Automatic electric measuring and stacking machine for high-speed wire electric connector

Abstract

This invention relates to the field of tray-stacking machine technology, and in particular discloses an automatic tray-stacking machine for high-speed wire connectors, comprising an electrical testing component, a conveying mechanism, a tray-stacking mechanism, a transfer mechanism, and a control center. An external feeding mechanism conveys the connectors to a testing station between the electrical testing component and the transfer mechanism. The transfer mechanism is located between the external feeding mechanism and the tray-stacking mechanism, and the conveying mechanism is located above the electrical testing component, the tray-stacking mechanism, and the transfer mechanism. The electrical testing component performs electrical tests on the connectors and transmits the test results back to the control center. The control center analyzes whether the connectors are qualified based on the test results. If the connectors are qualified, they are placed on the transfer mechanism for posture correction. If the connectors are unqualified, the external feeding mechanism conveys the unqualified connectors to an external waste collection station.

Description

Technical Field

[0001] This invention relates to the field of tray-stacking machine technology, and in particular discloses an automatic tray-stacking machine for high-speed wire connector electrical testing. Background Technology

[0002] After high-speed wire connectors are manufactured, they need to undergo electrical continuity testing, posture correction, automatic transfer, and neat tray placement. Currently, traditional manual-assisted tray placement and semi-automatic tray placement equipment generally suffer from numerous defects in actual production processes, including poor detection and alignment accuracy, low product gripping stability, poor posture correction effect, easy product misalignment and missed placement, and poor process coordination. Traditional equipment often uses a single vacuum adsorption or rigid clamping method for material handling, which easily leads to problems such as adsorption detachment, clamping scratches on products, and adsorption residue from fallen materials. Furthermore, it lacks a precise self-inspection structure for the suction status, making it impossible to promptly identify abnormal conditions such as suction failure, empty suction, and biased suction. At the same time, traditional tray placement structures cannot achieve continuous automatic tray changing operations, resulting in frequent downtime due to manual tray changing and reduced production efficiency. The existing equipment suffers from low efficiency, relying solely on mechanical positioning, resulting in assembly gap deviations and difficulty in achieving high-precision attitude micro-correction. Furthermore, the electrical testing probes are mostly rigid docking structures, unable to compensate for the positional tolerances of incoming materials, easily leading to poor contact, misjudgments, and probe wear. The overall equipment exhibits poor sequential linkage between processes, insufficient operational stability, and weak fault tolerance, making it difficult to meet the demands of high-speed, high-precision, automated, and continuous batch production. Therefore, there is an urgent need to design a high-speed automatic electrical testing and tray-sanding machine for wire connectors that integrates automatic electrical testing, controllable magnetic suction for precise material handling, automatic attitude correction, self-inspection of the picking status, automatic tray changing, and full-process sequential linkage to address the numerous technical deficiencies of the existing technology. Summary of the Invention

[0003] In order to overcome the shortcomings and deficiencies of the existing technology, the purpose of this invention is to provide an automatic tray-loading machine for electrical testing of high-speed wire connectors.

[0004] To achieve the above objectives, the present invention provides an automatic electrical testing and tray-stacking machine for high-speed wire connectors, comprising an electrical testing component, a conveying mechanism, a tray-stacking mechanism, a transfer mechanism, and a control center. The external loading mechanism, electrical testing component, conveying mechanism, tray-stacking mechanism, and transfer mechanism are all electrically connected to the control center. The external loading mechanism conveys the connectors to a testing station between the electrical testing component and the transfer mechanism. The transfer mechanism is located between the external loading mechanism and the tray-stacking mechanism. The conveying mechanism is positioned above the electrical testing component, the tray-stacking mechanism, and the transfer mechanism. The conveying mechanism includes a moving guide rail, a first moving component, and a second moving component reciprocating on the moving guide rail. The connectors are transported to the electrical testing component and the transfer mechanism via the external loading mechanism. Between the transfer mechanisms, the electrical testing component performs electrical tests on the electrical connectors and transmits the test results back to the control center. The control center analyzes the electrical test results to determine if the electrical connectors are qualified. If the electrical connectors are qualified, the control center controls the first moving component to pick up the electrical connectors placed on the external loading mechanism and move them along the moving guide rail to place them on the transfer mechanism for posture correction. The second moving component picks up the electrical connectors placed on the transfer mechanism and moves them along the moving guide rail to place them on the tray mechanism. If the electrical connectors are unqualified, the external loading mechanism transports the unqualified electrical connectors to the external waste collection station.

[0005] This equipment relies on the control center to coordinate the collaborative work of the external feeding mechanism, electrical testing components, conveying mechanism, transfer mechanism, and tray placement mechanism. During operation, the external feeding mechanism delivers the electrical connectors to the testing station, where the electrical testing components perform electrical testing and feed back data to the control center to determine the quality of the products. Qualified products are transferred to the transfer mechanism via the first moving component for posture correction, and then transferred to the tray placement mechanism by the second moving component for orderly placement. Unqualified products are directly conveyed to the waste collection station by the external feeding mechanism for automatic rejection. This equipment achieves full automation of the feeding, testing, sorting, posture adjustment, transfer, and tray placement process. The division of labor is clear, and the process connections are smooth, effectively reducing the cost of manual intervention, improving testing accuracy and production efficiency, and ensuring that the products are placed neatly and uniformly. It can meet the needs of large-scale continuous production of electrical connectors.

[0006] The transfer mechanism includes a bracket, a rotating block mounted on the bracket, and a rotating assembly that is connected to the rotating block in a transmission manner. The rotating assembly includes a rotating motor, a first gear mounted on the output shaft of the rotating motor, a second gear mounted at one end of the rotating block, and a belt fitted onto the first and second gears. The rotating block has multiple sets of placement protrusions on its periphery, which are respectively arranged along the four sides of the rotating block. When changing the external electrical connector, the rotating motor drives the rotating block to rotate to switch the sides of the rotating block, and the placement protrusions on different sides are adapted to the corresponding specifications of the electrical connector.

[0007] During operation, the rotating motor drives the rotating block to rotate through the first gear, belt and second gear, switching the placement protrusions on different sides to adapt to different specifications of electrical connectors, and the bracket achieves overall stable support; the structure has smooth transmission and convenient switching, can quickly complete product specification adaptation, has strong versatility, and can effectively meet the posture support and transportation needs of multiple types of electrical connectors.

[0008] The placement protrusion has a built-in electrically controlled electromagnet, which is electrically connected to the control center to achieve controllable magnetic attraction: when the electrical connector is placed in place, the control center controls the electromagnet to be energized to generate magnetism, which magnetically attracts and fixes the metal part of the electrical connector to prevent the product from loosening or shifting; when it is necessary to remove the electrical connector, the control center controls the electromagnet to be de-energized in advance to release the magnetic attraction.

[0009] The control center can control the energization and de-energization of the electromagnet inside the placement protrusion in real time. When the electrical connector is placed on the protrusion, the electromagnet is energized and generates magnetism, magnetically fixing the metal parts of the connector. This, combined with the mechanical limit of the protrusion, constrains the product position, effectively preventing the connector from loosening, shifting, or misaligning during posture correction and waiting for transfer. When material needs to be picked up and transferred, the control center pre-emptively de-energizes the electromagnet, completely releasing the magnetic constraint and ensuring that the picking component can smoothly pick up the product without any adsorption residue. The overall structure achieves controllable magnetic positioning, with high positioning stability and rapid unlocking response, significantly improving the orientation accuracy of the electrical connector and the smoothness of the transfer operation. The electromagnet generates attraction when energized, applying a uniform magnetic pull to the metal parts of the connector. If the product has a slight tilt or shift, the magnetic force will pull it to the standard position that fits the protrusion, completing micro-correction. Subsequently, the rotating component drives the rotating block to rotate as a whole, and the placement protrusion, along with the fixed electrical connector, rotates synchronously, thereby changing the product's orientation and completing the posture conversion at the preset angle.

[0010] The electrical connector falls between two sets of protrusions, its shape held and limited by the protrusions, restricting its forward, backward, left, and right displacement, thus completing coarse positioning. A magnetic micro-correction electromagnet is energized, attracting the product's original metal parts; if the product is slightly tilted or misaligned, the uniform magnetic force will pull the product to a standard position where it is completely aligned with the protrusions, correcting minor deviations. An angle adjustment rotating block rotates the protrusions and the product together, changing the product's orientation and completing the specified angle posture change. Once the unlocking and picking posture is in place, the electromagnet is de-energized, the magnetic force disappears, and the upper picking mechanism can easily remove the product. The electrical testing assembly includes a telescopic motor mounted on the side of the external feeding mechanism, a support unit connected to the output end of the telescopic motor, and an electrical testing module mounted on the support unit. The telescopic motor is electrically connected to the control center, and the support unit moves horizontally forward and backward with the telescopic motor. The electrical testing module includes a continuity test probe and a data acquisition module. When the electrical connector is transported to the testing station by the external feeding mechanism, the telescopic motor extends to push the support unit forward, and the continuity test probe makes electrical connection with the metal contacts of the electrical connector to test the circuit continuity performance. The data acquisition module collects the detection signal from the continuity test probe and uploads it to the control center.

[0011] Driven by the control center, the telescopic motor moves the support unit and electrical testing module horizontally forward and backward. After the electrical connector arrives at the testing station, the continuity testing probe moves forward to contact the metal contacts of the product to complete the continuity test. The data acquisition module simultaneously uploads the test signal to the control center. This structure is flexible in movement and precise in docking. It can automatically complete electrical testing and data transmission. The testing process is highly automated, which can effectively improve testing efficiency and the reliability of results.

[0012] Both the first and second moving components include a first sliding plate that slides back and forth on a moving guide rail, a second sliding plate that slides back and forth on the first sliding plate, a suction block disposed on the second sliding plate, a first sliding drive component that drives the first sliding plate to slide back and forth, and a second sliding drive component that drives the second sliding plate to slide back and forth. The suction block has a built-in electromagnetic adsorption structure, and the electromagnetic adsorption structure is electrically connected to the control center, which can realize controllable magnetic suction of materials. The first and second moving components have the same structure and are independently slidably disposed on the moving guide rail. The first moving component is responsible for transferring qualified electrical connectors from the external feeding mechanism to the transfer mechanism, and the second moving component is responsible for transferring electrical connectors that have been adjusted by the transfer mechanism to the tray mechanism.

[0013] During operation, the first and second sliding drive components drive the first and second sliding plates to move horizontally and vertically, respectively. In conjunction with the electromagnetic adsorption structure built into the suction block, controllable magnetic material suction is achieved. The two sets of moving components work independently, sequentially transferring qualified electrical connectors to the transfer mechanism and the tray mechanism. This structure features flexible movement dimensions, stable and reliable material handling, and the division of labor and cooperation between the two components makes the process connection smoother, effectively improving the overall transfer efficiency and the continuity of equipment operation.

[0014] The suction end of the suction block is provided with a first protrusion and a second protrusion, and a gap is provided between the first protrusion and the second protrusion. The external electrical connector is provided with a first groove and a second groove. The first protrusion and the second protrusion can be respectively inserted into the first groove and the second groove to achieve positioning, and together with controllable magnetic adsorption, a double fixing structure is formed.

[0015] During operation, the first and second protrusions of the suction block are mechanically positioned by correspondingly engaging with the first and second grooves of the electrical connector. This, combined with the internal electromagnetic adsorption structure, forms a double fixation. The spacer can be adapted to the product's shape to achieve precise engagement. This combined structure provides reliable positioning and effectively prevents the product from shifting or slipping during transport, further improving gripping stability and alignment accuracy.

[0016] The tray-sliding mechanism includes a tray-sliding guide rail, a lifting drive component slidably mounted on the tray-sliding guide rail, a tray receiving unit located at the output end of the lifting drive component, and a tray-sliding drive component that drives the lifting drive component to reciprocate. Both the lifting drive component and the tray-sliding drive component are electrically connected to the control center. The tray receiving unit is used to place the tray. The moving direction of the lifting drive component intersects with the moving direction of the second moving component. The tray is provided with multiple sets of equidistant receiving slots. Through the cross displacement cooperation of the lifting drive component and the second moving component, the tray can be adapted to the receiving slots at different positions on the tray, so as to realize the orderly placement of electrical connectors.

[0017] During operation, the swivel drive unit drives the lifting drive unit and the swivel body receiving unit to slide along the swivel guide rail. Combined with the cross movement of the lifting drive unit and the second moving component, the equidistant receiving slots on the material tray are sequentially connected to the material picking position, completing the orderly placement of the electrical connectors. This matching method has precise alignment, can be adapted to continuous swivel of multiple slots, runs smoothly, and effectively ensures the neatness of placement and work efficiency.

[0018] The tray receiving unit includes a base plate connected to a lifting drive, a stop plate vertically mounted on the base plate, and a clamping assembly mounted on the side of the base plate. The trays are stacked on the base plate. There are four sets of stop plates, which are arranged around the base plate to limit the movement of the trays. There are two sets of clamping assemblies, each including a clamping cylinder and a clamping plate connected to the output end of the clamping cylinder. The clamping plate clamps and limits the movement of the trays on both parallel sides. When a tray is full of electrical connectors, it is removed by an external robot. The lifting drive then moves the base plate upward, lifting the empty trays stacked below the full trays to the tray placement station to replace the full trays and continue receiving and placing the trays.

[0019] During operation, stacked trays are placed on the base plate, and the surrounding stop plates, along with the clamping cylinders and clamping plates on both sides, work together to limit the movement of the trays and prevent them from shifting. Once the trays are full, they are removed by an external robotic arm, and the lifting drive immediately raises the base plate, sending the empty trays below to the tray-setting station for continued operation. This structure provides reliable limiting and convenient tray changing, ensuring continuous tray-setting work.

[0020] Both the first and second moving components have an absorption status detection module on their absorption blocks. The absorption status detection module includes a Hall sensor installed inside the absorption block and a judgment circuit electrically connected to the control center. After the electromagnetic adsorption structure is energized, it generates a predetermined magnetic field at the absorption end. The Hall sensor is installed at the air gap of the magnetic circuit at the absorption end to detect the magnetic induction intensity at the air gap in real time. When the absorption block presses down to adhere to the electrical connector and the electromagnetic adsorption structure is energized, the metal part of the electrical connector enters the air gap of the magnetic circuit. The metal conductor generates a short circuit effect on the magnetic lines of force, and the real-time magnetic induction intensity value at the air gap undergoes a characteristic change. The judgment circuit compares the real-time magnetic induction intensity value collected by the Hall sensor with a preset threshold. If the magnetic induction intensity value drops below the preset threshold, the absorption is determined to be successful, and the control center drives the first or second moving component to perform a transfer action. If the magnetic induction intensity value does not drop to the preset threshold, the absorption is determined to be unsuccessful, and the control center controls the first or second moving component to return to its original position and issues a supplementary absorption command.

[0021] The Hall sensor is fixedly installed in the middle of the suction end of the suction block, within the air gap region of the electromagnetic adsorption structure's magnetic circuit, to collect the magnetic induction intensity signal at the air gap in real time. During operation, the Hall sensor detects the magnetic induction intensity of the air gap in the suction block's magnetic circuit in real time. The determination circuit compares the collected data with a preset threshold and determines whether the electrical connector has been successfully suctioned based on the influence of the metal conductor on the magnetic field. If suction is successful, a transfer action is executed; if suction fails, the component is controlled to return to its original position and a supplementary suction command is triggered. This module can automatically identify abnormal situations such as empty suction and biased suction, effectively reducing the probability of equipment failure and improving the stability and automation level of the gripping operation. After the electromagnetic adsorption structure is energized, a fixed magnetic field is formed at the suction end, and the Hall sensor measures a reference magnetic field value. When the suction block adheres to and attracts the electrical connector, the metal conductor on the product will intervene in the magnetic circuit and disperse the magnetic lines of force, causing the magnetic field at the air gap to weaken, and the sensor reading to decrease. The circuit compares the reading with a preset threshold to distinguish between successful suction or empty / biased suction.

[0022] The front end of the continuity detection probe is provided with a floating connector, which includes a probe body, a floating sleeve sleeved on the probe body, and an elastic reset member disposed between the floating sleeve and the probe body. The elastic reset member is a compression spring that provides axial elastic preload. When the telescopic motor pushes the support forward, at the instant the continuity detection probe contacts the metal contact of the electrical connector, the floating sleeve generates a slight axial float under the action of the elastic reset member, automatically compensating for the positional tolerance of the electrical connector in the conveying direction and avoiding probe damage or poor contact caused by rigid docking.

[0023] During operation, the telescopic motor drives the probe forward, and the floating sleeve achieves a slight axial movement with the help of the elastic force of the compression spring. This can automatically compensate for the positional deviation of the incoming material, ensuring a reliable fit between the probe and the metal contacts of the electrical connector. This avoids damage to the probe caused by rigid hard contact and eliminates detection misjudgments caused by poor contact, effectively improving detection stability and probe lifespan.

[0024] The side of the tray is equipped with multiple sets of snap-fit ​​slots. The size of the snap-fit ​​slots is adapted to the grippers of a general industrial robot. When the tray is full of electrical connectors, the grippers of the external robot can be snapped into the snap-fit ​​slots to hold and remove the full tray smoothly.

[0025] A quick-change interface is provided between the suction block and the second sliding plate. The quick-change interface includes a positioning pin hole at the bottom of the suction block, a positioning pin on the second sliding plate, and a quick-locking buckle on the outer periphery of the positioning pin. The positioning pin hole and the positioning pin cooperate to achieve circumferential positioning of the suction block. The quick-locking buckle is electrically connected to the control center. After the control center controls the quick-locking buckle to unlock, the operator can manually pull out the suction block along the direction of the positioning pin for replacement. When a new suction block is replaced, the operator pushes the suction block into the second sliding plate, the positioning pin inserts into the positioning pin hole to achieve circumferential positioning, and the control center controls the quick-locking buckle to lock. The suction status detection module automatically performs a suction test. If the suction test passes, the control center confirms that the suction block replacement is complete and allows production to resume. If the suction test fails, the control center issues a suction block installation abnormality prompt.

[0026] The beneficial effects of this invention are as follows: This invention achieves full automation of the "feeding → electrical testing → sorting → posture adjustment → tray placement" process by coordinating the operation of the electrical testing component, the dual-moving component conveying mechanism, the four-sided switching transfer mechanism, and the cross-displacement tray placement mechanism through the control center. The electrical testing component uses a floating probe to flexibly dock and complete the continuity test, automatically rejecting defective products. The dual-moving component runs independently along the same track, sequentially transferring qualified products to the transfer mechanism and the tray placement mechanism. The transfer mechanism uses a rotating block with four-sided switching and electromagnetic adsorption micro-correction to achieve multi-specification adaptation and posture uniformity. The tray placement mechanism completes the material handling through lifting and lateral cross-displacement. The orderly filling of the trays has the following advantages: electromagnetic adsorption combined with Hall sensor magnetic circuit detection enables real-time judgment of the suction status and automatic replenishment, greatly reducing the failure rate of empty suction and bias suction; the floating connector uses spring preload to compensate for the material tolerance, avoiding probe damage and detection misjudgment; the four-sided placement of raised structures on the rotating block allows a single machine to quickly adapt to multiple specifications of electrical connectors without stopping the machine to change molds; the dual-component parallel anti-collision and quick-change suction block design ensures reliability and maintenance convenience under high-speed continuous operation; the overall solution effectively replaces manual labor to achieve high-precision and high-efficiency automated tray production of large batches of electrical connectors. Attached Figure Description

[0027] Figure 1This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the conveying mechanism of the present invention; Figure 3 For the present invention Figure 1 A magnified structural diagram of part A in the middle; Figure 4 For the present invention Figure 2 A magnified structural diagram of part B in the middle section; Figure 5 This is a schematic diagram of the transfer mechanism of the present invention; Figure 6 This is a schematic diagram of the structure of the first or second moving component of the present invention; Figure 7 This is a schematic diagram of the plate-stacking mechanism of the present invention; Figure 8 For the present invention Figure 7 A magnified structural diagram of section C; Figure 9 This is a schematic diagram of the floating connector of the present invention.

[0028] The reference numerals in the figures include: 1. Electrical testing component; 2. Conveying mechanism; 3. Plate-swinging mechanism; 4. Transfer mechanism; 5. Moving guide rail; 6. First moving component; 7. Second moving component; 8. Support; 9. Rotating block; 11. Rotating motor; 12. First gear; 13. Second gear; 14. Belt; 15. Placement protrusion; 16. Telescopic motor; 17. Support part; 18. Electrical testing module; 19. Continuity testing probe; 21. Data acquisition module; 22. First sliding plate; 23. Second sliding plate; 24. 25. Suction block; 26. First sliding drive component; 27. Second sliding drive component; 28. First protrusion; 29. ​​Second protrusion; 30. Spacing part; 31. Disc guide rail; 32. Lifting drive component; 33. Disc receiving unit; 35. Receiving groove; 36. Base plate; 37. Stop plate; 38. Clamping assembly; 39. Clamping cylinder; 41. Clamping plate; 42. Floating connector; 43. Probe body; 44. Floating sleeve; 45. Elastic reset component; 46. Snap-fit ​​groove; 47. Quick-change interface. Detailed Implementation

[0029] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to embodiments and accompanying drawings. The content mentioned in the embodiments is not intended to limit the present invention.

[0030] Please see Figures 1 to 9As shown, an automatic electrical testing and tray-stacking machine for high-speed wire connectors according to the present invention includes an electrical testing component 1, a conveying mechanism 2, a tray-stacking mechanism 3, a transfer mechanism 4, and a control center. The external feeding mechanism, electrical testing component 1, conveying mechanism 2, tray-stacking mechanism 3, and transfer mechanism 4 are all electrically connected to the control center. The external feeding mechanism conveys the electrical connectors to the testing station between the electrical testing component 1 and the transfer mechanism 4. The transfer mechanism 4 is located between the external feeding mechanism and the tray-stacking mechanism 3. The conveying mechanism 2 is located above the electrical testing component 1, the tray-stacking mechanism 3, and the transfer mechanism 4. The conveying mechanism 2 includes a moving guide rail 5, a first moving component 6 and a second moving component 7 reciprocatingly mounted on the moving guide rail 5. The electrical connectors are transported to the electrical testing component via the external feeding mechanism. Between component 1 and transfer mechanism 4, electrical testing component 1 performs electrical tests on the electrical connector. Electrical testing component 1 transmits the electrical test results back to the control center. The control center analyzes whether the electrical connector is qualified based on the electrical test results. If the electrical connector is qualified, the control center controls the first moving component 6 to pick up the electrical connector placed on the external feeding mechanism and move it along the moving guide rail 5, placing the electrical connector on the transfer mechanism 4 for posture correction. The second moving component 7 picks up the electrical connector placed on the transfer mechanism 4 and moves it along the moving guide rail 5, placing the electrical connector on the tray mechanism 3. If the electrical connector is unqualified, the external feeding mechanism transports the unqualified electrical connector to the external waste collection station.

[0031] This equipment relies on the control center to coordinate the external feeding mechanism, electrical testing component 1, conveying mechanism 2, transfer mechanism 4, and tray placement mechanism 3. During operation, the external feeding mechanism delivers the electrical connectors to the testing station, where the electrical testing component 1 performs electrical testing and feeds back data to the control center to determine the quality of the products. Qualified products are transferred to the transfer mechanism 4 via the first moving component 6 for posture correction, and then transferred to the tray placement mechanism 3 via the second moving component 7 for orderly placement. Unqualified products are directly conveyed to the waste collection station by the external feeding mechanism for automatic rejection. This equipment achieves full automation of the feeding, testing, sorting, posture adjustment, transfer, and tray placement process. The division of labor is clear, and the process is smoothly connected, effectively reducing the cost of manual intervention, improving testing accuracy and production efficiency, and ensuring that the products are placed neatly and uniformly. It can meet the needs of large-scale continuous production of electrical connectors.

[0032] The transfer mechanism 4 includes a bracket 8, a rotating block 9 mounted on the bracket 8, and a rotating assembly that is connected to the rotating block 9 in a transmission manner. The rotating assembly includes a rotating motor 11, a first gear 12 mounted on the output shaft of the rotating motor 11, a second gear 13 mounted on one end of the rotating block 9, and a belt 14 sleeved on the first gear 12 and the second gear 13. The rotating block 9 has multiple sets of placement protrusions 15 on its periphery, and the multiple sets of placement protrusions 15 are respectively arranged along the four sides of the rotating block 9. When the external electrical connector is replaced, the rotating motor 11 drives the rotating block 9 to rotate to switch the sides of the rotating block 9, and the placement protrusions 15 on different sides are adapted to the corresponding specifications of the electrical connector.

[0033] During operation, the rotating motor 11 drives the rotating block 9 to rotate through the first gear 12, belt 14 and second gear 13, switching the placement protrusions 15 on different sides to adapt to different specifications of electrical connectors. The bracket 8 provides overall stable support. This structure has smooth transmission, convenient switching, and can quickly complete product specification adaptation. It is highly versatile and can effectively meet the posture support and transportation needs of multiple types of electrical connectors.

[0034] The placement protrusion 15 has a built-in electrically controlled electromagnet, which is electrically connected to the control center to achieve controllable magnetic attraction: when the electrical connector is placed in place, the control center controls the electromagnet to be energized to generate magnetism, which magnetically attracts and fixes the metal part of the electrical connector to prevent the product from loosening or shifting; when it is necessary to remove the electrical connector, the control center controls the electromagnet to be de-energized and demagnetized in advance to release the magnetic attraction.

[0035] The control center can control the energization and de-energization of the electromagnet inside the placement protrusion 15 in real time. When the electrical connector is placed on the placement protrusion 15, the electromagnet is energized and generates magnetism, magnetically fixing the metal part of the electrical connector. This, together with the mechanical limit of the placement protrusion 15, constrains the product position, effectively preventing the electrical connector from loosening, shifting, or misaligning during posture correction and waiting for transfer. When material needs to be picked up and transferred, the control center controls the electromagnet to be de-energized in advance, completely releasing the magnetic constraint and ensuring that the picking component can smoothly pick up the product without any adsorption residue. The overall structure achieves controllable magnetic positioning, with high positioning stability and rapid unlocking response, significantly improving the posture adjustment accuracy of the electrical connector and the smoothness of the transfer operation. The electromagnet generates attraction when energized, applying a uniform magnetic pull to the metal part of the electrical connector. If the product has a slight tilt or shift, the magnetic force will pull it to the standard position that fits the protrusion, completing micro-correction. Subsequently, the rotating component drives the rotating block 9 to rotate as a whole, and the placement protrusion 15 and the fixed electrical connector rotate synchronously, thereby changing the product orientation and completing the posture conversion of the preset angle.

[0036] The electrical connector falls between two sets of protrusions, its shape being held and limited by the protrusions, restricting its forward, backward, left, and right displacement, thus completing coarse positioning. A magnetic micro-correction electromagnet is energized, attracting the product's original metal parts; if the product is slightly tilted or misaligned, the uniform magnetic force will pull the product to a standard position where it is completely aligned with the protrusions, correcting minor deviations. Angle adjustment rotating block 9 rotates the protrusions and the product together, changing the product's orientation and completing the specified angle posture change. Once the unlocking and picking posture is in place, the electromagnet is de-energized, the magnetic force disappears, and the upper picking mechanism can easily remove the product. The electrical testing component 1 includes a telescopic motor 16 disposed on the side of the external feeding mechanism, a support part 17 connected to the output end of the telescopic motor 16, and an electrical testing module 18 disposed on the support part 17. The telescopic motor 16 is electrically connected to the control center, and the support part 17 moves horizontally forward and backward with the telescopic movement of the telescopic motor 16. The electrical testing module 18 includes a continuity test probe 19 and a data acquisition module 21. When the electrical connector is transported to the testing station by the external feeding mechanism, the telescopic motor 16 extends to push the support part 17 forward, and the continuity test probe 19 makes electrical connection with the metal contacts of the electrical connector to detect the circuit continuity performance. The data acquisition module 21 collects the detection signal of the continuity test probe 19 and uploads it to the control center.

[0037] Driven by the control center, the telescopic motor 16 moves the support part 17 and the electrical testing module 18 horizontally forward and backward. After the electrical connector arrives at the testing station, the continuity testing probe 19 moves forward to contact the metal contacts of the product to complete the continuity test. The data acquisition module 21 simultaneously uploads the test signal to the control center. This structure is flexible in movement and precise in docking. It can automatically complete electrical testing and data transmission. The testing process is highly automated and can effectively improve testing efficiency and result reliability.

[0038] The first moving component 6 and the second moving component 7 each include a first sliding plate 22 that slides back and forth on the moving guide rail 5, a second sliding plate 23 that slides back and forth on the first sliding plate 22, a suction block 24 disposed on the second sliding plate 23, a first sliding drive 25 that drives the first sliding plate 22 to slide back and forth, and a second sliding drive 26 that drives the second sliding plate 23 to slide back and forth. The suction block 24 has a built-in electromagnetic adsorption structure, and the electromagnetic adsorption structure is electrically connected to the control center, which can realize controllable magnetic suction of materials. The first moving component 6 and the second moving component 7 have the same structure and are independently slidably disposed on the moving guide rail 5. The first moving component 6 is responsible for transferring qualified electrical connectors from the external feeding mechanism to the transfer mechanism 4, and the second moving component 7 is responsible for transferring the electrical connectors that have been adjusted by the transfer mechanism 4 to the tray mechanism 3.

[0039] During operation, the first sliding drive component 25 and the second sliding drive component 26 drive the first sliding plate 22 and the second sliding plate 23 to move horizontally and vertically, respectively. Together with the electromagnetic adsorption structure built into the suction block 24, controllable magnetic material suction is achieved. The two sets of moving components work independently and sequentially transfer qualified electrical connectors to the transfer mechanism 4 and the tray mechanism 3. This structure has flexible movement dimensions and stable and reliable material handling. The division of labor and cooperation between the two components makes the process connection smoother and effectively improves the overall transfer efficiency and the continuity of equipment operation.

[0040] The suction end of the suction block 24 is provided with a first protrusion 27 and a second protrusion 28, and a spacer 29 is provided between the first protrusion 27 and the second protrusion 28. The external electrical connector is provided with a first groove and a second groove. The first protrusion 27 and the second protrusion 28 can be respectively inserted into the first groove and the second groove to achieve positioning, and form a double fixing structure with controllable magnetic adsorption.

[0041] During operation, the first protrusion 27 and the second protrusion 28 of the suction block 24 are mechanically positioned by correspondingly engaging with the first and second grooves of the electrical connector. Combined with the internal electromagnetic adsorption structure, a double fixation is formed. The spacer 29 can be adapted to the product shape to achieve precise engagement. This combined structure provides reliable positioning and can effectively prevent the product from shifting or slipping during transportation, further improving gripping stability and alignment accuracy.

[0042] The tray-sliding mechanism 3 includes a tray-sliding guide rail 31, a lifting drive 32 slidably mounted on the tray-sliding guide rail 31, a tray receiving unit 33 located at the output end of the lifting drive 32, and a tray-sliding drive that drives the lifting drive 32 to slide back and forth. The lifting drive 32 and the tray-sliding drive are both electrically connected to the control center. The tray receiving unit 33 is used to place the tray. The moving direction of the lifting drive 32 intersects with the moving direction of the second moving component 7. The tray is provided with multiple sets of equidistant receiving slots 35. Through the cross displacement cooperation of the lifting drive 32 and the second moving component 7, the receiving slots 35 at different positions on the tray can be adapted to achieve orderly placement of electrical connectors.

[0043] During operation, the swivel drive unit drives the lifting drive unit 32 and the tray receiving unit 33 to slide along the swivel guide rail 31. Combined with the cross movement of the lifting drive unit 32 and the second moving component 7, the equidistant receiving slots 35 on the material tray are sequentially connected to the material picking position, completing the orderly placement of the electrical connectors. This matching method has precise alignment, can be adapted to continuous swivel of multiple slots, runs smoothly, and effectively ensures the neatness of placement and work efficiency.

[0044] The tray receiving unit 33 includes a base plate 36 connected to the lifting drive 32, a stop plate 37 vertically arranged on the base plate 36, and a clamping assembly 38 arranged on the side of the base plate 36. The trays are stacked on the base plate 36. There are four sets of stop plates 37, which are arranged around the base plate 36 to limit the trays around the perimeter. There are two sets of clamping assemblies 38. The clamping assembly 38 includes a clamping cylinder 39 and a clamping plate 41 connected to the output end of the clamping cylinder 39. The clamping plate 41 clamps and limits the two parallel sides of the tray. When a tray is full of electrical connectors, it is removed by an external robot. The lifting drive 32 drives the base plate 36 to move upward, lifting the empty tray stacked below the full tray to the tray placement station to replace the full tray and continue receiving and placing the trays.

[0045] During operation, the stacked trays are placed on the base plate 36. The surrounding stop plates 37, along with the clamping cylinders 39 and clamping plates 41 on both sides, work together to limit the movement of the trays and prevent them from shifting. Once the trays are full, they are removed by an external robotic arm. The lifting drive 32 then drives the base plate 36 to rise, sending the empty trays below to the tray-sanding station for continued operation. This structure provides reliable limiting and convenient tray changing, ensuring continuous tray-sanding operations.

[0046] Both the first moving component 6 and the second moving component 7 have an absorption status detection module on their absorption block 24. The absorption status detection module includes a Hall sensor installed inside the absorption block 24 and a judgment circuit electrically connected to the control center. After the electromagnetic adsorption structure is energized, a predetermined magnetic field is generated at the absorption end. The Hall sensor is installed at the air gap of the magnetic circuit at the absorption end to detect the magnetic induction intensity at the air gap in real time. When the absorption block 24 presses down to adhere to the electrical connector and the electromagnetic adsorption structure is energized, the metal part of the electrical connector enters the air gap of the magnetic circuit. The metal conductor generates a short circuit effect on the magnetic lines of force, and the real-time magnetic induction intensity value at the air gap undergoes a characteristic change. The judgment circuit compares the real-time magnetic induction intensity value collected by the Hall sensor with a preset threshold. If the magnetic induction intensity value drops below the preset threshold, the absorption is determined to be successful, and the control center drives the first moving component 6 or the second moving component 7 to perform a transfer action. If the magnetic induction intensity value does not drop to the preset threshold, the absorption is determined to be unsuccessful, and the control center controls the first moving component 6 or the second moving component 7 to return to its original position and issues a supplementary absorption command.

[0047] During operation, the Hall sensor continuously monitors the magnetic field strength of the air gap in the magnetic circuit of the suction block 24. The judgment circuit compares the collected data with a preset threshold and determines whether the electrical connector has been successfully picked up based on the influence of the metal conductor on the magnetic field. If the pick-up is successful, a transfer action is executed; if the pick-up fails, the component is controlled to return to its original position and a supplementary pick-up command is triggered. This module can automatically identify abnormal situations such as empty pick-up and biased pick-up, effectively reducing the probability of equipment failure and improving the stability and automation level of the gripping operation. After the electromagnetic adsorption structure is energized, a fixed magnetic field is formed at the suction end, and the Hall sensor measures a reference magnetic field value. When the suction block 24 adheres to and attracts the electrical connector, the metal conductor on the product will intervene in the magnetic circuit and disperse the magnetic lines of force, causing the magnetic field at the air gap to weaken and the sensor reading to drop. The circuit compares the reading with the preset threshold to distinguish between successful pick-up and empty / biased pick-up.

[0048] The front end of the continuity detection probe 19 is provided with a floating connector 42. The floating connector 42 includes a probe body 43, a floating sleeve 44 sleeved on the probe body 43, and an elastic reset member 45 disposed between the floating sleeve 44 and the probe body 43. The elastic reset member 45 is a compression spring that provides axial elastic preload. When the telescopic motor 16 pushes the support part 17 forward, at the moment when the continuity detection probe 19 contacts the metal contact of the electrical connector, the floating sleeve 44 generates a slight axial float under the action of the elastic reset member 45, automatically compensating for the positional tolerance of the electrical connector in the conveying direction and avoiding probe damage or poor contact caused by rigid docking.

[0049] During operation, the telescopic motor 16 drives the probe forward, and the floating sleeve 44 achieves a slight axial floating by means of the elastic force of the compression spring. This can automatically compensate for the positional deviation of the incoming material, ensuring a reliable fit between the probe and the metal contacts of the electrical connector. This avoids damage to the probe caused by rigid hard contact and eliminates detection misjudgments caused by poor contact, effectively improving detection stability and probe lifespan.

[0050] The side of the tray is provided with multiple sets of snap-fit ​​slots 46. The size of the snap-fit ​​slots 46 is adapted to the grippers of the general industrial robot. When the tray is full of electrical connectors, the grippers of the external robot can be snapped into the snap-fit ​​slots 46 to hold and remove the full tray smoothly.

[0051] A quick-change interface 47 is provided between the suction block 24 and the second sliding plate 23. The quick-change interface 47 includes a positioning pin hole at the bottom of the suction block 24, a positioning pin on the second sliding plate 23, and a quick-locking buckle on the outer periphery of the positioning pin. The positioning pin hole and the positioning pin cooperate to achieve circumferential positioning of the suction block 24. The quick-locking buckle is electrically connected to the control center. After the control center controls the quick-locking buckle to unlock, the operator can manually pull out the suction block 24 along the direction of the positioning pin for replacement. When a new suction block 24 is replaced, the operator pushes the suction block 24 into the second sliding plate 23, the positioning pin inserts into the positioning pin hole to achieve circumferential positioning, and the control center controls the quick-locking buckle to lock. The suction status detection module automatically performs a suction test. If the suction test passes, the control center confirms that the suction block 24 has been replaced and allows production to resume. If the suction test fails, the control center issues a suction block 24 installation abnormality prompt.

[0052] The above description is only a preferred embodiment of the present invention. For those skilled in the art, there will be changes in the specific implementation and application scope based on the ideas of the present invention. The content of this specification should not be construed as a limitation of the present invention.

Claims

1. An automatic tray-loading machine for electrical testing of high-speed wire connectors, characterized in that: The system includes an electrical testing component (1), a conveying mechanism (2), a tray-mounting mechanism (3), a transfer mechanism (4), and a control center. The external loading mechanism, electrical testing component (1), conveying mechanism (2), tray-mounting mechanism (3), and transfer mechanism (4) are all electrically connected to the control center. The external loading mechanism transports the electrical connector to the testing station between the electrical testing component (1) and the transfer mechanism (4). The transfer mechanism (4) is located between the external loading mechanism and the tray-mounting mechanism (3). The conveying mechanism (2) is located above the electrical testing component (1), the tray-mounting mechanism (3), and the transfer mechanism (4). The conveying mechanism (2) includes a moving guide rail (5), a first moving component (6), and a second moving component (7) reciprocating on the moving guide rail (5). The electrical connector is transported to the electrical testing component (1) via the external loading mechanism. Between the transfer mechanism (4) and the transfer mechanism (5), the electrical testing component (1) performs electrical tests on the electrical connector. The electrical testing component (1) transmits the electrical test results back to the control center. The control center analyzes whether the electrical connector is qualified based on the electrical test results. If the electrical connector is qualified, the control center controls the first moving component (6) to pick up the electrical connector placed on the external feeding mechanism and move it along the moving guide rail (5) to place the electrical connector on the transfer mechanism (4) for posture correction. The second moving component (7) picks up the electrical connector placed on the transfer mechanism (4) and moves it along the moving guide rail (5) to place the electrical connector on the tray mechanism (3). If the electrical connector is unqualified, the external feeding mechanism transports the unqualified electrical connector to the external waste collection station.

2. The automatic tray-mounting machine for high-speed wire connector electrical testing according to claim 1, characterized in that: The transfer mechanism (4) includes a bracket (8), a rotating block (9) mounted on the bracket (8), and a rotating assembly that is connected to the rotating block (9) in a transmission. The rotating assembly includes a rotating motor (11), a first gear (12) mounted on the output shaft of the rotating motor (11), a second gear (13) mounted on one end of the rotating block (9), and a belt (14) mounted on the first gear (12) and the second gear (13). The rotating block (9) has multiple sets of placement protrusions (15) on its periphery, and the multiple sets of placement protrusions (15) are respectively arranged along the four sides of the rotating block (9). When the external electrical connector is replaced, the rotating motor (11) drives the rotating block (9) to rotate to switch the sides of the rotating block (9), and the placement protrusions (15) on different sides are adapted to the corresponding specifications of the electrical connector.

3. The automatic tray-mounting machine for high-speed wire connector electrical testing according to claim 2, characterized in that: The placement protrusion (15) has a built-in electromagnet, which is electrically connected to the control center to achieve controllable magnetic attraction: when the electrical connector is placed in place, the control center controls the electromagnet to be energized to generate magnetism, which magnetically fixes the metal part of the electrical connector to prevent the product from loosening or shifting; when the electrical connector needs to be removed, the control center controls the electromagnet to be de-energized in advance to release the magnetic attraction.

4. The automatic tray-mounting machine for high-speed wire connector electrical testing according to claim 1, characterized in that: The electrical testing component (1) includes a telescopic motor (16) located on the side of the external feeding mechanism, a support part (17) connected to the output end of the telescopic motor (16), and an electrical testing module (18) located on the support part (17). The telescopic motor (16) is electrically connected to the control center, and the support part (17) moves horizontally forward and backward with the telescopic movement of the telescopic motor (16). The electrical testing module (18) includes a continuity test probe (19) and a data acquisition module (21). When the electrical connector is transported to the testing station by the external feeding mechanism, the telescopic motor (16) extends to push the support part (17) forward. The continuity test probe (19) is electrically connected to the metal contacts of the electrical connector to detect the continuity performance of the circuit. The data acquisition module (21) collects the detection signal of the continuity test probe (19) and uploads it to the control center.

5. The automatic tray-mounting machine for high-speed wire connector electrical testing according to claim 1, characterized in that: The first moving component (6) and the second moving component (7) each include a first sliding plate (22) that slides back and forth on the moving guide rail (5), a second sliding plate (23) that slides back and forth on the first sliding plate (22), a suction block (24) that is set on the second sliding plate (23), a first sliding drive (25) that drives the first sliding plate (22) to slide back and forth, and a second sliding drive (26) that drives the second sliding plate (23) to slide back and forth. The suction block (24) has a built-in electromagnetic adsorption structure, and the electromagnetic adsorption structure is electrically connected to the control center, which can realize controllable magnetic suction of materials. The first moving component (6) and the second moving component (7) have the same structure and are independently slidably set on the moving guide rail (5). The first moving component (6) is responsible for transferring the qualified electrical connectors from the external feeding mechanism to the transfer mechanism (4), and the second moving component (7) is responsible for transferring the electrical connectors that have been adjusted by the transfer mechanism (4) to the tray mechanism (3).

6. The automatic electrical testing tray machine for high-speed wire connectors according to claim 5, characterized in that: The suction end of the suction block (24) is provided with a first protrusion (27) and a second protrusion (28), and a gap (29) is provided between the first protrusion (27) and the second protrusion (28). The external electrical connector is provided with a first groove and a second groove. The first protrusion (27) and the second protrusion (28) can be respectively inserted into the first groove and the second groove to achieve positioning, and form a double fixing structure with controllable magnetic adsorption.

7. The automatic tray-mounting machine for high-speed wire connector electrical testing according to claim 1, characterized in that: The tray-sliding mechanism (3) includes a tray-sliding guide rail (31), a lifting drive (32) slidably mounted on the tray-sliding guide rail (31), a tray-containing unit (33) mounted at the output end of the lifting drive (32), and a tray-sliding drive that drives the lifting drive (32) to slide back and forth. The lifting drive (32) and the tray-sliding drive are both electrically connected to the control center. The tray-containing unit (33) is used to place the tray. The moving direction of the lifting drive (32) intersects with the moving direction of the second moving component (7). The tray is provided with multiple sets of equidistant receiving slots (35). Through the cross displacement cooperation of the lifting drive (32) and the second moving component (7), the receiving slots (35) at different positions on the tray can be adapted to achieve orderly placement of electrical connectors.

8. The automatic tray-mounting machine for high-speed wire connector electrical testing according to claim 7, characterized in that: The tray receiving unit (33) includes a base plate (36) connected to the lifting drive (32), a stop plate (37) vertically arranged on the base plate (36), and a clamping assembly (38) arranged on the side of the base plate (36). The trays are stacked on the base plate (36). There are four sets of stop plates (37), which are arranged around the base plate (36) to limit the trays. There are two sets of clamping assemblies (38). The clamping assembly (38) includes a clamping cylinder (39) and a clamping plate (41) connected to the output end of the clamping cylinder (39). The clamping plate (41) clamps and limits the two parallel sides of the tray. When a tray is full of electrical connectors, it is removed by an external robot. The lifting drive (32) drives the base plate (36) to move upward, lifting the empty tray stacked below the full tray to the tray placement station, replacing the full tray to continue receiving and placing the tray.

9. The automatic tray-mounting machine for high-speed wire connector electrical testing according to claim 5, characterized in that: The first moving component (6) and the second moving component (7) are each equipped with an absorption state detection module on their absorption block (24). The absorption state detection module includes a Hall sensor installed inside the absorption block (24) and a judgment circuit electrically connected to the control center. After the electromagnetic adsorption structure is energized, a predetermined magnetic field is generated at the absorption end. The Hall sensor is installed at the air gap of the magnetic circuit at the absorption end to detect the magnetic induction intensity at the air gap in real time. When the absorption block (24) presses down to fit the electrical connector and the electromagnetic adsorption structure is energized, the metal part of the electrical connector enters the air gap of the magnetic circuit. The metal conductor generates a short circuit effect on the magnetic lines of force, and the real-time magnetic induction intensity value at the air gap undergoes a characteristic change. The judgment circuit compares the real-time magnetic induction intensity value collected by the Hall sensor with a preset threshold. If the magnetic induction intensity value drops below the preset threshold, the absorption is determined to be successful, and the control center drives the first moving component (6) or the second moving component (7) to perform a transfer action. If the magnetic induction intensity value does not drop to the preset threshold, the absorption is determined to be unsuccessful, and the control center controls the first moving component (6) or the second moving component (7) to return to its original position and issues a supplementary absorption command.

10. The automatic tray-mounting machine for high-speed wire connector electrical testing according to claim 4, characterized in that: The front end of the continuity detection probe (19) is provided with a floating connector (42). The floating connector (42) includes a probe body (43), a floating sleeve (44) sleeved on the probe body (43), and an elastic reset member (45) disposed between the floating sleeve (44) and the probe body (43). The elastic reset member (45) is a compression spring that provides axial elastic preload. When the telescopic motor (16) pushes the support part (17) forward, at the instant the continuity detection probe (19) contacts the metal contact of the electrical connector, the floating sleeve (44) generates a slight axial float under the action of the elastic reset member (45), automatically compensating for the positional tolerance of the electrical connector in the conveying direction, and avoiding probe damage or poor contact caused by rigid docking.

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