A combined processing, inspection, assembly, and control method and system for lighting fixtures

Abstract

This invention relates to the field of automated lighting production technology, and discloses a combined processing, inspection, assembly, and control method and system for lighting fixtures. The system includes a path allocation module that assigns target inspection levels to a moving conveyor plate, and splits the initial task message into an in-transit pre-test sequence and a residual pulse task based on an estimated conveying time window. During displacement, a follow-up drive module executes the in-transit pre-test sequence, adjusting the disconnection time according to deviations to perform phase alignment compensation. A preliminary screening and sorting module captures feature data and links the lifting machine to perform sorting. After entering the target inspection level, a data acquisition and release module completes the residual pulse task and triggers parameter acquisition. This invention shortens queuing time and inspection cycle by splitting tasks and executing them in advance during conveying; ensures that the lighting fixture reaches a stable state before parameter acquisition by performing phase alignment compensation; and prevents unqualified lighting fixtures from entering the target inspection level by capturing feature deviations and sorting them in advance.

Description

Technical Field

[0001] This invention relates to the field of automated production technology for lighting fixtures, specifically to a combined processing, inspection, assembly, and control method and system for lighting fixtures. Background Technology

[0002] With the popularization of automated production technology, lighting fixtures typically rely on moving conveyor plates to move between multiple inspection levels during the processing and inspection process. The existing control method mainly adopts a fixed-station inspection mode. During the displacement of the lighting fixture between each inspection level, it is in a non-operating state. Only after the moving conveyor plate has completely entered the predetermined coordinates of the target station and completed positioning will the system start the preset electrical test program.

[0003] In this production model, the physical displacement of the luminaires and the electrical testing process are sequentially connected, which limits the equipment utilization rate at the testing level to the displacement time of the luminaires. Since all test pulse tasks are executed after the luminaires arrive at the workstation, when the initial task message contains a large number of tests, the time the luminaires occupy at the testing workstation increases, which can easily lead to the accumulation of testing queues and prolong the product turnaround time.

[0004] The existing control logic lacks a dynamic compensation mechanism for physical displacement deviations and electrical phases during the movement of the conveyor plate to the inspection level entrance. This results in fluctuations in the electrical state of the luminaires at the moment of handover, affecting the consistency of subsequent data acquisition. Furthermore, for defective luminaires, the existing system typically only performs sorting after completing the full-process inspection at a fixed station, causing non-conforming products to occupy valuable displacement space and inspection resources during the conveying and inspection stages. Therefore, implementing in-transit testing, electrical steady-state control, and pre-sorting of defective products during luminaire conveying is a problem that needs to be solved in this field. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a combined processing, inspection, assembly, and control method and system for lamps. It solves the problems of long inspection cycles caused by the physical displacement of lamps and the sequential execution of electrical inspections under the existing fixed-station inspection mode, the impact of electrical state fluctuations at the handover moment on the consistency of collected data, and the delayed sorting of unqualified lamps occupying effective inspection resources.

[0006] To address the above problems, the present invention provides the following technical solution: This invention provides a combined processing, inspection, assembly, and control method for lighting fixtures, employing the following technical solution: A method for controlling the combined processing, inspection, assembly, and control of lighting fixtures includes the following steps: The path allocation module receives the lamp arrival signal and assigns a target detection level to the moving conveyor plate carrying the lamp, extracts the initial task message, and combines the estimated delivery time window calculated by the progress calibration module to split the initial task message into an in-transit pre-test sequence and a residual pulse task. During the displacement of the moving conveyor plate, the follow-up drive module executes the in-transit pre-test sequence, adjusts the disconnection time to perform phase alignment compensation based on the deviation between the actual consumption time fed back by the progress calibration module and the estimated conveying time window, and records the completed test progress. During the execution of the in-transit pre-test sequence by the follow-up drive module, the initial screening and sorting module captures the operating characteristic data of the lamp and calculates the characteristic deviation. When the characteristic deviation exceeds a preset threshold, a failure mark is generated and the hoist is linked to perform a sorting action. After the moving conveyor plate enters the target detection level, the acquisition and release module reads the completed test progress, controls the controlled power supply to complete the residual pulse task, and triggers parameter acquisition and executes the release command after the lamp reaches a stable state.

[0007] By adopting the above technical solution, the design of splitting the initial task and executing the pre-test sequence in advance during the transportation process utilizes the physical transfer time of the lamps between workstations, significantly shortening the dwell period of the lamps at the fixed inspection level. Simultaneously, the pulse disconnection time is dynamically adjusted based on the deviation of the actual transportation time to achieve phase alignment compensation, ensuring that the electrical phase of the lamps upon arrival at the fixed workstation matches the subsequent testing requirements, avoiding electrical shocks or test data fluctuations caused by switching control. The initial screening and sorting mechanism executed synchronously during transportation can identify and promptly remove abnormal products at an early stage, preventing defective products from occupying inspection resources, thereby improving the processing, inspection, and assembly efficiency of the entire production line.

[0008] Furthermore, the path allocation module periodically obtains the queue length and single detection cycle of each detection level, calculates the load weight based on the product of the queue length and the single detection cycle, and assigns the mobile conveyor plate to the detection level with the lowest load weight and the queuing time less than a preset time threshold as the target detection level.

[0009] By adopting the above technical solution, a load weight evaluation mechanism based on queue length and cycle is introduced, which realizes dynamic load balancing among multi-level inspection stations, avoids local station congestion, and optimizes the overall production line logistics scheduling.

[0010] Furthermore, the initial task message includes the pulse on-time, pulse off-time, and total number of pulses; the path allocation module calculates the estimated delivery time window based on the delivery path length and displacement speed, and after removing the safety margin time from the estimated delivery time window, it calculates the number of pre-executions in transit by combining the pulse on-time and the pulse off-time, thereby dividing the total number of pulses into the pre-test sequence in transit corresponding to the number of pre-executions in transit and the residual pulse task.

[0011] By adopting the above technical solution, combining motion parameters and electrical test parameters to accurately divide the test task and removing the safety margin time, the operation conflict caused by the incomplete task at the moment of docking of the moving conveyor plate can be prevented, thus ensuring a stable transition between in-transit testing and fixed-station testing.

[0012] Furthermore, the follow-up drive module obtains electrical energy through the electrically powered sliding contact structure and drives the lamp to perform on / off actions according to the pulse on-time and pulse off-time; the progress calibration module obtains the displacement sensor pulse signal on the track node to monitor the spatial coordinates of the moving conveyor plate, and records the time span from the displacement starting point to the current coordinate as the actual time consumed.

[0013] By adopting the above technical solution, the electro-sliding contact structure ensures a continuous power supply for the mobile device during displacement, while the use of sensor pulse signals from the track nodes for spatial and temporal monitoring provides an accurate and real operational data basis for subsequent phase alignment operations.

[0014] Furthermore, the process of the follow-up drive module performing phase alignment compensation is as follows: when the moving conveyor plate reaches a preset buffer distance from the entrance of the hoist, based on the deviation between the estimated conveying time window and the actual consumption time, the compensation disconnection time of the last pulse cycle currently being executed is calculated, and the compensation disconnection time is used to cover the original pulse disconnection time, so that the electrical state of the lamp is at a steady-state phase point at the instant the moving conveyor plate reaches the pallet of the hoist.

[0015] By adopting the above technical solution, the system can absorb time errors during the mechanical conveying process. By controlling the disconnection time of the last cycle, the on / off cycle of the lamps is adjusted, ensuring that the electrical state of the lamps is within a stable range at the moment of handover, thus eliminating interference caused by mechanical displacement delay on the continuity of the test.

[0016] Furthermore, the process by which the initial screening and sorting module captures the operational characteristic data and calculates the characteristic deviation includes: using a high-frequency sampling circuit to obtain a current sequence during the stable lighting phase of the pulse turn-on time; calculating the average current value by averaging the current data after avoiding the sampling delay time of the surge current; and comparing the average current value with the standard reference value to calculate the electrical abnormality deviation as the characteristic deviation.

[0017] By adopting the above technical solution, the sampling timing avoids the surge phase at the initial stage of power-on, and obtains the average value during the stable period. This can filter out transient electrical interference, improve the accuracy and reliability of early characteristic deviation calculation, and prevent good products from being incorrectly sorted due to misjudgment.

[0018] Furthermore, when the electrical abnormal deviation exceeds the preset threshold and the abnormal state recurs within the continuous judgment window length, the lamp is determined to be unqualified and the failure mark is generated; the central control unit binds the failure mark with the number of the mobile conveyor plate and sends it to the scheduling controller of the hoist, and drives the track switching device to guide the mobile conveyor plate carrying the failure mark to the defective product collection area.

[0019] By adopting the above technical solution, the continuous judgment window mechanism enhances the fault tolerance capability of fault judgment and avoids misjudgment caused by single, accidental data fluctuations. By binding the failure marker to the vehicle number, synchronous linkage between information flow and logistics is achieved, ensuring that defective products are automatically rejected.

[0020] Furthermore, the data acquisition and release module establishes data exchange with the follow-up drive module through a near-field communication interface set on the dark box wall of the testing station, and reads the completed test progress stored in the internal register of the follow-up drive module; the controlled power supply couples with the power input terminal of the moving conveyor plate by executing a switching logic of first connecting and then disconnecting, and switches the driving control of the lamp from the follow-up drive module to the data acquisition and release module.

[0021] By adopting the above technical solution, contactless synchronization of test progress data is achieved using near-field communication, avoiding the physical action of plugging and unplugging communication cables. The electrical switching logic of first connecting and then disconnecting ensures the continuity of power supply to the luminaire during the handover of control, maintaining the electrothermal stability of the internal components of the luminaire.

[0022] Furthermore, the acquisition and release module calculates the total acquisition time based on the time point when the moving conveyor plate enters the target detection level, the number of pulse cycles of the residual pulse task, the pulse cycle duration, and the sampling and holding delay time. When the system clock reaches the total acquisition time, the optical sensor and the electrical parameter analyzer are synchronously triggered to perform data acquisition.

[0023] By adopting the above technical solution, the appropriate time for data acquisition can be accurately predicted and locked through the synthesis and calculation of multi-dimensional time parameters, ensuring that optical and electrical parameters are collected at the same time when the lamp is in a stable state, thereby improving the consistency of the detection data and the scientific nature of the evaluation criteria.

[0024] This invention also provides a combined processing, inspection, assembly, and control system for lamps, employing the following technical solution:

[0025] A combined processing, inspection, assembly, and control system for lighting fixtures, comprising: The path allocation module is used to receive the lamp arrival signal and assign the target detection level to the moving conveyor plate carrying the lamp. It also parses and splits the initial task message into an in-transit pre-test sequence and residual pulse task in combination with the estimated delivery time window. The progress calibration module is used to calculate the estimated delivery time window and output it to the path allocation module, while recording the actual time consumed by the moving conveyor plate; The follow-up drive module is used to receive and execute the in-transit pre-test sequence, obtain the actual consumption time recorded by the progress calibration module, adjust the disconnection time based on the deviation between the actual consumption time and the estimated delivery time window to perform phase alignment compensation, and record the completed test progress. The initial screening and sorting module is used to capture the operating characteristic data of the lamp and calculate the characteristic deviation during the execution of the in-transit pre-test sequence by the follow-up drive module. When the characteristic deviation exceeds a preset threshold, it outputs a failure mark and links the hoist to perform sorting action. The acquisition and release module is used to receive the completed test progress recorded by the follow-up drive module after the moving conveyor plate enters the target detection level, coordinate with the controlled power supply to complete the residual pulse task and trigger parameter acquisition.

[0026] By adopting the above technical solution and relying on the collaborative mechanism of each functional module, a control architecture that synchronizes data flow and time flow was constructed. The path allocation module and the follow-up drive module work together to realize parallel processing of test tasks during physical space transfer, reducing the testing time at fixed workstations; the progress calibration module, in conjunction with the initial screening and sorting module, realizes dynamic monitoring and pre-interception of defective products during transportation. The overall system operation avoids interference with the main process cycle time, improving the equipment utilization rate and product flow efficiency of the modular assembly and testing production line.

[0027] This invention provides a combined processing, inspection, assembly, and control method and system for lighting fixtures. It has the following beneficial effects:

[0028] 1. This invention uses a path allocation module combined with an estimated delivery time window to split the initial task message into an in-transit pre-test sequence and a residual pulse task. During the displacement of the moving conveyor plate, the follow-up drive module executes the in-transit pre-test sequence. After the moving conveyor plate enters the target detection level, the controlled power supply is controlled to complete the residual pulse task, thereby shortening the queuing time and single detection cycle of the moving conveyor plate at the target detection level.

[0029] 2. This invention uses a follow-up drive module to adjust the disconnection time based on the deviation between the actual consumption time and the estimated conveying time window to perform phase alignment compensation. This ensures that the electrical state of the lamp is at a steady-state phase point when the moving conveyor plate arrives at the pallet of the hoist. Combined with the controlled power supply, the switching logic of connecting first and then disconnecting is used to switch the driving control of the lamp to the acquisition and release module, ensuring that the lamp reaches a stable state before the trigger parameter acquisition.

[0030] 3. The present invention captures the operating characteristic data of the lamps and calculates the characteristic deviation during the execution of the in-transit pre-test sequence by the initial screening and sorting module and the follow-up drive module. When the characteristic deviation exceeds the preset threshold and the abnormal state recurs within the continuous judgment window length, the lamps are determined to be unqualified and a failure mark is generated. The drive track switching device guides the moving conveyor plate carrying the failure mark to the defective product collection area to prevent it from entering the target detection level. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of a lamp assembly and testing system according to a specific embodiment of the present invention. Figure 2 This is a flowchart of a lamp assembly and testing control method according to a specific embodiment of the present invention; Figure 3 This is a waveform diagram of the driving logic level state and phase alignment compensation according to a specific embodiment of the present invention; Figure 4 This is a graph showing the junction temperature response and relative luminous flux variation according to a specific embodiment of the present invention. Detailed Implementation

[0032] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] See attached document Figure 1 This invention provides a lamp assembly and testing system, including a path allocation module, a progress calibration module, a follow-up drive module, a primary screening and sorting module, and a data collection and release module.

[0034] This system is built on a distributed control network of discrete manufacturing production lines, logically linking the central scheduling layer, logistics execution layer, and end-of-line inspection layer via industrial Ethernet. The system hardware support environment includes a U-shaped manual assembly line, inspection cabinets with multiple independent inspection spaces, elevators, and conveyor plates that circulate on tracks.

[0035] The path allocation module, deployed at the central control station, is responsible for receiving trigger signals indicating the completion of the assembly process. By accessing the status registers of the multi-layer testing cabinet in real time, the module obtains the real-time occupancy status of the second, third, and fourth layer testing spaces and assigns the target testing layer to the current luminaire accordingly. Simultaneously, the path allocation module retrieves preset test parameters from the human-machine interface, including pulse on-time, pulse off-time, and total number of pulses, and encapsulates these parameters into an initial test task command, which is then sent to the communication link.

[0036] The progress calibration module connects to displacement sensors and timing units on the track to acquire the dynamic coordinates of the conveyor plate in physical space. The module establishes a mapping logic between spatial position and time, calculating the estimated conveying time window for the conveyor plate to move from the end of the assembly line to the entrance of the target inspection space. The progress calibration module is responsible for converting the material displacement into usable process time resources, providing a synchronization benchmark for subsequent test execution, and ensuring that the inspection step points maintain synchronous offset with the physical position.

[0037] The servo drive module is physically integrated inside the moving conveyor plate and includes a microprocessor, a powered sliding contact mechanism, and a power regulation circuit. The powered sliding contact mechanism obtains electrical energy through contact with the sliding contact line below the track. The servo drive module receives task instructions from the path allocation module and, as the conveyor plate moves toward the hoist, drives the onboard socket to perform preset pulse cycles or thermal balance preheating actions on the lamps, thereby distributing the long-cycle electrical stress testing process during the physical conveying stage.

[0038] The initial screening and sorting module is integrated with the sampling circuit of the follow-up drive module to monitor the current fluctuations of the lamps in real time during the follow-up test. The initial screening and sorting module analyzes the current fingerprint characteristics and compares the deviation of the real-time current value with the standard reference value. If the deviation exceeds a preset range, the initial screening and sorting module generates a failure status marker and reports it to the control center. This marker directly links to the operating logic of the hoist, causing abnormal lamps to skip the lifting and warehousing procedure and enter the sorting area when they reach the hoist position, thus achieving early rejection of invalid loads.

[0039] The data acquisition and release module is located inside the multi-layer testing cabinet. After the conveyor plate is hoisted into the predetermined testing level, the module reads the completed test progress stored inside the conveyor plate via a communication interface and controls the darkroom power supply to complete the remaining tasks. Once the module confirms that the luminaire has reached a stable electrical parameter state, it triggers the optical sensors inside the darkroom to acquire transient parameters. After data acquisition is complete, the module sends a release command to the track drive mechanism, completing the testing cycle for a single luminaire.

[0040] The various modules of this system are logically linked through data flow. The target level determined by the path allocation module is the prerequisite for the progress calibration module to calculate the path. The execution data of the follow-up drive module is the basis for the initial screening and sorting module to make judgments. The data acquisition and release module utilizes the in-transit data accumulated by the aforementioned modules during the transportation process to significantly reduce the dwell time in the detection space.

[0041] See attached document Figure 2 This invention provides a method for controlling the processing, inspection, assembly, and control of combined lighting fixtures, comprising the following steps: S10. The central control unit receives the arrival signal of the lamp at the end of the manual operation assembly line, retrieves the real-time occupancy status of the multi-level detection station through the path allocation module and assigns the target detection level to the moving conveyor plate. At the same time, it generates an initial task message containing the pulse on time, pulse off time and total number of pulses according to the process parameters, and uses the progress calibration module to estimate the conveying time window to complete the task splitting. S20. During the physical displacement of the moving conveyor plate towards the target detection level, it obtains electrical energy through the electro-sliding contact structure. The follow-up drive module executes the pre-pulse cycle, while the progress calibration module monitors the actual time consumed in real time and calculates the number of completed pulses. By dynamically adjusting the disconnection time of the last pulse cycle, it compensates for the phase deviation caused by the fluctuation of the material speed, ensuring that the test sequence is aligned with the physical position. S30. During the execution of the pre-test sequence, the initial screening and sorting module captures the operating current of the lamps in real time through the current sampling circuit and calculates the average current value of the current cycle. The average current value is compared with the standard reference value to obtain the electrical abnormality deviation. If the deviation exceeds the preset threshold, a failure mark is generated and uploaded to the central control station. The linkage elevator performs the emptying and sorting action when the moving conveyor plate reaches the entrance. S40. After the qualified mobile conveyor plate enters the dark box of the target level, the acquisition and release module reads the number of completed pulses through the communication interface and controls the power supply to make up the remaining pulse steps. After the lamp reaches the stable state of electrical parameters and meets the release delay requirements, the optical sensor is triggered to acquire parameters, and a release command is issued after the acquisition is completed to complete the detection cycle.

[0042] The path allocation module first initiates the task allocation and resource scheduling program. In step S10, the central control unit receives the trigger signal from the position sensor located at the end of the manual operation assembly line via the industrial fieldbus, determining that the lamp to be tested has been assembled and entered the conveying starting point. The path allocation module obtains the number of the moving conveyor plate currently carrying the lamp through the identification mechanism and simultaneously initiates the scheduling program for the downstream testing resources. Its principle lies in utilizing the physical displacement time during the material transport process to pre-execute long-cycle electrical stress tests. The progress calibration module establishes a mapping relationship between the material transport path and the process time, distributing the testing tasks that originally required static time in the testing darkroom to the dynamic transport path, thereby significantly reducing the occupancy rate of the testing stations.

[0043] S101, the path allocation module periodically polls the real-time status registers of the second, third, and fourth layer detection spaces in the multi-layer detection cabinet via the industrial Ethernet protocol. These status registers store the occupancy status, queue length, and remaining detection time for each detection layer in bit information format. The occupancy status logic is defined using binary bits; for example, logic 1 represents that the sensor at that station has been triggered and is in a locked state, while logic 0 represents that the station is idle. For the communication handshake and data frame parsing of the industrial Ethernet protocol, those skilled in the art use standard protocol stacks for implementation; the specific implementation methods are well-known in the field and will not be elaborated upon here.

[0044] S102. The path allocation module executes dynamic addressing logic based on the status data of each detection layer. The path allocation module compares the load weights of the second-layer detection space with those of the third and fourth-layer detection spaces. The formula for calculating the load weights is as follows: ; In this formula, For load weight, This represents the current length of the queue to be inspected at this level. This represents the single inspection cycle for this model of lamp. If the queuing time in the second inspection space is less than a preset threshold, the target level of the moving conveyor plate is assigned to the second layer. The preset threshold is typically set between 60s and 180s based on the total production line cycle time. The assignment result is stored as a logical index in the memory mapping table of the central control unit for path guidance of subsequent nodes.

[0045] S103. The path allocation module retrieves a test recipe matching the current luminaire model from the process database. This test recipe includes the pulse on-time, pulse off-time, and total number of pulses required to perform the electrical stress test. In practical applications, the typical range for pulse on-time is set to 0.5s to 2s, and the typical range for pulse off-time is set to 0.5s to 1s. These parameters are encapsulated in the data field of the initial task message and sent to the edge side.

[0046] S104. The progress calibration module calculates the estimated delivery time window using a preset path mapping model. The formula for calculating the estimated delivery time window is as follows: ; In this formula, The length of the transport path is in meters. The rated speed of the conveyor belt is measured in meters per second, and its value is usually set between 0.1 m / s and 0.5 m / s depending on the frequency of the production line motor. This is the estimated delivery time window, measured in seconds. The progress calibration module feeds back the calculated estimated delivery time window to the path allocation module.

[0047] S105. The path allocation module performs spatial partitioning of the test task based on the estimated delivery time window. The path allocation module uses a logic comparator to determine whether the estimated delivery time window is sufficient to cover part of the pulse cycle. If the preset time length condition is met, the path allocation module calculates the number of pre-execution steps in transit according to the following formula after removing a safety margin from the logistics time: ; In this formula, This refers to the pulse on-time. The pulse disconnection time, To estimate the delivery time window, The preset safety margin time is used to compensate for the reset action delay and communication handshake overhead during hoist connection. Its value range is usually set to 2s to 5s. This refers to the number of pre-executions in progress, expressed in times. This indicates a rounding down operation. The path allocation module divides the total number of pulses into the number of pre-executions executed by the follow-up drive module and the remaining executions supplemented by the dark box. It then sends out a complete initial task message containing the pulse on-time, pulse off-time, total number of pulses, and estimated delivery time window to complete the initialization configuration.

[0048] Subsequently, the system enters the in-transit execution and phase alignment stage. In step S20, the moving conveyor plate carrying the luminaire undergoes physical displacement from the assembly process starting point to the elevator entrance of the target detection level, and a preliminary electrical stress test is performed simultaneously during the displacement. This step dynamically adjusts the execution rhythm of the electrical control program by sensing the progress of the physical displacement in real time. Due to differences in manual assembly speed or slippage in mechanical transmission, the time when the luminaire arrives at the elevator is uncertain. This method ensures that the electrical stress phase experienced by the luminaire is consistent before entering the detection dark box by logically correlating the time parameters of the material flow with the electrical pulse parameters, thereby eliminating the influence of in-transit factors on the consistency of optical parameter detection.

[0049] S201, the follow-up drive module establishes an electrical connection with the sliding contact line laid on the side of the conveyor track through the powered sliding contact structure. The powered sliding contact structure uses a carbon brush current collector with self-lubricating function to obtain uninterrupted power. The DC-DC converter circuit inside the moving conveyor plate converts the obtained raw power into a stable DC logic level and power drive power. After detecting the powered signal, the microprocessor of the follow-up drive module retrieves the initial task message issued in step S10 from the local register and drives the power switching unit to control the on / off state of the lamp socket according to the pulse on-time and pulse off-time. For the circuit connection and electromagnetic compatibility design of the power switching unit and the powered sliding contact structure, those skilled in the art use standard industrial-grade power drive circuits.

[0050] S202, the progress calibration module monitors the actual spatial coordinates of the moving conveyor plate by acquiring real-time pulse signals from displacement sensors distributed at key nodes of the conveyor track. The displacement sensors employ high-precision photoelectric encoders or proximity switch arrays with a sampling resolution better than 5mm, used to capture instantaneous speed fluctuations caused by the mechanical vibration of the conveyor belt. The progress calibration module, in conjunction with the system clock of the central control unit, records the time interval elapsed from the moment the moving conveyor plate is triggered to the current coordinate moment, defined as the actual time consumed, in seconds.

[0051] S203. The follow-up drive module calculates the current number of completed pulses in real time based on the actual time consumed, as reported by the progress calibration module. The formula for calculating the number of completed pulses is as follows: ; In this formula, This refers to the pulse on-time. The pulse disconnection time, The actual time consumed is in seconds. This represents the number of pulses completed, expressed in times. This indicates a floor function. This operation determines the number of electrical test cycles that have been fully executed within the current logistics displacement cycle.

[0052] S204. To eliminate the impact of fluctuations in material speed caused by manual assembly cycle time variations or conveyor belt mechanical vibrations on test consistency, the servo drive module performs phase alignment compensation. Based on the deviation between the pre-calculated estimated conveying time window and the actual consumption time in real-time feedback, the servo drive module dynamically calculates the compensation disconnection time for the last pulse cycle currently being executed, when the moving conveyor plate is at a preset buffer distance from the elevator inlet, for example, 0.5 meters to 1 meter. The formula for calculating the compensation disconnection time is as follows: ; In this formula, This refers to the pulse on-time. The pulse disconnection time, This represents the actual time consumed. The number of pulses completed. To compensate for disconnection time, and to ensure the stability of the algorithm, the compensation for disconnection time must satisfy the following constraints: If the calculated value exceeds this range, the servo drive module performs segmented compensation by fine-tuning the duty cycle of the penultimate cycle.

[0053] S205, the follow-up drive module overwrites the original pulse disconnection time with the calculated compensated disconnection time and executes it in the current cycle. By adjusting the disconnection duration of the last cycle, the follow-up drive module ensures that the electrical state of the luminaire it carries is at the boundary point of the transition from on to off or at a preset steady-state phase point the moment the moving conveyor plate physically reaches the hoist tray. This spatiotemporal offset compensation mechanism ensures that the phase of the luminaire remains consistent when it enters the subsequent darkroom station, providing a unified reference benchmark for subsequent transient parameter capture.

[0054] While conducting in-transit testing, the initial screening and sorting module simultaneously performs quality monitoring. In step S30, while executing the pre-test sequence in the moving state, the initial screening and sorting module performs online diagnostics on the operating status of the lamps and executes early filtering actions against invalid loads based on the diagnostic results. This step identifies and rejects defective products with obvious faults in advance by utilizing the electrical pulse response characteristics during the conveying process before the lamps enter the inspection dark box. The online diagnostic mechanism transforms the inspection process from serial execution to partially parallel execution, ensuring that dark box resources are used for qualified products, thereby improving the output density of the entire line.

[0055] S301, the initial screening and sorting module utilizes the high-frequency sampling circuit within the follow-up drive module to capture the lamp's circuit current in real time during the pulse on-time phase. The sampling circuit converts the current signal into a voltage signal via a current transformer or shunt resistor, and then converts it into a digital current sequence via an analog-to-digital converter. The sampling frequency is preferably set to 5kHz to 20kHz. The initial screening and sorting module performs digital filtering on the digital current sequence to remove transient high-frequency noise caused by contact sparks from the sliding contact line. For the specific algorithms of analog-to-digital conversion and digital filtering, those skilled in the art can use well-known finite impulse response filters or median filtering algorithms.

[0056] S302. The initial screening and sorting module calculates the average current value within the current cycle during the stable lighting phase of each pulse cycle. To avoid interference from inductive or capacitive surge currents at the moment of lamp startup, the initial screening and sorting module sets a sampling delay time, typically 10% to 20% of the total pulse on-time. The module only calculates the average current data from the sampling delay time to the end of the pulse on-time. The initial screening and sorting module reads the standard reference value corresponding to the current lamp model from local non-volatile memory and calculates the electrical abnormality deviation using a subtraction operator. The formula for calculating the electrical abnormality deviation is as follows: ; In this formula, This is an electrical abnormal deviation. This is the average current value, in amperes. These are standard reference values, measured in amperes. Electrical anomaly deviations reflect the degree of deviation between the actual power consumption of the luminaire under test and the standard power model, and are used to identify whether the luminaire has leakage, micro-short circuits, or power mismatch issues.

[0057] S303. The initial screening and sorting module logically compares the calculated electrical anomaly deviation with a preset threshold. The preset threshold is typically set to 5% to 15% of the standard reference value according to process requirements, defining the allowable power fluctuation range. If the electrical anomaly deviation significantly exceeds the preset threshold, and the anomaly occurs repeatedly within a preset continuous judgment window length (typically 3 to 5 cycles), the initial screening and sorting module determines that the lamp has unqualified electrical performance and triggers the failure flag setting procedure. The value of the failure flag changes from the original state 0 to 1 and is stored in the status register of the follow-up drive module.

[0058] S304, the follow-up drive module sends the failure flag to the central control unit via a wireless communication link. The central control unit associates the received failure flag with the current moving conveyor plate number and sends the abnormal command to the hoist scheduling controller at the front end of the multi-layer detection cabinet.

[0059] S305. When a mobile conveyor plate carrying a failure mark arrives at the elevator inlet, the elevator dispatch controller identifies the load corresponding to the mobile conveyor plate as an invalid load. The elevator dispatch controller drives the elevator's actuator to change the preset lifting path, and through the control of the track switching device, guides the mobile conveyor plate directly to the defective product collection area located at the bottom of the elevator, instead of performing the lifting action of sending it into the dark box. Through this mechanism, the system significantly reduces the invalid occupation of the inspection station, ensuring that inspection resources are used for the precise parameter acquisition of qualified lamps.

[0060] Finally, qualified products enter the final testing stage. In step S40, the qualified mobile conveyor plate is sent into the target-level testing station by a hoist. The acquisition and release module completes the remaining electrical testing procedures and the final optical parameter acquisition. In this step, the darkroom controller takes over the electrical control of the mobile conveyor plate to make up for any stress cycles that were not completed during the transport. The acquisition and release module establishes a mapping between the physical clock and the logical task to ensure that the thermal characteristics and electrical performance indicators of the luminaire have reached the preset steady-state platform through stress testing before the optical sensor performs the acquisition action, thereby eliminating the impact of transient fluctuations on the testing accuracy.

[0061] S401. After the moving conveyor plate is positioned to the preset location of the inspection station by the hoist, the data acquisition and release module establishes data exchange with the follow-up drive module inside the moving conveyor plate through the near-field communication interface set on the wall panel of the dark box. The near-field communication interface adopts a radio frequency identification link with an operating frequency of 13.56 MHz and is configured with a cyclic redundancy check algorithm to ensure the integrity of data transmission. The data acquisition and release module reads the real-time test status data stored in the register inside the moving conveyor plate to obtain the number of completed pulses that the lamp has executed during the conveying process. For the modulation and demodulation method and error checking logic of the near-field communication interface, those skilled in the art use well-known infrared communication or radio frequency identification technology, and the specific protocol implementation is well-known technology in the field, and will not be described in detail here.

[0062] S402. The acquisition and release module calculates the remaining pulse task quantity for the lamp based on the acquired number of completed pulses and the total number of pulses. The formula for calculating the remaining pulse task quantity is as follows: ; In this formula, This represents the total number of pulses, and its value is usually set from 100 to 500 times depending on the aging level of the lamp. This represents the number of pulses completed. The remaining pulse count represents the number of pulses required for the task. The acquisition and release module dynamically adjusts the power control timing inside the darkroom based on the calculation results to ensure that the total pulse stress on the luminaires meets the process requirements.

[0063] S403. The controlled power supply inside the darkroom switches to external control mode, coupling with the power input terminal of the moving conveyor plate via telescopic contacts or robotic grippers. To prevent test interruption due to power failure and reset of the luminaire driver during the control switch, the controlled power supply executes a seamless switching logic of first connecting and then disconnecting, ensuring that the voltage drop of the moving carrier plate during power switching is less than 5% of the rated voltage. The acquisition and release module switches the drive control of the luminaire, and the control power supply continues to execute the remaining pulse cycle according to the pulse on-time and pulse off-time. During the execution of the remaining pulse tasks, the acquisition and release module synchronously monitors the thermal balance status of the luminaire. The thermal balance status is determined by a preset compensation timer to ensure that the cumulative power-on time of the luminaire before performing optical acquisition meets the thermal stability threshold of this model of luminaire.

[0064] S404. The data acquisition and release module calculates the total acquisition completion time based on the time the moving conveyor plate enters the dark box, the remaining residual pulse task items, and the sampling hold delay. The formula for calculating the total acquisition completion time is as follows: ; In this formula, The time point in seconds when the moving conveyor plate enters the dark chamber; For residual pulse task items; This refers to the pulse on-time; This refers to the pulse disconnection time; The sampling hold delay time, in seconds, typically ranges from 0.5s to 2s. The total time point for data acquisition is expressed in seconds. This formula ensures that the trigger time for data acquisition falls within the open interval of the last pulse cycle.

[0065] S405. When the system clock reaches the total time point for data acquisition completion, the acquisition release module sends synchronization trigger pulses to the optical sensor and electrical parameter analyzer inside the darkroom. The optical sensor acquires the luminous flux, color temperature, and color rendering index of the luminaire, while the electrical parameter analyzer acquires the power factor and harmonic content of the luminaire. After the data acquisition is completed, the acquisition results are uploaded to the central control unit for final quality level determination.

[0066] S406. After parameter acquisition is completed, the acquisition release module unlocks the locking mechanism at the darkroom exit and sends a release command to the track driver. The moving conveyor plate leaves the inspection station under driving force and enters the finished product packaging area via the subsequent physical track, completing the lamp processing, inspection, and assembly cycle. This step dynamically reduces the dwell time in the darkroom by calculating the in-transit progress, achieving a match between the logistics cycle and the inspection cycle.

[0067] Specific application examples:

[0068] To verify the technical solution of the combined processing, inspection, assembly, and control system and method for lamps of the present invention, the present invention will be described below in conjunction with a specific application scenario and accompanying drawings. This specific application embodiment is built on a high-power LED industrial and mining lamp production line. Its hardware environment includes an inspection cabinet with four independent inspection spaces and a U-shaped conveyor track. A lamp with a rated power of 200W is selected as the test object for actual measurement and verification.

[0069] During the task initialization phase, the path allocation module receives the assembly process completion signal. The process parameters for this type of lamp are set as follows: pulse on-time... The pulse disconnection time is 1.0s. The duration is 1.0s, and the total number of pulses is [number missing]. The number of times is 110. The length of the transport path is known. The length is 30m, and the rated speed of the conveyor belt is... The speed is 0.2 m / s. The progress calibration module substitutes the values ​​into the formula to calculate the estimated delivery time window. : ; The numerical calculation process is as follows: ; Calculate the estimated delivery time window Set the preset safety margin time to 150 seconds. The time is 2 seconds. The path allocation module uses the formula to calculate the number of pre-execution steps in progress. : ; The numerical calculation process is as follows: ; Calculate the number of pre-executions in transit The total number of pulses is 74. This calculation logic breaks down the total task into the first 74 pulses executed in the follow-up driving phase and the residual task completed inside the dark box.

[0070] During the on-the-go execution and phase alignment phase, the actual time it takes for the lamp to reach the elevator inlet is affected by speed fluctuations caused by mechanical slippage of the conveyor belt. The duration is 149.8s. At this point, the servo drive module performs phase alignment compensation. This is after completing the required number of pulses. When the value is 74, the servo drive module substitutes the formula to calculate the compensation disconnection time for the 75th cycle. : ; The numerical calculation process is as follows: ; Calculate the compensation disconnection time The response time is 0.8s. This dynamic response effect is reflected in the attached... Figure 3 (See attached document) Figure 3 The horizontal axis represents the system physical clock, and the vertical axis represents the drive logic level state. The dashed line in the figure represents the traditional uncompensated phase-shift waveform, which remains in the middle of a high-level pulse at 149.8s, failing to align with the physical position. In contrast, the solid line in the figure represents the dynamic compensation waveform of this invention, which, by compressing the disconnection time of the 75th pulse cycle from 1.0s to 0.8s, ensures that the falling edge of its waveform precisely points to the position indicated by the diagonal arrow at the elevator inlet. This result verifies that the compensation mechanism can eliminate phase deviations caused by material flow fluctuations, ensuring that the lamps are at the preset steady-state phase point when entering the box.

[0071] While conducting in-transit testing, the initial screening and sorting module monitors the lamp current and sets a standard reference value for this type of lamp. The current is 0.90A, and the allowable deviation threshold is 10%. If the average current value is measured during the sampling process... The value is 1.15A. The electrical abnormality deviation of the primary screening and sorting module is calculated using the formula. : ; The numerical calculation process is as follows: ; Due to the calculated electrical abnormal deviation The value was 0.25A, which significantly exceeded the preset threshold of 0.09A. The initial screening and sorting module determined that the lamp was a failed load. At this time, the failure flag was set from 0 to 1, and the linkage elevator performed a sorting action at 149.8s, guiding it to the defective product area, thus achieving early rejection of the failed load.

[0072] If the deviation between the average current value measured during the sampling process and the standard reference value is within a preset threshold, the initial screening and sorting module determines that the lamp is a qualified load.

[0073] During the terminal testing phase, qualified lamps enter the darkroom. The data acquisition and release module obtains the number of completed pulses. The total number of pulses is 75. The number of times is 110. The residual pulse task remainder is calculated by substituting the data into the formula in the data acquisition and release module. : ; The numerical calculation process is as follows: ; The residual pulse task remainder was calculated. 35 times. Set the sampling hold delay time. The time is 1.2 seconds. The total time for the data acquisition and release module to complete the acquisition is calculated by substituting the values ​​into the formula. The timing of the moving conveyor plate entering the dark box It is 149.8s: ; The numerical calculation process is as follows: ; Calculation results show that when the system clock reaches 220s, the acquisition and release module triggers optical parameter acquisition. This process corresponds to the attached... Figure 4 The curve shown. (Refer to the appendix.) Figure 4 The horizontal axis represents the total test cycle time, the left vertical axis represents the junction temperature response, and the right vertical axis represents the relative luminous flux. The solid line in the figure represents the junction temperature curve, which enters a stable region after 200 seconds. The dashed line represents the relative luminous flux curve, which reaches thermal equilibrium at 220 seconds. The diagonal arrow in the figure precisely points to the steady-state acquisition point of the optical sensor marked with a triangle, and its horizontal coordinate of 220 seconds matches the theoretically calculated value. This demonstrates that the system can significantly reduce the dwell time of the dark box by calculating the in-transit execution progress.

[0074] To verify the technical superiority of this invention, a comparative experiment was conducted on the traditional serial detection mode and the combined detection mode of this invention under the same production line environment. The results are shown in the table below: Single darkroom time 305.0s 70.2s Detecting beat (UPH) 11.8 units / h 51.3 units / h Test data consistency (CV value) 3.2% 0.8% Early filtering mechanism for invalid loads none Automated sorting

[0075] Based on the above experimental data analysis, compared with the traditional serial mode, the single-unit darkroom occupancy time of this invention is reduced from 305.0s to 70.2s, a reduction of 77.0%; the detection cycle time is increased from 11.8 units / h to 51.3 units / h, an improvement of 334.7%. Regarding data consistency, the CV value is optimized from 3.2% to 0.8%. Furthermore, this invention achieves early automatic sorting of invalid loads through the newly added initial screening and sorting module, eliminating the resource waste caused by the need for failed parts to still enter the darkroom for occupancy detection in the traditional mode.

[0076] Experimental data shows that this invention achieves logical overlap between logistics time and detection time through pre-transit testing and dynamic phase compensation. (See attached document.) Figure 3 With appendix Figure 4 As shown, the system not only completes the phase alignment of electrical parameters the instant the physical position is reached, but also ensures that the acquisition action occurs when the thermal performance of the lamp is stable. Without sacrificing detection accuracy, it significantly improves the throughput of the production line and solves the efficiency bottleneck problem of the detection station in discrete manufacturing.

Claims

1. A method for controlling the combined processing, inspection, assembly, and control of lighting fixtures, characterized in that, Includes the following steps: The path allocation module receives the lamp arrival signal and assigns a target detection level to the moving conveyor plate carrying the lamp, extracts the initial task message, and combines the estimated delivery time window calculated by the progress calibration module to split the initial task message into an in-transit pre-test sequence and a residual pulse task. During the displacement of the moving conveyor plate, the follow-up drive module executes the in-transit pre-test sequence, adjusts the disconnection time to perform phase alignment compensation based on the deviation between the actual consumption time fed back by the progress calibration module and the estimated conveying time window, and records the completed test progress. During the execution of the in-transit pre-test sequence by the follow-up drive module, the initial screening and sorting module captures the operating characteristic data of the lamp and calculates the characteristic deviation. When the characteristic deviation exceeds a preset threshold, a failure mark is generated and the hoist is linked to perform a sorting action. After the moving conveyor plate enters the target detection level, the acquisition and release module reads the completed test progress, controls the controlled power supply to complete the residual pulse task, and triggers parameter acquisition and executes the release command after the lamp reaches a stable state.

2. The combined processing, inspection, assembly, and control method for a lamp fixture according to claim 1, characterized in that, The path allocation module periodically obtains the queue length and single detection cycle of each detection level, calculates the load weight based on the product of the queue length and the single detection cycle, and assigns the mobile conveyor plate to the detection level with the lowest load weight and the queuing time less than a preset time threshold as the target detection level.

3. The combined processing, inspection, assembly, and control method for a lamp fixture according to claim 1, characterized in that, The initial task message includes the pulse on-time, pulse off-time, and total number of pulses; The path allocation module calculates the estimated delivery time window based on the delivery path length and displacement speed. After removing the safety margin time from the estimated delivery time window, it calculates the number of pre-executions in transit by combining the pulse on-time and the pulse off-time. Thus, the total number of pulses is divided into the pre-test sequence in transit corresponding to the number of pre-executions in transit and the residual pulse task.

4. The combined processing, inspection, assembly, and control method for a lamp fixture according to claim 3, characterized in that, The follow-up drive module obtains electrical energy through the electrically received sliding contact structure and drives the lamp to perform on / off actions according to the pulse on-time and pulse off-time. The progress calibration module acquires the displacement sensor pulse signal on the track node to monitor the spatial coordinates of the moving conveyor plate, and records the time span from the displacement starting point to the current coordinate as the actual time consumed.

5. The combined processing, inspection, assembly, and control method for a lamp fixture according to claim 4, characterized in that, The process by which the follow-up drive module performs phase alignment compensation is as follows: When the moving conveyor plate reaches a preset buffer distance from the entrance of the elevator, the compensation disconnection time of the last pulse cycle currently being executed is calculated based on the deviation between the estimated conveying time window and the actual consumption time. The compensation disconnection time is used to cover the original pulse disconnection time, so that the electrical state of the lamp is at a steady-state phase point at the instant the moving conveyor plate reaches the pallet of the elevator.

6. The combined processing, inspection, assembly, and control method for a lamp fixture according to claim 3, characterized in that, The process by which the primary screening and sorting module captures the operational characteristic data and calculates the characteristic deviation includes: The current sequence is obtained during the stable lighting phase of the pulse turn-on time using a high-frequency sampling circuit. After avoiding the sampling delay time of the surge current, the average current value is calculated by averaging the current data. The average current value is compared with the standard reference value to calculate the electrical abnormality deviation as the characteristic deviation.

7. The combined processing, inspection, assembly, and control method for a lamp fixture according to claim 6, characterized in that, When the electrical abnormality deviation exceeds the preset threshold and the abnormal state recurs within the continuous determination window length, the lamp is determined to be unqualified and the failure mark is generated. The central control unit binds the failure mark to the number of the mobile conveyor plate and sends it to the scheduling controller of the hoist. The drive track switching device guides the mobile conveyor plate carrying the failure mark to the defective product collection area.

8. The combined processing, inspection, assembly, and control method for a lamp fixture according to claim 1, characterized in that, The data acquisition and release module establishes data exchange with the follow-up drive module through the near-field communication interface set on the dark box wall of the detection station, and reads the completed test progress stored in the internal register of the follow-up drive module. The controlled power supply is coupled to the power input terminal of the moving conveyor plate by executing a switching logic of first connecting and then disconnecting, thereby switching the driving control of the lamp from the follow-up drive module to the acquisition and release module.

9. The combined processing, inspection, assembly, and control method for a lamp fixture according to claim 1, characterized in that, The acquisition and release module calculates the total acquisition time based on the time point when the moving conveyor plate enters the target detection layer, the number of pulse cycles of the residual pulse task, the pulse cycle duration, and the sampling and holding delay time. When the system clock reaches the total acquisition time, it synchronously triggers the optical sensor and the electrical parameter analyzer to perform data capture.

10. A combined processing, inspection, assembly, and control system for lamps, characterized in that, A combined processing, inspection, assembly, and control method for a lamp fixture as described in any one of claims 1-9, comprising: The path allocation module is used to receive the lamp arrival signal and assign the target detection level to the moving conveyor plate carrying the lamp. It also parses and splits the initial task message into an in-transit pre-test sequence and residual pulse task in combination with the estimated delivery time window. The progress calibration module is used to calculate the estimated delivery time window and output it to the path allocation module, while recording the actual time consumed by the moving conveyor plate; The follow-up drive module is used to receive and execute the in-transit pre-test sequence, obtain the actual consumption time recorded by the progress calibration module, adjust the disconnection time based on the deviation between the actual consumption time and the estimated delivery time window to perform phase alignment compensation, and record the completed test progress. The initial screening and sorting module is used to capture the operating characteristic data of the lamp and calculate the characteristic deviation during the execution of the in-transit pre-test sequence by the follow-up drive module. When the characteristic deviation exceeds a preset threshold, it outputs a failure mark and links the hoist to perform sorting action. The acquisition and release module is used to receive the completed test progress recorded by the follow-up drive module after the moving conveyor plate enters the target detection level, coordinate with the controlled power supply to complete the residual pulse task and trigger parameter acquisition.

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