on one side of the transmission device (4), a pre-discharge inspection device (6) is provided on one side of the ultrasonic welding device (5), and a discharge device (7) is provided on one side of the pre-discharge inspection device (6). The adhesive soldering device (3) includes a first rotating motor (31) located inside the frame (1), the outlet of the first rotating motor (31) is located on the frame (1) and a first rotating disk (32) is provided on the first rotating disk (32), and a plurality of first workstation blocks (33) are provided on the first rotating disk (32); the first rotating disk (32) is also arranged in a circular pattern with a laser marking station (34), a first code reading station (35), a pre-soldering inspection station (36), an automatic soldering head (37) connected to the pre-soldering inspection station (36), a post-soldering inspection station (38), a glue dispensing device (39), a glue path inspection station (310) and a material feeding and gripping device (311); The transmission device (4) is also equipped with a curing station (8), and the ultrasonic welding device (5) is located on a frame (1) on one side of the transmission device (4); the ultrasonic welding device (5) and the transmission device (4) are also equipped with an upper and lower shell assembly device (9). The pre-feeding detection device (6) includes a second rotating motor (61) located inside the frame (1). The outlet of the second rotating motor (61) is located on a second rotating disk (62) on the frame (1). The second rotating disk (62) is provided with several second workstation blocks (63). The second rotating disk (62) is provided with a second code reading station (64), a resistance test station (65), a pin size detection station (66), and a pin height detection station (67) arranged in a circular pattern. The pin height detection station (67) is located on one side of the feeding device (7).

2. The full-automatic assembling equipment for air duct sensor according to claim 1, characterized in that: A first housing visual shape locator (10) is provided between the feeding device (2) and the first rotating disk (32) and faces the first rotating disk (32), and a second housing visual shape locator (11) is provided on one side of the upper and lower housing assembly device (9).

3. The fully automated assembly equipment for air duct sensors according to claim 2, characterized in that: The transmission device (4) includes a driven roller (41) located on one side of the feeding gripping device (311), a transmission motor (42) located on one side of the ultrasonic welding detection device, an active roller (43) located at the outlet of the transmission motor (42), and a transmission belt (44) sleeved on the active roller (43) and the driven roller (41). The transmission belt (44) passes through the curing station (8).

4. The fully automated assembly equipment for air duct sensors according to claim 3, characterized in that: The feeding device (2) includes a placement box (21) located on the frame (1), feeding straight modules (22) are provided on both sides of the placement box (21), and a feeding transverse straight module (23) is provided between the feeding straight modules (22). The feeding transverse straight module (23) is provided with a feeding mechanical gripper (24).

5. The fully automated assembly equipment for air duct sensors according to claim 4, characterized in that: The dispensing device (39) includes a dispensing rack (391) located on the frame (1), a dispensing linear module (392) provided on the dispensing rack (391), and an online visual dispensing machine (393) provided on the dispensing linear module (392).

6. The fully automated assembly equipment for air duct sensors according to claim 5, characterized in that: The feeding gripping device (311) includes a feeding gripping bracket (312) located on one side of the transmission belt, a feeding gripping linear module (313) on the feeding gripping bracket (312), and a feeding gripping mechanical gripper (314) on the feeding gripping linear module (313).

7. The fully automated assembly equipment for air duct sensors according to claim 6, characterized in that: The upper and lower housing assembly device (9) includes a support rod (91) located on one side of the transmission belt near the ultrasonic welding device (5) on both sides. The support rod (91) is provided with an upper and lower housing linear module (92). The upper and lower housing linear module (92) is also provided with an upper and lower housing transverse linear module (93). The upper housing gripping robot (94) is also provided on the upper housing. The upper housing storage box (95) is provided on one side of the transmission belt (44). The upper housing storage box (95) is provided with a downward sloping slide (96) on one side. The frame (1) is also provided with a placement platform (97) connected to the slide (96). The frame (1) below the placement platform (97) is also provided with a vibrator (98) connected to the placement platform (97). The upper part of the placement platform (97) is provided with a first visual locator (99) for controlling and positioning the upper housing gripping robot (94). The placement platform (97) is also provided with a second visual locator (910) for controlling the position of the upper housing after gripping and the position of the workpiece on the transmission belt (44).

8. The fully automated assembly equipment for air duct sensors according to claim 7, characterized in that: The ultrasonic welding device (5) includes a bracket (51) located between the transmission belt (44) and the second rotating disk (62), a cam-type pick-and-place robot (52) is provided on the bracket (51), and an ultrasonic welding head (53) is also provided on one side of the bracket (51).

9. The fully automated assembly equipment for air duct sensors according to claim 8, characterized in that: The feeding device (7) includes a storage box (71) located on the frame (1), feeding straight modules (72) are provided on both sides of the storage box (71), and a feeding transverse straight module (73) is provided between the feeding straight modules (72). The feeding transverse straight module (73) is provided with a feeding mechanical gripper (74).

10. The fully automated assembly equipment for air duct sensors according to claim 9, characterized in that: Several third workstation blocks (12) are also fixedly installed on the transmission belt (44).

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