Energy storage converter module assembly system and method

Abstract

This invention relates to the field of energy storage converter module assembly technology, specifically to an energy storage converter module assembly system. The system includes a truss transfer mechanism and a conveying mechanism. The conveying mechanism comprises multiple production lines, with the truss transfer mechanism covering each production line to complete the loading of radiator raw materials and the transfer of semi-finished materials between the production lines. It also includes, along the material conveying direction, sequentially arranged beside the conveying mechanism, an IGBT automatic placement station, an IGBT fixing station, an automatic welding station, an automatic dispensing station, an adhesive curing station, and a unloading station. The IGBT automatic placement station picks up IGBTs and places them in the corresponding positions on the radiator raw materials. The automatic welding station includes various welding equipment for welding various converter modules. Each station is independently set up, separate from the conveying mechanism. The system also includes a tray compatible with various radiator raw materials. This invention solves the technical problems of low production efficiency and limited production models in existing energy storage converter production lines.

Description

Technical Field

[0001] This invention relates to the field of energy storage converter module assembly technology, specifically to an energy storage converter module assembly system and assembly method. Background Technology

[0002] With the rapid development of the new energy industry, energy storage technology, as a core means of energy consumption and grid peak shaving, has been widely applied and developed rapidly. As a core component of energy storage systems, the market demand for energy storage converters continues to rise, and the demand for energy storage converter modules, as the core unit of energy storage converters, has also increased significantly. Currently, energy storage converter modules are available in various capacity specifications depending on the application scenario. The assembly processes for different specifications of modules are complex and diverse, leading the industry to place higher demands on the flexibility, versatility, and automation of energy storage converter module manufacturing.

[0003] In the field of automated assembly of converter products, existing technologies have been researched and tested. For example, Chinese patent application CN112548548A discloses a traction converter assembly system. This system, through the cooperation of guide rails, guide trolleys, a first alignment camera, and a second alignment camera, combined with multi-dimensional adjustment of lifting mechanisms, moving platforms, and rotating platforms, achieves precise alignment of the traction converter components to be assembled with the bolt holes of the cabinet. This solves the positioning deviation problem in the assembly process of heavy power modules, improves the automation level of traction converter assembly, and provides an important technical approach for the automated assembly of converter products.

[0004] However, the traction converter assembly system is designed for the alignment and assembly of the cabinet and heavy components of the EMU traction converter. Its assembly process and equipment structure are only suitable for the single assembly scenario of the traction converter. The energy storage converter module and the traction converter have significant differences in product structure, assembly process and specification diversity. The traction converter assembly system cannot directly adapt to the multi-process and multi-specification production and assembly needs of the energy storage converter module, and it is difficult to meet the industry's requirements for flexible and universal production of energy storage converter modules.

[0005] Currently, the production and manufacturing of energy storage converter modules are still mainly based on the traditional offline decentralized production mode. This production mode has many drawbacks: 1. The equipment and tooling of the production line can only be adapted to the production needs of a single specification of energy storage converter module and do not have the ability to be compatible with multiple products. When facing the production needs of different specifications of modules, it is necessary to manually switch the production mode multiple times, which is cumbersome and time-consuming, and seriously restricts production efficiency.

[0006] 2. The production area is relatively dispersed, and the integration of various assembly processes is low. Material transfer and product flipping during module assembly are all done manually, which is inefficient. Furthermore, the automation level of key processes such as screw tightening, welding, gluing, and weld inspection is low, and they are highly dependent on the professional skills of production personnel. This not only significantly increases the labor intensity of production, but the subjectivity of manual operation can also easily lead to poor consistency in product assembly quality, making it difficult to guarantee the production quality of modules.

[0007] 3. The existing production lines lack the ability to be quickly reconfigured, have poor adaptability, and cannot flexibly adjust the layout of workstations and production processes according to actual production needs.

[0008] 4. The lack of a comprehensive data traceability system in the production process makes it difficult to effectively collect and record process parameters and equipment operating parameters of key processes, thus hindering the full-process traceability of the production process. Summary of the Invention

[0009] This invention provides an energy storage converter module assembly system to solve the technical problems of low production efficiency and limited production models in existing energy storage converter production lines; the purpose of this invention is also to provide a method for assembling energy storage converter modules using the above-mentioned energy storage converter module assembly system.

[0010] To address the above problems, the present invention provides an energy storage converter module assembly system using the following technical solution: An energy storage converter module assembly system includes a truss transfer mechanism and a conveying mechanism. The conveying mechanism includes multiple production lines, and the truss transfer mechanism covers each production line to complete the feeding of radiator raw materials and the transfer of semi-finished materials between the production lines. It also includes an IGBT automatic placement station, an IGBT fixing station, an automatic welding station, an automatic dispensing station, an adhesive curing station, and a material unloading station arranged sequentially along the material conveying direction next to the conveying mechanism. The IGBT automatic placement station is used to grab IGBTs and place them in the corresponding positions on the radiator raw materials. The IGBT fixing station is used to fix the IGBTs on the corresponding radiator raw materials. The automatic welding station includes a variety of welding equipment for welding various converter modules. Each station is set up independently from the conveying mechanism. It also includes a tray for carrying radiator materials, the tray being compatible with a variety of radiator materials.

[0011] Furthermore, the truss transfer mechanism includes a loading truss unit, a welding loading truss unit, and a welding unloading truss unit. The loading truss unit includes a truss manipulator, which can move and rotate in three axes (X / Y / Z) and its stroke covers each production line to realize cross-line transfer of materials between each production line. The conveying mechanism includes a first production line, a second production line, and a third production line. An automatic welding station is located between the first production line and the second production line. A welding loading truss unit is located between the first production line and the automatic welding station and is used to transfer semi-finished materials from the first production line to the automatic welding station. The welding unloading truss unit is located between the automatic welding station and the second production line, and is used to transfer the semi-finished materials from the automatic welding station to the second production line.

[0012] Furthermore, the IGBT automatic placement station includes a material feeding robot and an IGBT feeding device. The IGBT feeding device adopts AGV automatic material feeding and turnover. The material feeding robot integrates an industrial camera, suction cup clamps and material detection components, which can identify the IGBT position and prevent the material from falling off, so as to achieve precise placement of IGBTs on the heat sink.

[0013] Furthermore, the IGBT fixing station includes a screw pre-tightening unit and a screw fastening unit. The screw pre-tightening unit includes a screw feeding structure, a positioning arm, a pre-tightening gun mounted on the positioning arm, and an industrial camera, so as to complete the automatic screw feeding and screw pre-tightening action according to a predetermined program. The screw fastening unit includes a fastening robot, an industrial camera, and two electric fastening tools with torque acquisition function mounted on the fastening robot. It is used to fasten two screws simultaneously to meet the diagonal fastening requirements of IGBTs. The fastening robot uses the industrial camera to photograph the product mark point to determine the final tightening position of the screw. After fastening, it can collect torque and angle data and bind them to the product barcode for uploading.

[0014] Furthermore, a vision inspection station is provided between the automatic welding station and the automatic dispensing station. The vision inspection station includes a three-axis moving structure and an inspection camera mounted on the three-axis moving structure to realize weld point inspection.

[0015] Furthermore, the downstream of the adhesive curing station is also equipped with a flipping mechanism, which is used to flip / release materials according to the converter module assembly requirements.

[0016] Furthermore, the production line consists of multiple automated workstations, each of which includes a transmission unit, a support frame, a stopper, and a check block. The transmission unit is mounted on the support frame and consists of two layers: the upper layer is used to drive the pallet to rotate along the conveying direction, and the lower layer is used for pallet return. The stopper and check block are used to stop the pallet during the conveying process.

[0017] The beneficial effects of the energy storage converter module assembly system provided by this invention are: 1. The energy storage converter module assembly system provided by this invention achieves efficient material loading and semi-finished product transfer between multiple production lines by setting up a truss transfer mechanism covering multiple production lines. It can be adjusted according to the production mode requirements of different products, achieving the effect of simultaneously meeting the production needs of multiple products. This solves the problem of low efficiency and poor quality caused by high manual intervention in material transfer in traditional production. The functional workstations arranged sequentially along the material conveying direction form a standardized and automated assembly process. Each workstation is set up independently from the conveying mechanism, and its layout can be flexibly adjusted and quickly reassembled according to production needs, greatly improving the flexibility of the production line. The automatic welding workstation is equipped with a variety of welding equipment, which can adapt to the welding process requirements of various converter modules, realizing the production of multiple specifications of products on a single production line. At the same time, a universal pallet compatible with various radiator materials is set up to avoid pallet change operations when producing different products, reduce production preparation time, further improve production efficiency, and reduce the overall labor intensity of production.

[0018] 2. The truss transfer mechanism is divided into a loading truss unit, a welding loading truss unit, and a welding unloading truss unit. Each unit has a clear division of labor, and in conjunction with the layout of the three production lines, the material transfer is more targeted. The truss robot in the loading truss unit has X / Y / Z three-axis movement and flipping functions, and its stroke covers all production lines, realizing the precise cross-line transfer of semi-finished products between production lines and meeting the complex production flow requirements such as double-sided assembly of products. The automatic welding station is set between the first and second production lines, and the connection between materials and the welding station is realized through the welding loading and unloading truss units, making the material input and output of the welding process smoother, avoiding production congestion, realizing the seamless connection between the welding process and the main assembly process, and improving the overall production line operating efficiency.

[0019] 3. The IGBT feeding device adopts AGV automatic feeding and turnover, replacing the traditional manual feeding method. This reduces manual operation and labor intensity, while achieving continuous and automated feeding, ensuring smooth production transitions. The unloading robot integrates an industrial camera, suction cup clamps, and material detection components. The industrial camera can accurately identify the IGBT position, ensuring the placement accuracy of the IGBTs on the heat sink and avoiding the impact of placement deviations on the quality of subsequent fixing, welding, and other processes. The material detection components can effectively prevent material from falling during the gripping process, reducing material loss and improving product yield. The suction cup clamps are adapted to the gripping requirements of IGBTs, achieving stable gripping and placement of IGBTs. Overall, this significantly improves the automation and accuracy of the IGBT assembly process.

[0020] 4. By adopting a step-by-step fixing method, the connection between the IGBT and the heat sink is made more secure and stable, avoiding loosening or component deformation caused by single tightening. The screw pre-tightening unit integrates the screw feeding structure, positioning arm, pre-tightening gun, and industrial camera, realizing automatic screw feeding and precise pre-tightening without manual positioning and feeding, thus improving the automation level of the pre-tightening process. The screw fastening unit is equipped with two electric fastening tools with torque acquisition function, which can simultaneously tighten two screws, meeting the process requirements of diagonal tightening of IGBTs and avoiding IGBT warping and deformation caused by asynchronous diagonal tightening, thereby improving assembly quality. The fastening robot determines the final tightening position of the screw by photographing the product mark point, further improving the accuracy of tightening. At the same time, it collects torque and angle data and binds them to the product barcode for uploading, realizing the traceability of process data of IGBT fastening process, facilitating production quality control and problem tracing, and ensuring product quality.

[0021] 5. By setting a flipping mechanism downstream of the glue curing station, the mechanism can flexibly flip or release materials according to the assembly requirements of the converter module, adapting to the process differences of single-sided and double-sided assembly of different specification modules, and further improving the flexibility of the production line.

[0022] 6. By breaking down the production line into multiple automated workstations, the modularity of the production line is increased. The automated workstations can be flexibly combined and adjusted according to production needs to adapt to the production processes of different products. The transmission unit is designed with a two-layer structure. The upper layer facilitates the rotation of pallets along the conveying direction, while the lower layer completes the pallet return, achieving automated pallet recycling. This eliminates the need for manual pallet collection and handling, reducing manual operations and improving production efficiency. Simultaneously, the installation of stoppers and check blocks ensures precise stopping and positioning of pallets during conveying, preventing slippage and deviation on the production line. This guarantees accurate material processing at each workstation, improves assembly precision in each process, and makes the production line's conveying more stable and reliable.

[0023] To address the above problems, the present invention provides an energy storage converter module assembly method using the following technical solution: An energy storage converter module assembly method is implemented using an energy storage converter module assembly system, and the specific steps are as follows: S1. The radiator raw materials are fed into the conveying mechanism via the truss transfer mechanism; S2. Apply silicone grease to the heat sink material on the production line; S3. Complete the automatic assembly of IGBTs on the heat sink material, and sequentially perform screw pre-tightening and fastening operations, and collect and upload the process data of the final fastening process. S4. Based on the welding process parameters corresponding to the product specifications, perform selective welding of semi-finished products and weld quality inspection. S5. Perform automatic dispensing of adhesive on the semi-finished product, and then cure the adhesive after completion; S6. The truss transfer mechanism is used to carry out material turnover according to the product production process, and to complete the assembly and transfer of materials on one or both sides. S7. The finished product is removed from the assembly line through the unloading mechanism, completing the entire assembly process.

[0024] Furthermore, in step S3, the screw tightening is performed in a fixed sequence, and the torque and angle data collected by the electric tightening tool are uploaded to the production line system for storage; if an NG situation occurs during the final tightening of the screw, the tightening of the remaining screws of the current IGBT is stopped, and the tightening work of the next IGBT is directly started.

[0025] Furthermore, the specific logic of material turnover in step S6 is as follows: if the product needs to be installed on both sides, the gantry robot will flip the semi-finished product and turn it back to the initial position of the conveying mechanism to continue to complete the assembly of the other side; if the product only needs to be installed on one side, the gantry robot will directly transfer the semi-finished product to the third production line.

[0026] The beneficial effects of the energy storage converter module assembly method provided by this invention are: 1. The energy storage converter module assembly method provided by this invention forms a standardized and automated assembly process from raw material feeding to finished product output. The process is seamlessly connected, significantly reducing manual operation and dependence on the professional skills of operators, while improving overall production efficiency. The method matches the corresponding welding process parameters according to product specifications, realizing compatible production of multiple product specifications. Furthermore, the fully automated operation of silicone grease application, IGBT assembly and fixing, welding inspection, and adhesive curing ensures the assembly quality of each process and improves the consistency of product quality. At the same time, it can complete single-sided or double-sided assembly according to product requirements, adapting to the process requirements of different energy storage converter modules, making the assembly method more flexible, and achieving high efficiency, high quality, and flexibility in the overall production of energy storage converter modules.

[0027] 2. By ensuring a fixed screw tightening sequence, uniform force distribution across all IGBT locations is guaranteed, preventing issues such as excessive local stress and warping caused by improper tightening order. This improves the connection stability and assembly quality between the IGBT and the heatsink. Torque and angle data collected by the electric tightening tool are uploaded to the production line system for storage, enabling full traceability of the tightening process data. This facilitates quality control and subsequent problem identification during production. Furthermore, a handling logic for non-conforming (NG) situations is implemented. If a tightening defect occurs, the tightening of the remaining screws on the current IGBT is immediately stopped, and the tightening process begins on the next IGBT. This avoids ineffective operation on defective parts, reduces production time, and improves production efficiency. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the truss transfer mechanism; Figure 2 This is a structural diagram of the incoming material pallet; Figure 3 A schematic diagram of the IGBT automatic placement workstation; Figure 4 This is a schematic diagram of the screw preload unit. Figure 5 This is a schematic diagram of the screw fastening unit. Figure 6 This is a structural diagram of an AOI visual inspection workstation; Figure 7 This is a structural diagram of an automated dispensing station; Figure 8 This is a structural diagram of an automated workstation; Figure 9 This is a schematic diagram of the transmission unit. Figure 10 This is a schematic diagram of the tray structure; Figure 11 This is a structural diagram of the material unloading station; Figure 12 A top view of an energy storage converter module assembly system provided by the present invention; Figure 13 This is a flowchart illustrating an energy storage converter module assembly method provided by the present invention.

[0029] Explanation of reference numerals in the attached figures: 1. Conveying mechanism; 11. First production line; 12. Second production line; 13. Third production line; 2. Truss transfer mechanism; 21. Loading truss unit; 211. Truss frame; 2111. Guide rail support beam; 2112. Guide rail; 2113. Feed gate; 2114. Line A gate; 2115. Line B gate; 2116. Line C gate; 2117. Truss support beam; 212. Truss robot; 213. Fixture quick change tray; 214. Incoming material pallet; 2141. Material rack base plate; 2142. Positioning block; 2143. Radiator loading rack; 2144. Loading positioning structure; 2145. Guide wheel; 2146. Anti-collision plate; 2147. AGV; 22. Welding loading truss unit; 23. Welding unloading truss unit; 3. IGBT automatic placement station; 31. Unloading robot; 32. IGBT feeding device; 33. Industrial camera; 34. Suction cup clamp; 35. Material detection structure; 4. Screw pre-tightening unit; 41. Screw feeding structure; 42. Lower frame; 43. Fixed base; 44. Positioning lever arm; 45. Pre-tightening gun; 46. Lifting shaft; 47. Mounting plate; 5. Screw fastening unit; 51. Fastening robot; 52. Support base; 53. Support frame; 54. Robot platform; 55. Controller; 56. Electric fastening tool; 6. Automated welding station; 7. AOI vision inspection station; 72. Three-axis moving structure; 73. Inspection camera; 74. Frame legs; 75. Top frame; 8. Automated dispensing station; 81. Dispensing robot; 82. Glue gun; 9. UV curing oven; 10. Semi-finished product flipping mechanism; 101. Automated workstation; 102. Transmission unit; 103. Pallet; 104. Support frame; 105. Stopper; 106. Check block; 107. Pallet bottom plate; 108. Limit block; 109. Unloading station; 110. Assist arm; 111. Lifting device; 112. Special clamp; 113. Quick-change structure; 114. Transmission frame; 115. Transmission shaft; 116. Motor; 117. Transmission chain. Detailed Implementation

[0030] The principles and spirit of the present invention will be explained in detail below with reference to several representative embodiments.

[0031] An embodiment of an energy storage converter module assembly system provided by the present invention: like Figures 1 to 12 As shown, an energy storage converter module assembly system of the present invention includes a truss transfer mechanism 2, a conveying mechanism 1 and multiple functional workstations. Each functional workstation is arranged on the side of the conveying mechanism 1 along the material conveying direction and is set independently from the conveying mechanism 1.

[0032] In this embodiment, as Figure 12As shown, the conveying mechanism 1 includes a first production line 11, a second production line 12, and a third production line 13 arranged in parallel. The overall stroke of the truss transfer mechanism 2 covers each production line, enabling it to complete the loading of radiator raw materials and the cross-line transfer of semi-finished materials between the production lines. Specifically, the truss transfer mechanism 2 includes a loading truss unit 21, a welding loading truss unit 22, and a welding unloading truss unit 23.

[0033] like Figure 2 As shown, the loading truss unit 21 includes a truss frame 211, a truss robot 212 fixed to the top of the truss frame 211, a quick-change clamping tray 213 for automatic quick clamping, and a material receiving tray 214 for material turnover. The truss frame 211 is fixed to the ends of the first production line 11, the second production line 12, and the third production line 13, and includes a guide rail support beam 2111, a truss support beam, a guide rail 2112, a feeding gate 2113, a line A gate 2114, a line B gate 2115, a line C gate 2116, and a truss enclosure. The guide rail support beam 2111 supports the guide rail 2112 to allow the truss robot 212 to move along the Z-axis, fulfilling the functions of radiator loading and turnover between production lines. A truss support beam 2117 spans across the guide rail 2112, and a truss robot arm 212 and a quick-change fixture plate 213 are installed at its bottom. The quick-change fixture plate 213 is used to quickly switch between different fixtures to meet the clamping needs of different products. Line A door 2114, line B door 2115, and line C door 2116 are used for the passage of the first production line 11, the second production line 12, and the third production line 13, respectively.

[0034] The gantry robot 212 can achieve free movement and positioning along the X / Y / Z axes, and also has a flipping function, which can meet the needs of multi-directional material transfer and double-sided product assembly, and realize precise cross-line transfer of materials between different production lines. The robot is also equipped with an industrial camera 33 and a distance sensor to determine the phase and direction during the radiator loading and gripping process. The incoming material pallet 214 includes a material rack base plate 2141, a positioning block 2142, a radiator loading rack 2143, and a loading and positioning structure 2144. It is also equipped with guide wheels 2145 and anti-collision plates 2146 to guide and position materials. The positioning block 2142 is used to fix different types of products. After the radiator loading rack 2143 receives the materials, it is transferred by the AGV 2147 to the loading and positioning structure 2144. The entire incoming material pallet 214 is also transferred by the AGV 2147 to the inlet gate 2113, and then the gantry robot 212 sends the radiator into the first production line 11 to complete the online process.

[0035] The welding loading truss unit 22 spans the radiator assembly line, the automatic welding station 6, and the radiator component welding line. The operating principle of the welding loading truss unit 22 is the same as that of the loading truss unit 21. It can transfer the components to be welded to different welding equipment according to the production program to complete the cross-line transfer and welding position allocation. The welding unloading truss unit 23 is used to transfer the components welded by the automatic welding station 6 back to the main production line to continue the subsequent production process. Its structural principle is the same as that of the loading truss unit 21. The truss manipulator 212 of both the welding loading truss unit 22 and the welding unloading truss unit 23 is equipped with a quick-change plate 213 at the end of the gripper. The gripper is compatible with four types of converters. The gripper is equipped with a flipping mechanism that can achieve 180-degree flipping. The quick-change plate 213 is equipped with a signal point to confirm that the gripper is used correctly. There is also a dedicated gripper placement base nearby, which can automatically change the gripper according to the product type.

[0036] like Figure 12 As shown, the following components are arranged sequentially along the material conveying direction on the side of the conveying mechanism 1: IGBT automatic placement station 3, screw pre-tightening unit 4, screw fastening unit 5, automatic welding station 6, AOI vision inspection station 7, automatic dispensing station 8, UV curing oven 9, semi-finished product flipping mechanism 10, automated workstation 101, and unloading station 109.

[0037] like Figure 3 As shown, the IGBT automatic placement station 3 includes a set of unloading robot arms 31 and two sets of IGBT feeding devices 32. The unloading robot arm 31 is a four-axis robot arm. The station adopts a dual-channel feeding method to ensure production continuity. The IGBT feeding device 32 adopts AGV2147 automatic feeding and turnover. The end gripper of the unloading robot arm 31 is equipped with an industrial camera 33, a suction cup gripper 34 and a material detection structure 35. The material detection structure 35 is used to effectively prevent the workpiece from falling during the material gripping process. The industrial camera 33 can identify the position of the IGBT and work with the robot arm to accurately place the IGBT in the designated position of the heat sink.

[0038] like Figure 4 As shown, the screw pre-tightening unit 4 includes a screw feeding structure 41, a lower frame 42, a fixed base 43, a positioning arm 44, a pre-tightening gun 45, and an industrial camera 33. The positioning arm 44 is mounted on the lower frame 42 via the fixed base 43. The screw feeding structure 41 is also mounted on the lower frame 42. A vertically extending lifting shaft 46 is mounted on the positioning arm 44. A mounting plate 47 is fixed to the lower end of the lifting shaft 46. The industrial camera 33 is fixed on the mounting plate 47 and moves vertically via the lifting shaft 46, enabling precise screw positioning. After the positioning arm 44, in conjunction with the screw feeding mechanism, delivers the screw to the corresponding position of the IGBT, the screw pre-tightening action is completed sequentially according to a predetermined program.

[0039] like Figure 5As shown, the screw fastening unit 5 includes a fastening robot 51, an industrial camera 33, a support base 52, a support frame 53, a robot platform 54, a controller 55, and an electric fastening tool 56 with torque acquisition function. The fastening robot 51 is a four-axis robot, which, together with the support base 52, is fixed on the robot platform 54. The robot platform 54, together with the controller 55, is fixed on the support frame 53. The end effector of the robot is equipped with an industrial camera 33 and two sets of electric fastening tools 56, which can fasten two screws simultaneously, meeting the diagonal fastening requirements of IGBTs. After the fastening robot 51 is in position, the industrial camera 33 captures the product mark point to determine the final tightening position of the screw. The fastening robot 51 completes the final tightening of all screws in a fixed sequence. After tightening is completed, the electric fastening tool 56 binds the collected torque and angle data with the product barcode and uploads it to the production line system for recording. If an NG (not working) occurs during the tightening process, the remaining screws of the current IGBT will stop tightening, and the tightening work of the next IGBT module will begin directly.

[0040] The automatic welding station 6 is equipped with a variety of welding equipment and can perform selective welding operations according to the welding process parameters corresponding to different products, so as to adapt to the welding needs of four energy storage converter modules.

[0041] like Figure 6 As shown, the AOI visual inspection station 7 includes a frame, a three-axis moving structure 72, and an inspection camera 73. The frame includes two side frame legs 74 and a top frame 75. The three-axis moving structure 72 is mounted on the frame, and the inspection camera 73 is mounted on the three-axis moving structure 72. The inspection camera 73 includes one main camera and two side cameras, and is controlled by the three-axis moving structure 72 to achieve multi-directional movement. It performs comprehensive solder joint inspection on the board and records the inspection data. If a component with abnormal soldering is detected, the mechanism can accurately locate the abnormal solder joint, which is convenient for repair personnel to handle quickly. If AOI visual inspection is not required during the production process, the AOI equipment can be shielded through the control program, and the component can be directly transferred to the next process.

[0042] like Figure 7As shown, the automatic dispensing station 8 includes a dispensing robot 81, a glue gun 82, and an industrial camera 33. Both the glue gun 82 and the industrial camera 33 are mounted on the dispensing robot 81, which is a three-axis robot. The glue gun 82 uses a spray valve, and the feeding system is driven by an electric cylinder. The feeding system has glue quantity detection and low-material alarm functions, allowing real-time monitoring of the internal glue quantity to prevent insufficient glue from affecting the coating effect. After the product flows in, the industrial camera 33 captures the mark points on the product to determine the dispensing position, guiding the glue gun 82 to complete a precise automatic dispensing operation. The semi-finished product after dispensing is transferred to a UV curing oven 9 for glue curing. The UV curing oven 9 is controlled by a PLC and touchscreen. The software can record lamp usage time and is equipped with a SMEMA interface for communication. The oven has a built-in counting function and uses variable frequency power supply technology to ensure stable UV energy output. It is also equipped with a high-volume centrifugal fan, which effectively reduces the temperature of the product and inside the UV curing oven 9, improving the lamp life.

[0043] Downstream of the UV curing oven 9 is a semi-finished product flipping mechanism 10. This mechanism has both lifting and flipping functions. After the workpiece enters, it will automatically descend to the working position. If the product needs to be installed on both sides, it can be automatically flipped through this mechanism after one side is assembled. After the flipping is completed, the mechanism will lift up and the workpiece will automatically flow out. If the product does not need to be flipped, the workpiece will be released directly after entering.

[0044] like Figures 8 to 10 As shown, the automated workstation 101 includes a transmission unit 102, a tray 103, a support frame 104, a stopper 105, and a check block 106. The transmission unit 102 is mounted on the support frame 104 and includes a transmission frame 114, a transmission shaft 115, a motor 116, and transmission chains 117. Two transmission chains 117 are rotatably mounted on the transmission frame 114 and rotate synchronously through the transmission shaft 115. The motor 116 drives the transmission chains 117 to rotate. The automated workstation 101 has two sets of transmission units 102, divided into upper and lower layers. The upper layer drives the tray 103 to rotate along the conveying direction, and the lower layer is used for the return flow of the tray 103. The stopper 105 and the check block 106 are used to stop the tray 103 during the conveying process. The tray 103 includes a tray base plate 107 and three sets of limit blocks 108, which can meet the holding requirements of four types of radiators and modules, and can also be designed and adjusted according to later needs to enhance compatibility.

[0045] like Figure 11As shown, the unloading station 109 includes a support arm 110 and a lifting device 111. The lifting device 111 is fixed on the support arm 110. It also includes a special clamp 112 and a quick-change structure 113. The special clamp 112 is installed on the lifting device 111, and the quick-change structure 113 is fixed on the special clamp 112. It can be compatible with the clamping operation of four types of products and has a flipping function. The lifting device 111 is controlled by the support arm 110 to complete the flipping and unloading operation of the finished product.

[0046] The working principle of an energy storage converter module assembly equipment is summarized as follows: The equipment is centered around a truss transfer mechanism 2 and multiple production lines. A universal pallet 103 carries the radiator raw materials, which flow orderly along the production lines. Each independent workstation completes the assembly process sequentially. The loading truss unit 21 loads the radiator raw materials onto the first production line 11. The raw materials are first coated with silicone grease, then the IGBTs are precisely assembled at the IGBT automatic placement workstation 3. Subsequently, the screws are pre-tightened and finally tightened sequentially in the screw pre-tightening and fastening unit. Torque and angle data are collected and uploaded simultaneously during the fastening process. The welding loading truss unit 2221 transfers the semi-finished products to the automatic welding workstation 6 for selective welding. The welding unloading truss unit 23 then transfers them back to the second production line 12. After weld point inspection at the AOI vision inspection workstation 7, the adhesive is applied by the automatic dispensing workstation 8 and cured in the UV curing oven 9. Afterwards, the gantry robot 212 turns over materials according to product requirements. If double-sided assembly is required, it flips and returns to the initial position to continue assembly. If only single-sided assembly is required, it is transferred to the third production line 13. The finished product assembly and module turnover are completed by the semi-finished product flipping mechanism 10 and the automated workstation 101. Finally, the unloading station 109 controls the lifting device 111 through the assist arm 110 to complete the unloading of the finished product.

[0047] An embodiment of the energy storage converter module assembly method provided by the present invention: like Figure 13 As shown, an energy storage converter module assembly method is implemented using the aforementioned energy storage converter module assembly system, and the specific steps are as follows: S1. The gantry robot 212 of the loading gantry unit 21 takes the radiator raw material from the incoming material tray 214 and accurately sends the radiator into the unit production line through three-axis movement and positioning, thus completing the automated loading of the radiator raw material. S2. The heat sink material flows along the production line with the tray 103 on the line and completes the silicone grease coating operation at the silicone grease coating station. S3. The heat sink with the silicone grease applied is transferred to the IGBT automatic placement station 3. The unloading robot 31 takes out the IGBT from the IGBT feeding device 32, and after the orientation is identified by the industrial camera 33, the IGBT is accurately installed on the heat sink to complete the IGBT placement work. S4. The components with completed IGBT placement are transferred to the screw pre-tightening station. The positioning arm 44, in conjunction with the screw feeding mechanism, delivers the screws to the corresponding positions of the IGBTs. The screws are pre-tightened in sequence at the screw pre-tightening station according to the predetermined program. S5. The pre-tightened components are transferred to the IGBT automatic fastening station. The fastening robot 51, together with the end industrial camera 33, takes pictures of the product mark points to determine the final tightening position. All screws are tightened in a fixed order. The dual electric fastening tools 56 collect torque and angle data simultaneously, bind them with the product barcode, and upload them to the production line system. If an NG situation occurs, the tightening of the remaining screws of the current IGBT is stopped, and the fastening operation of the next IGBT module is directly started. S6. The welding loading truss unit 22 transfers the components to the corresponding welding equipment of the automatic welding station 6 according to the welding process parameters of different products to complete the selective welding. After the welding is completed, the welding unloading truss unit 23 transfers the components back to the main waterline. S7. The components are transferred to the AOI vision inspection mechanism. The three-axis moving structure 72 controls the inspection camera 73 to inspect the solder joints of the board and record the data. Abnormal solder joints are accurately located. When no inspection is required, the AOI equipment is shielded and the semi-finished products are directly transferred. S8. The components that have completed the solder joint inspection are transported to the automatic dispensing equipment. The dispensing robot 81 drives the glue gun 82 and works with the industrial camera 33 to grab the position determined by the mark point to complete the automatic dispensing. The material supply system detects the glue quantity in real time and issues an alarm when the material is insufficient. S9. The product after dispensing is transferred to the UV curing oven 9. The UV energy is stably output by the oven's frequency converter power supply to complete the curing of the adhesive. The system records the lamp usage time simultaneously. S10. After the glue has cured, the product is rotated by the gantry robot 212 of the loading gantry unit 21 according to the production process of different products. If the product needs to be installed on both sides, the gantry robot 212 flips the component and turns it back to the initial position of the first production line 11 to continue to complete the assembly work on the other side; if the product only needs to be installed on one side, the gantry robot 212 directly transfers the product to the third production line 13 area. S11. The components are transferred to the third production line 13 area via the loading truss unit 21. S12. After entering the third production line 13, the finished product assembly and flipping operation is completed by the semi-finished product flipping mechanism 10. The automated turnover of the product is completed by the automated workstation 101. The upper and lower layer structure of the transmission unit 102 realizes the turnover and return of the pallet 103. S13. After completing all assembly processes, the finished product is transferred to the off-line mechanism. The assist arm 110 controls the lifting device 111 to clamp and flip the finished product, and finally the finished product is off-lined, completing the assembly process of the entire energy storage converter module.

[0048] Based on the above description in this specification, those skilled in the art will also understand that the following terms, such as "upper," "lower," "front," "rear," "left," "right," "width," "horizontal," "top," "bottom," "inner," and "outer," which indicate orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings of this specification. They are only for the purpose of facilitating the explanation of the present invention and simplifying the description. Therefore, the above-mentioned orientation or positional relationship terms should not be construed as limiting the present invention.

Claims

1. An energy storage converter module assembly system, characterized in that, It includes a truss transfer mechanism and a conveying mechanism. The conveying mechanism includes multiple production lines, and the truss transfer mechanism covers each production line to complete the feeding of radiator raw materials and the transfer of semi-finished materials between each production line. It also includes an IGBT automatic placement station, an IGBT fixing station, an automatic welding station, an automatic dispensing station, an adhesive curing station, and a material unloading station arranged sequentially along the material conveying direction next to the conveying mechanism. The IGBT automatic placement station is used to grab IGBTs and place them in the corresponding positions on the radiator raw materials. The IGBT fixing station is used to fix the IGBTs on the corresponding radiator raw materials. The automatic welding station includes a variety of welding equipment for welding various converter modules. Each station is set up independently from the conveying mechanism. It also includes a tray for carrying radiator materials, the tray being compatible with a variety of radiator materials.

2. The energy storage converter module assembly system according to claim 1, characterized in that, The truss transfer mechanism includes a loading truss unit, a welding loading truss unit, and a welding unloading truss unit. The loading truss unit includes a truss manipulator, which can move and rotate in three axes (X / Y / Z) and its stroke covers each production line to realize cross-line transfer of materials between each production line. The conveying mechanism includes a first production line, a second production line, and a third production line. An automatic welding station is located between the first production line and the second production line. A welding loading truss unit is located between the first production line and the automatic welding station and is used to transfer semi-finished materials from the first production line to the automatic welding station. The welding unloading truss unit is located between the automatic welding station and the second production line, and is used to transfer the semi-finished materials from the automatic welding station to the second production line.

3. The energy storage converter module assembly system according to claim 1, characterized in that, The IGBT automatic placement station includes a material feeding robot and an IGBT feeding device. The IGBT feeding device adopts AGV automatic material feeding and turnover. The material feeding robot integrates an industrial camera, suction cup clamps and material detection components, which can identify the IGBT position and prevent the material from falling off, so as to achieve precise placement of IGBTs on the heat sink.

4. The energy storage converter module assembly system according to claim 1, characterized in that, The IGBT fixing station includes a screw pre-tightening unit and a screw fastening unit. The screw pre-tightening unit includes a screw feeding structure, a positioning arm, a pre-tightening gun mounted on the positioning arm, and an industrial camera, so as to automatically feed screws and perform screw pre-tightening actions according to a predetermined program. The screw fastening unit includes a fastening robot, an industrial camera, and two electric fastening tools with torque acquisition function mounted on the fastening robot. It is used to fasten two screws simultaneously to meet the diagonal fastening requirements of IGBTs. The fastening robot uses the industrial camera to photograph the product mark point to determine the final tightening position of the screw. After fastening, it can collect torque and angle data and bind them to the product barcode for uploading.

5. An energy storage converter module assembly system according to any one of claims 1-4, characterized in that, Between the automatic welding station and the automatic dispensing station, there is also a vision inspection station, which includes a three-axis moving structure and an inspection camera mounted on the three-axis moving structure to realize weld point inspection.

6. The energy storage converter module assembly system according to claim 5, characterized in that, Downstream of the adhesive curing station is a flipping mechanism, which is used to flip / release materials according to the converter module assembly requirements.

7. The energy storage converter module assembly system according to claim 1, characterized in that, The production line consists of multiple automated workstations. Each automated workstation includes a transmission unit, a support frame, a stopper, and a check block. The transmission unit is mounted on the support frame and consists of two layers: the upper layer is used to drive the pallet to rotate along the conveying direction, and the lower layer is used for pallet return. The stopper and check block are used to stop the pallet during the conveying process.

8. A method for assembling an energy storage converter module, characterized in that, It is implemented using the energy storage converter module assembly system according to any one of claims 1-7, and the specific steps are as follows: S1. The radiator raw materials are fed into the conveying mechanism via the truss transfer mechanism; S2. Apply silicone grease to the heat sink material on the production line; S3. Complete the automatic assembly of IGBTs on the heat sink material, and sequentially perform screw pre-tightening and fastening operations, and collect and upload the process data of the final fastening process. S4. Based on the welding process parameters corresponding to the product specifications, perform selective welding of semi-finished products and weld quality inspection. S5. Perform automatic dispensing of adhesive on the semi-finished product, and then cure the adhesive after completion; S6. The truss transfer mechanism is used to carry out material turnover according to the product production process, and to complete the assembly and transfer of materials on one or both sides. S7. The finished product is removed from the assembly line through the unloading mechanism, completing the entire assembly process.

9. The method for assembling an energy storage converter module according to claim 8, characterized in that, In step S3, the screw tightening is performed in a fixed sequence, and the torque and angle data collected by the electric tightening tool are uploaded to the production line system for storage. If an NG situation occurs during the final tightening of the screw, the tightening of the remaining screws of the current IGBT stops, and the tightening work of the next IGBT begins directly.

10. The energy storage converter module assembly method according to claim 9, characterized in that, The specific logic of material turnover in step S6 is as follows: if the product needs to be installed on both sides, the gantry robot will flip the semi-finished product and turn it back to the initial position of the conveying mechanism to continue to complete the assembly of the other side; if the product only needs to be installed on one side, the gantry robot will directly transfer the semi-finished product to the third production line.

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