IGBT pin detection method and system

Abstract

The present application relates to the technical field of semiconductor packaging, and particularly relates to an IGBT pin detection method and system, the method comprising: respectively preconfiguring theoretical motion curves of each cam on the same main shaft, the theoretical motion curve being a design reference curve of a corresponding follower of the cam in the full stroke of pin operation; the theoretical motion curve at least comprising a displacement reference curve; collecting real-time rotation angle data of the main shaft, and synchronously collecting real-time running data of the corresponding follower of each cam, at least comprising real-time displacement data, based on the rotation angle data of the main shaft; taking the rotation angle data of the main shaft as an index, comparing the real-time displacement data with the displacement reference curve point by point in the full stroke, and calculating displacement deviation. The present application takes the rotation angle of the main shaft as an index, and performs full stroke detection on multiple cams, thereby improving detection accuracy.

Description

Technical Field

[0001] This invention relates to the field of semiconductor packaging technology, and in particular to a method and system for detecting IGBT pins. Background Technology

[0002] In the semiconductor packaging field, especially in the manufacturing process of automotive-grade IGBT modules, the pin insertion process is a crucial step in precisely inserting external electrical pins or terminals into the substrate or housing. The quality of the pin insertion directly affects the electrical connection reliability, heat dissipation performance, and long-term stability under vehicle operating conditions. High-precision pin insertion machines generally employ cam-driven mechanisms to achieve core actions such as feeding, stabilizing, clamping, and pin insertion. The cam motion curve defines the motion state, start-stop logic, and action sequence of the follower throughout its entire stroke. In a typical IGBT pin insertion machine, all core actions are driven by the cam mechanism, which is coaxially mounted on the same spindle. For every 360° rotation of the spindle, four cams synchronously complete one complete action cycle, corresponding to the production of one IGBT module.

[0003] With the rapid development of the new energy vehicle and power semiconductor industries, the current control of cams in pin insertion machines generally adopts an offline detection mode, which only checks the contour machining accuracy of the cams using a coordinate measuring machine before the equipment leaves the factory or during periodic maintenance. For deviations in the actual motion curve, existing technologies can only detect the fault after a batch of defective products has occurred, resulting in irreversible material scrapping and production capacity loss. This cannot meet the high reliability and real-time closed-loop control requirements of automotive-grade production lines in the semiconductor packaging field. A few existing technologies can only perform spot checks on the rotation angle or end displacement of a single cam, and cannot achieve real-time comparison of parameters throughout the cam's entire stroke. They also do not detect the phase synchronization of the cams, making it difficult to guarantee the timing accuracy when multiple cams work together, thus limiting the yield improvement of the pin insertion process for semiconductor packaging electrical components.

[0004] The information disclosed in this background section is intended only to enhance the understanding of the general background of this disclosure and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0005] In view of at least one of the above technical problems, the present invention provides an IGBT pin detection method and system, which uses the spindle rotation angle as the sole reference to perform real-time comparison of the full stroke motion curves and phase synchronization detection of each coaxially mounted cam, so as to achieve early warning and closed-loop control.

[0006] This invention provides a method for detecting IGBT pins, comprising the following steps: The theoretical motion curves of each cam on the same spindle are pre-configured, and the theoretical motion curves are the design reference curves of the followers corresponding to the cams during the entire stroke of the pin insertion operation; The theoretical motion curve includes at least a displacement reference curve; The rotation angle data of the main shaft is collected in real time, and the real-time running data of the corresponding follower of each cam is collected synchronously based on the rotation angle data, including at least the real-time displacement data. Using the spindle rotation angle data as an index, the real-time displacement data is compared with the displacement reference curve point by point throughout the entire stroke to calculate the displacement deviation.

[0007] Furthermore, the theoretical motion curve also includes a theoretical phase, and the real-time operating data also includes the actual phase corresponding to the key motion nodes of each cam. The phase synchronization deviation between each cam is calculated based on the actual phase and the theoretical phase.

[0008] Furthermore, each of the cams includes at least a feeding cam, a stabilizing cam, a clamping cam, and a needle-attaching cam; The real-time operating data includes at least the feeding displacement data of the feeding cam follower, the stabilizing displacement data of the stabilizing cam follower, the clamping displacement data and clamping force data of the clamping cam follower, and the needle insertion displacement data and insertion force data of the needle insertion cam follower.

[0009] Furthermore, the acquisition of the real-time operational data includes a forward mode: The spindle rotation angle data is collected by an absolute encoder and used as the sole synchronization reference. The real-time running data of each cam corresponding to the follower within the full cycle of 360° is continuously collected to form the full stroke continuous data of the positive mode. In the continuous data of the entire stroke, the actual phase of each cam at the key action node is identified and stored in association with the continuous data of the entire stroke.

[0010] Furthermore, the acquisition of the real-time operational data includes a reverse mode: Using the key action nodes as trigger sources and establishing corresponding trigger sensors, when any of the key action nodes occurs, the trigger sensors collect the current spindle rotation angle data as the actual phase corresponding to the current key action node.

[0011] Furthermore, a first verification is included before calculating the displacement deviation: The actual phase of the key action node acquired by the reverse mode is obtained as the first actual phase; The actual phase of the same key action node identified from the continuous full-stroke data in the positive mode is obtained as the second actual phase; Calculate the phase difference between the first actual phase and the second actual phase; If the absolute value of the phase difference exceeds the preset first phase tolerance threshold, it is determined that the forward mode data acquisition is abnormal or the key action recognition algorithm is abnormal, and a first verification abnormal signal is issued.

[0012] Furthermore, the calculation of the phase synchronization deviation between the individual cams includes a second verification: Obtain the actual phase acquired by the reverse mode; Extract the theoretical phase corresponding to the same key motion node from the theoretical motion curve; The phase difference between the actual phase and the theoretical phase is calculated and used as the phase synchronization deviation. The phase synchronization deviation is compared with a preset phase synchronization tolerance threshold. If the phase synchronization deviation exceeds the phase synchronization tolerance threshold, it is determined to be a phase synchronization abnormality, and a phase synchronization warning signal is issued.

[0013] Furthermore, after calculating the phase synchronization deviation, a third verification is also included: The actual phase acquired in the reverse mode is used as a reference phase point; From the full-stroke continuous data of the positive mode, obtain the spindle rotation angle corresponding to the reference phase point, and obtain the displacement value, velocity value or acceleration value of the follower corresponding to the spindle rotation angle, as the positive continuous value; Calculate the consistency deviation between the reference phase point and the positive continuous value within a preset corner neighborhood; If the consistency deviation exceeds the preset second phase tolerance threshold, it is determined that the encoder accuracy is abnormal or the continuity of the positive full-cycle curve is abnormal, and a third verification abnormal signal is issued.

[0014] The present invention also provides an IGBT pin detection system, comprising: The theoretical curve configuration module pre-configures the theoretical motion curves of each cam on the same spindle. The theoretical motion curve is the design reference curve of the follower corresponding to the cam during the entire stroke of the pin insertion operation. The theoretical motion curve includes at least the displacement reference curve. The real-time acquisition module is communicatively connected to the absolute encoder and each displacement / force / vibration sensor to realize the synchronous acquisition of the real-time operating data corresponding to the spindle rotation angle and each of the cams. The curve comparison and deviation calculation module is used to compare the real-time running data with the full stroke of multiple theoretical motion curves, and to calculate the displacement deviation and the phase synchronization deviation.

[0015] Furthermore, this includes the detection and calibration of periodic zero-point events: Determine the mechanical zero position of the needle insertion machine. The mechanical zero position is the fixed position of the main shaft where the feeding cam, stabilizing cam, clamping cam, and needle insertion cam are all in a safe and stationary state with no risk of movement interference. The Z-phase zero-position pulse of the absolute encoder is calibrated by coinciding with the mechanical zero position, and is used as the electrical zero position. The reference point when the spindle rotation angle is 0° in the theoretical motion curve is coincidentally calibrated with the electrical zero point and used as the data zero point; The overlap of the mechanical zero point, electrical zero point and data zero point is periodically detected and calibrated to ensure that the overlap does not exceed the preset zero-point overlap tolerance threshold.

[0016] The technical solution of this invention can achieve the following technical effects: By using the spindle rotation angle as the sole reference, the full-stroke motion curves of the four linkage cams for feeding, stabilizing, clamping, and pinning are compared in real time, and the phase synchronization is detected. This achieves pre-warning and closed-loop control of micron-level deviations, effectively avoiding pin damage, substrate cracking, and motion interference caused by curve deviations and phase desynchronization, thereby improving the production yield of IGBT modules and the automotive-grade PPM-level zero-defect control capability.

[0017] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention 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 recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a partial logic diagram of the IGBT pin detection method in an embodiment of the present invention; Figure 2 This is a schematic diagram of the overall logic of the IGBT pin detection method in an embodiment of the present invention; Figure 3 This is a flowchart illustrating the IGBT pin detection method in an embodiment of the present invention; Figure 4 This is a schematic diagram of the forward mode acquisition process in an embodiment of the present invention; Figure 5 This is a flowchart illustrating the first verification step in an embodiment of the present invention. Figure 6 This is a schematic diagram of the second verification process in an embodiment of the present invention; Figure 7 This is a timing diagram showing the phase synchronization of the needle insertion and clamping core in an embodiment of the present invention. Figure 8 This is a flowchart illustrating the third verification process in an embodiment of the present invention; Figure 9 This is a timing diagram for the full system synchronization of the periodic zero-point event in an embodiment of the present invention. Detailed Implementation

[0020] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0021] Unless otherwise defined, 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 invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0022] This invention provides a method such as Figures 1 to 9 The IGBT pin detection method shown includes the following steps: The theoretical motion curves of each cam on the same spindle are pre-configured. The theoretical motion curves are the design reference curves of the followers corresponding to the cams during the entire stroke of the pin insertion operation. The theoretical motion curve should include at least the displacement reference curve; Real-time acquisition of spindle rotation angle data, and based on the spindle rotation angle data, synchronous acquisition of real-time operating data of each cam corresponding follower, including at least real-time displacement data; Using the spindle rotation angle data as an index, the real-time displacement data is compared with the displacement reference curve point by point throughout the entire stroke to calculate the displacement deviation.

[0023] The specific working principle of this invention is as follows: First, for the feeding cam, stabilizing cam, clamping cam, and pin insertion cam set on the same spindle of the IGBT pin insertion machine, the theoretical motion curve of the follower corresponding to each cam is pre-configured. The theoretical motion curve is the design reference curve of the follower corresponding to the cam in the entire stroke of the IGBT pin insertion operation. For example, the design reference curve of the feeding slide, stabilizing block, gripper, and pin insertion spindle in a complete operation cycle when the spindle rotates 360°. Its core function is to serve as a reference for subsequent comparison with the real-time running data of the follower, and to determine whether the pin insertion operation accuracy meets the preset requirements. The displacement reference curve uses the spindle rotation angle of the pin insertion machine as the abscissa and the displacement of the corresponding follower as the ordinate, accurately defining the standard displacement value of the follower at each spindle rotation angle position.

[0024] During the insertion process of the IGBT pin insertion machine, since all the cams in the same group rotate coaxially, the spindle rotation angle data is the only synchronization reference. Each rotation angle value corresponds to the real-time running data of each cam follower at that rotation angle value, including at least the real-time displacement data. Specifically, one rotation angle value corresponds to the displacement data of the follower, ensuring that the collected data corresponds one-to-one with the spindle rotation angle and avoiding comparison errors caused by asynchronous sampling.

[0025] A high-precision displacement sensor is installed on each follower, and a non-contact measurement method is used to avoid interference with the movement of the follower, ensuring the accuracy of displacement data acquisition. The comparison range covers the entire stroke of the spindle rotation, that is, each rotation step is compared point by point to ensure no detection blind spots. For each displacement deviation data generated during the comparison process, it can be bound to the corresponding spindle rotation angle, acquisition timestamp, and the unique ID of the IGBT module currently in operation.

[0026] In some embodiments of the present invention, such as Figure 2 As shown, the theoretical motion curve also includes the theoretical phase, and the real-time operation data also includes the actual phase corresponding to the key action nodes of each cam. The phase synchronization deviation between each cam is calculated based on the actual phase and the theoretical phase.

[0027] The theoretical phase is used to define the rotation angle value of the design spindle corresponding to the key action node of each cam during the entire stroke of the needle insertion operation. The key action node refers to the instantaneous state point of the cam follower when it completes a specific function, such as the clamping point of the clamping cam and the insertion starting point of the needle insertion cam.

[0028] During the operation of the pin insertion machine, the acquisition of real-time operating data also includes synchronously recording the actual spindle rotation angle corresponding to each cam when the key action node occurs, which is recorded as the actual phase. This can be obtained by setting a physical trigger device corresponding to the key action node on the follower's motion path, or by performing feature recognition on the real-time displacement data.

[0029] By comparing the actual phase and theoretical phase of the same key action node of the same cam and calculating the difference, the phase deviation of the current node is used. Furthermore, by integrating the phase relationship between key action nodes of different cams, the phase deviation is used to calculate the phase synchronization deviation between each cam, which directly reflects the actual synchronization accuracy of multiple cams in timing coordination, thereby determining whether there is any risk of interference.

[0030] In some embodiments of the present invention, each cam includes at least a feeding cam, a stabilizing cam, a clamping cam, and a pin-attaching cam; together they constitute the action execution system for pin insertion, wherein: the feeding cam is used to drive the feeding slide to realize the conveying of IGBT pins or materials; the stabilizing cam is used to drive the stabilizing block to pre-press and stabilize the material before pin insertion; the clamping cam is used to drive the gripper to complete the clamping and fixing of the pin or material; and the pin-attaching cam is used to drive the pin insertion spindle to perform the final pin insertion action.

[0031] Real-time operating data includes at least the feeding displacement data of the feeding cam follower, the stabilizing displacement data of the stabilizing cam follower, the clamping displacement data and clamping force data of the clamping cam follower, and the needle insertion displacement data and insertion force data of the needle insertion cam follower.

[0032] For the feeding cam, a displacement sensor is installed on the driven component to collect feeding displacement data in real time, reflecting the positional accuracy and smoothness of the feeding action. For the stabilizing cam, a displacement sensor is installed on the driven component to collect stabilizing displacement data in real time, monitoring whether the pressing position and stroke of the stabilizing block are in place. For the clamping cam, both a displacement sensor and a force sensor are installed on the driven component to collect clamping displacement and clamping force data in real time. The clamping displacement reflects the opening and closing position of the jaws, and the clamping force reflects the actual clamping force of the jaws on the pins, comprehensively evaluating the reliability of the clamping action. For the pin insertion cam, both a displacement sensor and a force sensor are installed on the driven component to collect pin insertion displacement and insertion force data in real time. The pin insertion displacement reflects the feeding depth and position of the pin, and the insertion force reflects the resistance changes encountered during the pin insertion process, effectively judging the pin quality.

[0033] In some embodiments of the present invention, such as Figure 4 As shown, the real-time data collection includes a forward mode: The spindle rotation angle data is collected by an absolute encoder and used as the sole synchronization reference. Real-time running data of each follower corresponding to each cam within 360° of the entire cycle are continuously collected to form continuous data of the entire stroke in the positive mode. In the continuous data of the entire stroke, the actual phase of each cam at key action nodes is identified and stored in association with the continuous data of the entire stroke.

[0034] An absolute encoder with a resolution of 17 bits or higher, a single-turn angle resolution of ≤0.0055°, and a response frequency of ≥20kHz is rigidly mounted coaxially at the end of the cam spindle. The encoder acquires spindle angle data in real time and uses it as the sole synchronous trigger signal for all sensor sampling. Corresponding sensors are installed at the actuator ends of the four cams, using the angle data acquired by the encoder as the synchronous trigger signal. The synchronous acquisition of data from all sensors is achieved through an industrial data acquisition card with a sampling frequency of ≥10kHz, ensuring that there is a corresponding data record for every 0.0055° within a complete 360° spindle angle cycle. The acquisition card aligns the angle data with the data from each sensor according to the timestamp, forming a data matrix indexed by the angle.

[0035] The continuous data throughout the entire stroke uses the rotation angle as the unique index, covers the entire cycle, and is synchronized in multiple dimensions. All data points use the spindle rotation angle as the horizontal coordinate. Data collected at the same rotation angle position are comparable. Under the same rotation angle index, multiple dimensions such as displacement, velocity, acceleration, and force are recorded simultaneously to form a complete description of the cam's motion state.

[0036] In some embodiments of the present invention, the acquisition of real-time runtime data includes a reverse mode: Using key action nodes as trigger sources and setting up corresponding trigger sensors, when any key action node occurs, the trigger sensor collects the current spindle rotation angle data as the actual phase corresponding to the current key action node.

[0037] For the key action nodes of the four cams, corresponding trigger sensors are set up. The key action nodes include, but are not limited to: the clamping position of the clamping cam, the insertion start point of the needle cam, the feeding position of the feeding cam, and the descent start point of the stabilizing cam. For different types of action nodes, appropriate trigger sensors are selected to achieve hardware-level accurate acquisition of the actual phase of the key action nodes, avoiding errors and delays caused by software recognition algorithms.

[0038] In some embodiments of the present invention, such as Figure 5 As shown, a first verification is included before calculating the displacement deviation: Obtain the actual phase of the key action nodes acquired in reverse mode, and use it as the first actual phase; The actual phase of the same key action node identified from the full-stroke continuous data of the positive mode is used as the second actual phase; Calculate the phase difference between the first actual phase and the second actual phase; If the absolute value of the phase difference exceeds the preset first phase tolerance threshold, it is determined that the forward mode data acquisition is abnormal or the key action recognition algorithm is abnormal, and the first verification abnormal signal is issued.

[0039] Before calculating displacement deviation, a first verification mechanism is introduced to avoid distortion in subsequent deviation calculations due to data source issues. After the continuous data acquisition of the entire stroke in forward mode is completed and the actual phase of key action nodes is identified, the first verification is performed before using the continuous data for curve deviation calculation. This verification is independent of the subsequent curve deviation calculation process. If the verification passes, the curve deviation calculation continues; if the verification fails, the subsequent calculation is terminated and an error signal is issued.

[0040] For each critical action node, the phase difference between the first actual phase and the second actual phase is calculated. A preset first phase tolerance threshold is used to determine whether the forward mode data is reliable. The setting of the first phase tolerance threshold is based on the equipment repeatability, sensor accuracy indicators, and process requirements. The absolute value of the calculated phase difference is compared with the threshold. If the absolute value of the phase difference of all critical action nodes does not exceed the threshold, the first verification is passed, and the subsequent curve deviation calculation continues.

[0041] If the absolute value of the phase difference at any critical action node exceeds the preset first phase tolerance threshold, it is determined that the forward mode data acquisition is abnormal or the critical action recognition algorithm is abnormal, and a first verification anomaly signal is issued. Possible causes of the anomaly include forward mode data acquisition anomalies, such as loose sensor installation or sensor malfunction; critical action recognition algorithm anomalies, such as improper threshold settings or algorithm logic errors; and environmental interference, such as temperature changes causing sensor zero-point drift or vibration causing measurement errors. When an anomaly is determined, subsequent displacement deviation calculations are terminated to avoid deviation analysis based on unreliable data.

[0042] In some embodiments of the present invention, such as Figure 6 As shown, the calculation of the phase synchronization deviation between the individual cams includes a second verification: Obtain the actual phase acquired in reverse mode; Extract the theoretical phase corresponding to the same key motion node from the theoretical motion curve; Calculate the phase difference between the actual phase and the theoretical phase, as the phase synchronization deviation; The phase synchronization deviation is compared with the preset phase synchronization tolerance threshold. If the phase synchronization deviation exceeds the phase synchronization tolerance threshold, it is determined to be a phase synchronization anomaly, and a phase synchronization warning signal is issued.

[0043] The purpose of the second verification is to directly calculate the phase synchronization deviation, which is a core step in automotive-grade zero-defect control. It uses the highly reliable actual phase acquired in reverse mode as a benchmark, compares it with the theoretical phase stored in the theoretical motion curve, accurately calculates the phase synchronization deviation, and determines whether there is a phase synchronization anomaly based on a preset phase synchronization tolerance threshold. The second verification is typically performed after the actual phase has been acquired in reverse mode and the theoretical curve has been pre-constructed.

[0044] The phase difference between the actual phase and the theoretical phase is then calculated as the phase synchronization deviation. For each critical action node, the phase synchronization deviation is the difference between the actual phase and the theoretical phase. The phase synchronization deviation value reflects the degree of deviation between the actual phase and the design phase of each critical action node of the cam. A positive deviation indicates that the action occurs after the design phase, and a negative deviation indicates that the action occurs ahead of the design phase.

[0045] A preset phase synchronization tolerance threshold is used to determine whether the phase synchronization deviation is within the allowable range. The phase synchronization threshold is set based on the functional differences and accuracy requirements of each cam. Specifically, the pin-inserting cam, as the core actuator of the pin insertion action, directly affects the pin insertion quality due to the phase synchronization accuracy of the insertion start point. Therefore, the most stringent phase synchronization tolerance threshold is set. The clamping point of the clamping cam directly affects the timing coordination between the clamping action and the pin insertion action. If the clamping is too late, the pin may not be clamped properly during insertion; if the clamping is too early, the safety margin may be compressed. Therefore, a relatively strict tolerance threshold is set. The feeding point of the feeding cam and the downward starting point of the stabilizing cam have relatively lower timing accuracy requirements and can be set with relatively lenient tolerance thresholds. Simultaneously, phase synchronization tolerance thresholds are also set between the four cams to verify the timing coordination relationship between different cams. For example, it verifies whether the phase difference between the clamping point of the clamping cam and the insertion start point of the pin-inserting cam meets the design requirement of a 45° safety phase margin. Different tolerance thresholds are set according to the functional differences and accuracy requirements of the four cams, thereby achieving differentiated threshold management.

[0046] If the phase synchronization deviation of all key action nodes does not exceed the corresponding tolerance threshold, and the phase difference between the four cams also meets the design requirements, then the second verification is passed, and the phase synchronization deviation data can be used for subsequent detection result generation and closed-loop control.

[0047] If the phase synchronization deviation of any critical action node exceeds the corresponding phase synchronization tolerance threshold, it is determined to be a phase synchronization anomaly, and a phase synchronization warning signal is issued. When a phase synchronization anomaly is determined, tiered measures are taken according to the degree of deviation: if the phase synchronization deviation exceeds the warning threshold but does not exceed the shutdown threshold, a phase synchronization warning signal is issued, and maintenance is recommended; if the phase synchronization deviation exceeds the shutdown threshold, the pin insertion machine is immediately shut down to avoid the generation of batch defective products.

[0048] Please refer to Figure 7 Taking the phase synchronization relationship between the clamping cam reaching the clamping point and the needle insertion cam starting point as an example, and setting the parameters according to conventional values, the required timing is: the clamping cam completes clamping at a 45° angle, and the needle insertion cam begins insertion at a 90° angle, with a 45° safety phase margin between them. If the second verification detects that the actual phase of the clamping cam reaching the clamping point is 45.08° and the actual phase of the needle insertion cam starting point is 90.00°, then the phase synchronization deviation at the clamping point is 0.08°. Although this does not exceed the preset tolerance threshold of ±0.10° for the clamping point itself, the phase difference between the clamping point and the insertion start is 44.92°, which is 0.08° different from the design value of 45°. If this difference exceeds the preset phase difference tolerance threshold of ±0.10° and is a negative deviation, it means that the clamping point is too late, compressing the safety margin, and is also judged as an abnormal phase synchronization. If the actual phase of the needle insertion cam starting point is detected to be 89.85°, which is 0.15° ahead of the design phase, the phase synchronization deviation is -0.15°, which exceeds the phase synchronization tolerance threshold of ±0.05° of the needle insertion cam. This is considered an abnormal phase synchronization, indicating that the needle insertion action may have started before the clamping is fully tightened, which poses a risk of pin bending. The system will immediately issue a warning signal and recommend stopping the machine for inspection.

[0049] Based on the above embodiments, the second verification can be performed by combining real-time calculation and periodic verification. Real-time calculation is performed immediately after each reverse mode acquisition, while periodic verification analyzes the statistical distribution of phase synchronization deviation at fixed intervals to evaluate the long-term stability of phase synchronization and avoid potential out-of-tolerance risks.

[0050] In some embodiments of the present invention, such as Figure 8 As shown, after calculating the phase synchronization deviation, a third verification is also included: Obtain the actual phase acquired in reverse mode as the reference phase point; From the full-stroke continuous data in the forward mode, obtain the spindle angle corresponding to the reference phase point, and obtain the displacement, velocity or acceleration value of the follower corresponding to the spindle angle, as the forward continuous value; Calculate the consistency deviation between the reference phase point and the positive continuous value within the preset turning angle neighborhood; If the consistency deviation exceeds the preset second phase tolerance threshold, it is determined that the encoder accuracy is abnormal or the continuity of the positive full cycle curve is abnormal, and a third verification abnormal signal is issued.

[0051] After calculating the phase synchronization deviation, a third verification mechanism is introduced to further verify the long-term accuracy stability of the encoder and the continuity of the forward full-cycle curve, avoiding systematic errors caused by encoder drift or forward curve anomalies. The high-reliability actual phase acquired in reverse mode is used as the reference phase point and compared with the value of the full-stroke continuous data in forward mode at the corresponding corner position. If the comparison result exceeds the preset second phase tolerance threshold, it is determined that the encoder accuracy is abnormal or the forward full-cycle curve continuity is abnormal, and a third verification abnormality signal is issued.

[0052] The actual phase acquired in reverse mode is used as a reference phase point for subsequent consistency comparison with forward mode data. The spindle angle corresponding to the reference phase point is obtained from the full-stroke continuous data of forward mode, and the displacement, velocity or acceleration value of the driven part corresponding to the spindle angle is obtained as forward continuous value. Based on the angle value of the reference phase point, the data corresponding to the angle position can be queried in the forward mode data for consistency comparison with the reference phase point.

[0053] Since the continuous data of the forward mode is stored as discrete sampling points with a sampling interval of 0.0055°, and the reference phase point acquired in the reverse mode may fall between two sampling points and may not exactly coincide with the forward mode data point, a preset corner neighborhood is set. Within the ±neighborhood range of the reference phase point's corner value, forward mode data points are searched. If a data point exists, its displacement value is extracted for comparison to tolerate normal system errors. The size of the preset corner neighborhood can be determined comprehensively based on the encoder resolution, sampling interval, and device repeatability.

[0054] The consistency deviation between the reference phase point and the positive continuous value in the preset corner neighborhood is calculated. The calculation method of the consistency deviation varies depending on the type of comparison parameter. For key action nodes characterized by displacement value, such as clamping to the position point and feeding to the position point, the deviation between the theoretical displacement value corresponding to the reference phase point and the positive continuous displacement value is calculated as the consistency deviation. If the consistency deviation exceeds the preset second phase tolerance threshold, it is determined that the encoder accuracy is abnormal.

[0055] The second phase tolerance threshold is used for the third verification, focusing on long-term monitoring of encoder accuracy and positive curve continuity. The threshold can be appropriately relaxed. At the same time, for displacement consistency deviation, a second displacement tolerance threshold can be set. The calculated consistency deviation is compared with the preset second phase tolerance threshold. If the absolute value of the consistency deviation does not exceed the threshold, the third verification is passed, indicating that the encoder accuracy is normal and the positive curve continuity is good. If the consistency deviation exceeds the threshold, it is judged as abnormal.

[0056] If the consistency deviation exceeds the preset second phase tolerance threshold, it is determined to be an encoder accuracy abnormality or a forward full-cycle curve continuity abnormality, and a third verification abnormality signal is issued. Possible causes of encoder accuracy abnormalities include: loose encoder installation leading to inaccurate angle measurement, and encoder Z-phase zero-position pulse drift causing reference offset, etc. Possible causes of forward full-cycle curve continuity abnormalities include: frame loss or data jumps during forward mode data acquisition, and sensor signal interference leading to abnormal values, etc. When an abnormality is determined, a third verification abnormality signal is issued, and corresponding handling measures are taken according to the abnormality type.

[0057] Based on the above embodiments, the detection results of the third verification are comprehensively analyzed and trend judged with the results of the first and second verifications. If the third verification anomaly occurs multiple times and is related to the first verification anomaly, the root cause of the anomaly can be further determined, thereby improving the accuracy of fault diagnosis.

[0058] Based on the same inventive concept as the IGBT pin detection method in the foregoing embodiments, the present invention also provides an IGBT pin detection system, comprising: The theoretical curve configuration module pre-configures the theoretical motion curves of each cam on the same spindle. The theoretical motion curve is the design reference curve of the follower corresponding to the cam during the entire stroke of the pin insertion operation. The theoretical motion curve includes at least the displacement reference curve. The real-time acquisition module communicates with the absolute encoder and various displacement / force / vibration sensors to realize the synchronous acquisition of real-time operating data of the spindle rotation angle and each cam. The curve comparison and deviation calculation module is used to compare real-time running data with multiple theoretical motion curves throughout the entire stroke, and to calculate displacement deviation and phase synchronization deviation.

[0059] The pin detection system described above in this invention can effectively implement the IGBT pin detection method, and the technical effects it can achieve are as described in the above embodiments, which will not be repeated here.

[0060] In some embodiments of the present invention, such as Figure 9 As shown, this includes the detection and calibration of periodic zero-point events: The zero-point event is the only synchronization anchor point for the entire cycle. All actions, data, and traceability are based on this hardware-triggered zero point, completely avoiding misalignment caused by software delays. Therefore, it is necessary to detect and calibrate the zero-point event of the cycle.

[0061] Determine the mechanical zero position of the needle insertion machine. The mechanical zero position is the fixed position of the main shaft where the feeding cam, stabilizing cam, clamping cam, and needle insertion cam are all in a safe and static state with no risk of interference. For example, according to the cam segmentation rules, all four cams are in a static state in the 315°~360° range. Any position in the range can be determined as the mechanical zero position. Manually rotate the cam main shaft to make the needle insertion cam reach the zero-speed static midpoint of the insertion and pressure holding section. Record this position as the mechanical zero position of the equipment and set physical marks on the main shaft and frame for subsequent calibration.

[0062] The Z-phase zero-position pulse of the absolute encoder is aligned with the mechanical zero position for calibration, which is then used as the electrical zero position. During calibration, the cam spindle is manually rotated to the mechanical zero position, and the encoder installation angle is adjusted so that the Z-phase zero-position pulse output of the encoder is completely aligned with the mechanical zero position.

[0063] The reference point when the spindle rotation angle is 0° in the theoretical motion curve is coincidentally calibrated with the electrical zero point and used as the data zero point. During calibration, the 0° rotation angle point of the theoretical curve is mapped to the electrical zero point. That is, when the encoder Z-phase pulse is triggered, the current rotation angle value is forcibly set to 0°. The subsequent collected rotation angle values ​​are all accumulated based on the zero point, so that the mechanical zero point, electrical zero point and data zero point are completely coincident, ensuring a unified correspondence between the actual motion of the equipment, the encoder output and the theoretical curve reference.

[0064] It can also synchronously read the IGBT module ID currently being produced each time a zero-point event is triggered. The production management system transmits the unique ID of each IGBT module to the pin insertion machine control system. When the spindle rotates to the zero-point position, the hardware triggers the latching of the current rotation angle value. At the same time, the control system reads the ID of the module currently being produced and binds the zero-point calibration data with the IGBT module ID for storage, providing a complete data chain for quality analysis and fault diagnosis.

[0065] Periodically check and calibrate the overlap between the mechanical zero point, electrical zero point, and data zero point to ensure that the overlap does not exceed the preset zero-point overlap tolerance threshold. The check can be performed forcibly each time the equipment starts; after each production run of a preset number of modules; after continuous operation exceeding a preset time; or after a collision or maintenance. The check method involves manually rotating the spindle to the mechanical zero point and reading the deviation of the encoder output angle from 0°. If the deviation exceeds the threshold, calibration is performed. This can be done automatically via software compensation or by manually adjusting the encoder installation position. After calibration, the check is repeated to ensure that the overlap returns to within the threshold range.

[0066] Although this application has been described in conjunction with specific features and embodiments, it is obvious that various modifications and combinations can be made thereto without departing from the spirit and scope of this application. Accordingly, this specification and drawings are merely exemplary illustrations of the application as defined herein, and are to be considered as covering any and all modifications, variations, combinations, or equivalents within the scope of this application. Clearly, those skilled in the art can make various alterations and modifications to this application without departing from its scope. Thus, if such modifications and modifications fall within the scope of this application and its equivalents, this application intends to include such modifications and modifications.

Claims

1. A method for detecting IGBT pins, characterized in that, Includes the following steps: The theoretical motion curves of each cam on the same spindle are pre-configured, and the theoretical motion curves are the design reference curves of the followers corresponding to the cams during the entire stroke of the pin insertion operation; The theoretical motion curve includes at least a displacement reference curve; The rotation angle data of the main shaft is collected in real time, and the real-time running data of the corresponding follower of each cam is collected synchronously based on the rotation angle data, including at least the real-time displacement data. Using the spindle rotation angle data as an index, the real-time displacement data is compared with the displacement reference curve point by point throughout the entire stroke to calculate the displacement deviation; The theoretical motion curve also includes a theoretical phase, and the real-time operation data also includes the actual phase corresponding to the key action nodes of each cam. The phase synchronization deviation between each cam is calculated based on the actual phase and the theoretical phase. Each of the cams includes at least a feeding cam, a stabilizing cam, a clamping cam, and a needle-attaching cam; The real-time operating data also includes at least the feeding displacement data of the feeding cam follower, the stabilizing displacement data of the stabilizing cam follower, the clamping displacement data and clamping force data of the clamping cam follower, and the needle insertion displacement data and insertion force data of the needle insertion cam follower.

2. The IGBT pin detection method according to claim 1, characterized in that, The collection of real-time operational data includes a forward mode: The spindle rotation angle data is collected by an absolute encoder and used as the sole synchronization reference. The real-time running data of each cam corresponding to the follower within the full cycle of 360° is continuously collected to form the full stroke continuous data of the positive mode. In the continuous data of the entire stroke, the actual phase of each cam at the key action node is identified and stored in association with the continuous data of the entire stroke.

3. The IGBT pin detection method according to claim 2, characterized in that, The collection of real-time operational data includes a reverse mode: Using the key action nodes as trigger sources and establishing corresponding trigger sensors, when any of the key action nodes occurs, the trigger sensors collect the current spindle rotation angle data as the actual phase corresponding to the current key action node.

4. The IGBT pin detection method according to claim 3, characterized in that, Before calculating the displacement deviation, a first verification is also included: The actual phase of the key action node acquired by the reverse mode is obtained as the first actual phase; The actual phase of the same key action node identified from the continuous full-stroke data in the positive mode is obtained as the second actual phase; Calculate the phase difference between the first actual phase and the second actual phase; If the absolute value of the phase difference exceeds the preset first phase tolerance threshold, it is determined that the forward mode data acquisition is abnormal or the key action recognition algorithm is abnormal, and a first verification abnormal signal is issued.

5. The IGBT pin detection method according to claim 4, characterized in that, The calculation of the phase synchronization deviation between the individual cams includes a second verification: Obtain the actual phase acquired by the reverse mode; Extract the theoretical phase corresponding to the same key motion node from the theoretical motion curve; The phase difference between the actual phase and the theoretical phase is calculated and used as the phase synchronization deviation. The phase synchronization deviation is compared with a preset phase synchronization tolerance threshold. If the phase synchronization deviation exceeds the phase synchronization tolerance threshold, it is determined to be a phase synchronization abnormality, and a phase synchronization warning signal is issued.

6. The IGBT pin detection method according to claim 5, characterized in that, After calculating the phase synchronization deviation, a third verification is also included: The actual phase acquired in the reverse mode is used as a reference phase point; From the full-stroke continuous data of the positive mode, obtain the spindle rotation angle corresponding to the reference phase point, and obtain the displacement value, velocity value or acceleration value of the follower corresponding to the spindle rotation angle, as the positive continuous value; Calculate the consistency deviation between the reference phase point and the positive continuous value within a preset corner neighborhood; If the consistency deviation exceeds the preset second phase tolerance threshold, it is determined that the encoder accuracy is abnormal or the continuity of the positive full-cycle curve is abnormal, and a third verification abnormal signal is issued.

7. An IGBT pin detection system, characterized in that, The detection method described in any one of claims 1 to 6 includes: The theoretical curve configuration module pre-configures the theoretical motion curves of each cam on the same spindle. The theoretical motion curve is the design reference curve of the follower corresponding to the cam during the entire stroke of the pin insertion operation. The theoretical motion curve includes at least the displacement reference curve. The real-time acquisition module is communicatively connected to the absolute encoder and each displacement / force / vibration sensor to realize the synchronous acquisition of the real-time operating data corresponding to the spindle rotation angle and each of the cams. The curve comparison and deviation calculation module is used to compare the real-time running data with the full stroke of multiple theoretical motion curves, and to calculate the displacement deviation and the phase synchronization deviation.

8. The IGBT pin detection system according to claim 7, characterized in that, Including the detection and calibration of periodic zero-point events: Determine the mechanical zero position of the needle insertion machine. The mechanical zero position is the fixed position of the main shaft where the feeding cam, stabilizing cam, clamping cam, and needle insertion cam are all in a safe and stationary state with no risk of movement interference. The Z-phase zero-position pulse of the absolute encoder is calibrated by coinciding with the mechanical zero position, and is used as the electrical zero position. The reference point when the spindle rotation angle is 0° in the theoretical motion curve is coincidentally calibrated with the electrical zero point and used as the data zero point; The overlap of the mechanical zero point, electrical zero point and data zero point is periodically detected and calibrated to ensure that the overlap does not exceed the preset zero-point overlap tolerance threshold.

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