A transformer comprehensive detection all-in-one machine

Abstract

This invention relates to an integrated machine for comprehensive transformer testing, belonging to the field of transformer testing technology. It solves the problems of existing methods that cannot continuously test the performance and appearance of transformers, have high investment costs, low automation, and low efficiency. The machine includes a cabinet containing a feeding mechanism, a performance testing mechanism, a laser marking mechanism, a visual inspection device, and an unloading mechanism. The performance testing mechanism includes a first testing component, an inter-turn testing component, and a withstand voltage testing component. The cabinet also includes a first transfer feeding component for sequentially conveying the transformer under test to the first testing component, the inter-turn testing component, the withstand voltage testing component, and the laser marking mechanism. It features a compact and ingenious structural design, and significantly improves testing efficiency through parallel operation logic, while simultaneously balancing the rigor of electrical performance testing with the detail of appearance inspection. It is an intelligent testing equipment that combines high efficiency, high precision, and a high degree of automation.

Description

Technical Field

[0001] This invention relates to the field of transformer testing technology, and in particular to an integrated machine for comprehensive transformer testing. Background Technology

[0002] After the transformer is manufactured through the winding and soldering assembly process, its performance needs to be tested and its appearance needs to be inspected for defects in order to avoid any defects that could affect the quality of the transformer's production.

[0003] Existing methods for inspecting transformers typically involve using a separate performance testing device to perform batch performance testing on the transformers, followed by a separate visual inspection machine to inspect for appearance defects (refer to existing patent publication number "CN120992489A", patent name: A fully automatic visual inspection machine for transformers, application date: 2025.08.19). Existing methods for inspecting the entire product require two separate sets of testing equipment to inspect each product individually, resulting in high investment costs. Furthermore, the entire process is discontinuous, leading to low efficiency. Summary of the Invention

[0004] The purpose of this invention is to provide an integrated machine for comprehensive transformer testing, which solves the problems of existing machines that cannot continuously test the performance and appearance of transformers, have high investment costs, low automation, and low efficiency.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: This invention provides an integrated machine for comprehensive transformer testing, including a cabinet. Inside the cabinet, a feeding mechanism, a performance testing mechanism, a laser marking mechanism, a visual inspection device, and a unloading mechanism are arranged sequentially along the feeding direction. The performance testing mechanism includes a first testing component, an inter-turn testing component, and a withstand voltage testing component. The cabinet is also equipped with a first transfer feeding component for sequentially conveying the transformer under test to the first testing component, the inter-turn testing component, the withstand voltage testing component, and the laser marking mechanism.

[0006] In one embodiment, the first transfer feeding assembly includes a support side plate, which is disposed inside the cabinet and located on one side of the performance testing mechanism. Five sets of independent and identical transfer components are disposed on the side of the support side plate opposite to the performance testing mechanism. The first three sets of transfer components cooperate to sequentially transfer the transformer delivered by the feeding mechanism to the first testing assembly, the inter-turn testing assembly, and the withstand voltage testing assembly. The latter two sets of transfer components cooperate to sequentially transfer the transformer that has passed the withstand voltage testing assembly to the marking laser mechanism and the visual inspection mechanism.

[0007] In one embodiment, two parallel sliding guide rails are horizontally arranged on the support side plate, and each transplanting component includes: A sliding plate, wherein the sliding plate is vertically arranged and slidably connected to the two sliding guide rails; The second lifting cylinder is disposed on the sliding plate, with its extension and retraction ends facing downwards; A gripper cylinder, the main body of which is connected to the telescopic end of the second lifting cylinder, is located directly above the performance testing mechanism; A conveyor belt is rotatably connected to the support side plate via pulleys. The conveyor belt is located between the two sliding guide rails, and the sliding plate is connected to the upper part of the conveyor belt. A drive motor is disposed on the other side of the support side plate, and the output shaft of the drive motor passes through the support side plate and is connected to one of the pulleys via a coupling.

[0008] In one embodiment, the withstand voltage test assembly includes: A support platform, on which a support tray for placing a transformer is placed along its length; A pressure-resistant testing component is provided, wherein at least one pressure-resistant testing component is distributed along the length of the support platform, and each pressure-resistant testing component includes two sets of mutually cooperating testing probes and a moving component that drives the two testing probes to move towards or away from each other, and the two sets of testing probes are arranged opposite to each other on both sides of the width direction of the support platform. The limiting component includes a strip-shaped limiting plate and a lifting cylinder that drives the strip-shaped limiting plate to move vertically. The lifting cylinder is mounted on the support side plate through a connecting plate. The strip-shaped limiting plate is located above the support platform between the two sets of detection probe groups. A pusher is provided on one side of the feeding end of the support platform and is used to push the support tray from the feeding end of the support platform to the discharging end; The recycling component returns the tray, which has been conveyed to the discharge end of the support platform, to the inlet end of the support platform. In one embodiment, the pusher includes: A pusher plate, wherein the pusher plate portion is disposed above the feeding end of the bearing platform; A pusher cylinder is disposed on one side of the support platform, with the telescopic end of the pusher cylinder facing the feed end of the support platform, and one end of the pusher plate is connected to the telescopic end of the pusher cylinder.

[0009] As one embodiment, the recycling component includes: A recycling platform is provided below the support platform and its length is adapted to the support platform. The lifting component has two sets of components respectively located at both ends of the upper surface of the recycling platform. The lifting component includes a magnetic suction plate and a lifting cylinder that drives the magnetic suction plate to move vertically. The main body of the lifting cylinder is located below the recycling platform. A through hole is provided on the support platform at a position corresponding to the magnetic suction plate for the magnetic suction plate to pass through. The return material component includes a return plate disposed on the recycling platform and a linear drive module disposed on the other side of the support platform. One side of the return plate is connected to a sliding member on the linear drive module, and the linear drive module drives the return plate to reciprocate along the length of the rotary table.

[0010] As one embodiment, the laser marking mechanism includes: The first rotating component includes a coding placement seat and a rotary cylinder that drives the coding placement seat to rotate 90° clockwise or counterclockwise. A laser marking device is disposed on one side of the first rotating assembly, and the laser emitted by the laser marking device is directed toward the marking placement base; The first temporary storage platform is disposed between the withstand voltage test component and the first rotating component, and is used to place the transformer after the withstand voltage test.

[0011] In one embodiment, a conveying assembly is provided between the laser marking mechanism and the visual inspection mechanism. The conveying assembly includes a conveying track, a second pusher plate disposed at the feeding end of the conveying track, and a second pusher cylinder disposed on one side of the conveying track. The second pusher plate is connected to the telescopic end of the second pusher cylinder, and a second product arrival detector is provided at the discharge end of the conveying track.

[0012] In one embodiment, the visual inspection mechanism includes a bottom visual inspection component, a top visual inspection component, and a side visual inspection component in sequence along the feeding direction. The visual inspection mechanism also includes a second transplanting feeding component, which is disposed on one side of the visual inspection mechanism. The structure of the second transplanting feeding component is the same as that of the first transplanting feeding component.

[0013] As one embodiment, the feeding mechanism includes: A position adjustment assembly, comprising an adjustment placement seat and a second rotary cylinder that drives the adjustment placement seat to rotate 90° clockwise or counterclockwise; The material feeding linear module has a material feeding base on its sliding block and a material tray on its material feeding base. The material feeding linear module cooperates with the last set of transplanting components in the second transplanting and feeding assembly to place qualified transformers in the material tray. The second temporary storage platform is disposed between the side visual inspection component and the position adjustment component, and is used to place the transformer that has passed the visual inspection.

[0014] Due to the application of the above technical solution, the present invention has the following advantages compared with the prior art: The present invention provides an integrated machine for comprehensive transformer testing, which not only has a compact and ingenious structural design, but also greatly improves the testing efficiency through parallel operation logic. At the same time, it takes into account the rigor of electrical performance testing and the fineness of appearance inspection. It is an intelligent testing equipment with high efficiency, high precision and high degree of automation. In addition, the feeding mechanism, comprehensive electrical performance testing, inter-turn testing, withstand voltage testing, laser marking, six-sided visual inspection, and unloading tray are integrated into a single cabinet, which greatly saves factory space and avoids transfer losses between multiple devices. From vibratory feeder feeding to final qualified product tray placement, the entire process is uniformly coordinated by the control components, requiring no manual intervention and achieving a high degree of automation. Attached Figure Description

[0015] The following sections will describe some specific embodiments of the invention in detail by way of example and not limitation, with reference to the accompanying drawings. The same reference numerals in the drawings denote the same or similar parts or portions. Those skilled in the art should understand that these drawings are not necessarily drawn to scale. In the drawings: Figure 1 This is a schematic diagram of the overall structure of a preferred embodiment of the present invention; Figure 2 This is a schematic diagram of the cooperative relationship between the performance testing mechanism and the first transplanting and feeding assembly in a preferred embodiment of the present invention; Figure 3 This is a partial structural schematic diagram of the feeding mechanism according to a preferred embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of the first test component and the inter-turn test component according to a preferred embodiment of the present invention; Figure 5 This is a schematic diagram of the structure of the withstand voltage test assembly according to a preferred embodiment of the present invention; Figure 6 This is a schematic diagram of the structure of the recycling component according to a preferred embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of the first transplanting and feeding assembly according to a preferred embodiment of the present invention; Figure 8This is a schematic diagram of the laser marking mechanism and conveying assembly according to a preferred embodiment of the present invention; Figure 9 This is a schematic diagram of the structure of the visual inspection mechanism according to a preferred embodiment of the present invention; Figure 10 This is a schematic diagram of the structure of the bottom surface visual inspection component and the top surface visual inspection component according to a preferred embodiment of the present invention; Figure 11 This is a schematic diagram of the structure of the side vision detection component according to a preferred embodiment of the present invention; Figure 12 This is a schematic diagram of the feeding mechanism according to a preferred embodiment of the present invention.

[0016] The reference numerals in the attached figures are explained as follows: 1. Server rack; 2. Vibrating conveyor track; 3. Performance testing organization; 31. First test component; 311. Test platform; 312. Defective product conveyor track; 313. Defective product pusher cylinder; 32. Inter-turn test assembly; 33. Withstand pressure test assembly; 331. Support platform; 332. Pressure resistance testing component; 3321. Testing probe assembly; 3322. Moving component; 33221. Support base; 33222. Moving cylinder; 333, Limiting component; 3331, Strip-shaped limiting plate; 3332, Lifting cylinder; 334. Pusher component; 3341. Pusher plate; 3342. Pusher cylinder; 335. Recyclable parts; 3351. Recycling station; 3352, Lifting component; 33521, Magnetic suction plate; 33522, Lifting cylinder; 3353, recycled parts; 33531, recycled plate; 33532, linear drive module; 4. Laser marking mechanism; 41. First rotating component; 411. Marking placement seat; 412. Rotary cylinder; 42. First temporary storage platform; 421. Marking defective product conveying track; 5. Visual inspection mechanism; 51. Bottom surface visual inspection component; 511. Bottom surface camera; 512. Bottom surface ring light source; 52. Top surface visual inspection component; 521. Four-station loading component; 522. Rotary loading motor; 523. Top surface camera; 524. Top surface ring light source; 53. Side vision inspection component; 531. Positioning module; 533. Distance adjustment component; 54. Second transplanting and feeding assembly; 6. Feeding mechanism; 61. Position adjustment assembly; 611. Adjustment placement seat; 612. Second rotary cylinder; 62. Material feeding linear module; 621. Material feeding base; 622. Material tray; 63. Second temporary storage platform; 7. First product arrival detector; 8. Pallet support; 9. First transplanting and feeding assembly; 91. Supporting side plate; 92. Transplanted parts; 92. Transplanting component; 921. Sliding plate; 922. Second lifting cylinder; 923. Gripper cylinder; 924. Conveyor belt; 10. Sliding guide rail; 11. Conveying assembly; 111. Conveying track; 112. Second pusher plate; 113. Second pusher cylinder; 114. Second product arrival detector. Detailed Implementation

[0017] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. 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.

[0018] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0019] Furthermore, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0020] refer to Figure 1 , Figure 2 , Figure 7 and Figure 8The present invention provides an integrated machine for comprehensive transformer testing, including a cabinet 1, a transparent observation window on the cabinet 1, through which the working conditions inside the cabinet 1 can be observed; inside the cabinet 1, along the feeding direction, there are sequentially arranged a feeding mechanism, a performance testing mechanism 3, a laser marking mechanism 4, a vision inspection mechanism 5, and a unloading mechanism 6, each of which is electrically connected to a control component, and the control component coordinates and controls the automated operation of the whole machine.

[0021] refer to Figure 1 , Figure 2 and Figure 3 The feeding mechanism includes a vibratory feeder (not shown in the figure) located outside the cabinet 1 and a vibratory conveying track 2 connected to the discharge port of the vibratory feeder. The vibratory conveying track 2 extends into the cabinet 1 to the side of the feed end of the performance testing mechanism 3. The transformer discharged from the vibratory feeder is conveyed to the performance testing mechanism 3 through the vibratory conveying track 2. A first product arrival detector 7 is provided at the discharge end of the vibratory conveying track 2. The first product arrival detector 7 is preferably a photoelectric sensor. When the first product arrival detector 7 detects that a transformer has arrived at the discharge end of the vibratory conveying track 2, it sends a signal to the control component. The control component then controls the vibratory conveying track 2 to stop vibrating and feeding continuously, and resumes vibrating feeding after the current transformer is removed.

[0022] refer to Figure 2 , Figure 4 and Figure 5 The performance testing mechanism 3 includes a first testing component 31, an inter-turn testing component 32, and a withstand voltage testing component 33 arranged sequentially along the feeding direction. The first testing component 31 is used to comprehensively test and evaluate the performance parameters of the transformer, such as voltage, current, insulation, and power. The inter-turn testing component 32 is used to test the interlayer insulation performance of the coils in the transformer. The withstand voltage testing component 33 is used to test the withstand capability of the insulating medium inside the transformer by applying an electric field.

[0023] refer to Figure 2 and Figure 4 Both the first testing component 31 and the inter-turn testing component 32 are equipped with a testing platform 311 and a defective product conveying track 312 arranged sequentially along the feeding direction. The testing platform 311 in the first testing component 31 is located at the discharge end of the vibrating conveying track 2, and each defective product conveying track 312 is equipped with a defective product pushing cylinder 313 at the inlet end. The tester (not shown in the figure) and the inter-turn tester (not shown in the figure) in the first testing component 31 are located on the side of the testing platform 311. After testing, the transformers are first transferred to the defective product conveying track 312. If a defective product is detected, the defective product is pushed along the defective product conveying track 312 to the defective product collection position by the defective product pushing cylinder 313. The transformers that pass the test are then picked up and moved to the next testing position.

[0024] refer to Figure 2 , Figure 4 and Figure 5 The withstand voltage test assembly 33 includes a support platform 331, a withstand voltage test component 332, a limiting component 333, a pushing component 334, and a recycling component 335. Multiple support trays 8 for placing transformers are placed on the support platform 331 along its length. In this application, five support trays 8 are provided, and three transformers are placed in each support tray 8. The upper end surface of the support platform 331 is provided with a guide groove for limiting the support trays 8.

[0025] refer to Figure 2 , Figure 4 and Figure 5 At least one pressure-resistant testing element 332 is provided. In this application, three pressure-resistant testing elements 332 are provided and distributed along the length of the support platform 331. Each pressure-resistant testing element 332 includes two sets of cooperating testing probe groups 3321 and a moving element 3322 that drives the two testing probe groups 3321 to move towards or away from each other. The two sets of testing probe groups 3321 are arranged opposite to each other on both sides of the width direction of the support platform 331. The moving element 3322 includes a support base 33221 and a moving cylinder 33222 provided on the support base 33221. The testing probe group 3321 is fixed to the telescopic end of the moving cylinder 33222.

[0026] refer to Figure 2 , Figure 4 and Figure 5 A pusher 334 is disposed on one side of the feeding end of the support platform 331, and is used to push the support tray 8 from the feeding end of the support platform 331 to the discharging end. The pusher 334 includes a pusher plate 3341 and a pusher cylinder 3342. The pusher plate 3341 is arranged in an L-shape and is laterally positioned above the feeding end of the support platform 331. The pusher cylinder 3342 is disposed on one side of the support platform 331, and the telescopic end of the pusher cylinder 3342 faces the feeding end. The vertical part of the pusher plate 3341 is connected to the telescopic end of the pusher cylinder 3342. During pushing, the pusher 334 pushes the support tray 8 at the feeding end of the support platform 331 toward the discharging end, thereby moving the remaining support tray 8.

[0027] refer to Figure 2 , Figure 4 and Figure 5 The length of the bearing platform 331 and the length of the bearing tray 8 are set according to the actual working conditions. In this application, only five bearing trays 8 can be placed on the upper surface of the bearing platform 331. Among them, the three bearing trays 8 in the middle are respectively located between the three withstand voltage test pieces 332, which can ensure the accuracy of the placement position of the bearing trays 8, and at the same time ensure the accurate testing of the transformer by the withstand voltage test pieces 332.

[0028] refer to Figure 2 , Figure 4 and Figure 5 The recycling component 335 returns the tray 8, which has been conveyed to the discharge end of the support platform 331, to the feed end of the support platform 331. The recycling component 335 includes a recycling platform 3351, a lifting component 3352, and a return component 3353. The recycling platform 3351 is located below the support platform 331 and its length is adapted to the support platform 331. The lifting component 3352 is provided with two sets, which are respectively located at both ends of the upper end face of the recycling platform 3351. The lifting component 3352 includes a magnetic suction plate 33521 and a lifting cylinder 33522 that drives the magnetic suction plate 33521 to rise and fall longitudinally. The main body of the lifting cylinder 33522 is located below the recycling platform 3351. A through hole is provided on the support platform 331 at a position corresponding to the magnetic suction plate 33521 for the magnetic suction plate to pass through. The return material component 3353 includes a return material plate 33531 mounted on the recycling platform and a linear drive module 33532 mounted on the other side of the support platform 331. One side of the return material plate 33531 is connected to a sliding component on the linear drive module 33532, which drives the return material plate 33531 to reciprocate along the length of the recycling platform 3351. The magnetic attraction force of the magnetic suction plate 33521 on the support tray 8 is less than the pushing force of the return material component on the support tray 8, ensuring that the adsorbed support tray 8 can be detached from the magnetic suction plate 33521 during material return.

[0029] refer to Figure 2 , Figure 4 and Figure 5During operation, the lifting cylinder 33522 located at the feeding end (below the feeding end of the support platform 331) lifts the magnetic suction plate 33521 and the tray on the magnetic suction plate 33521 to the set height at the feeding end of the support platform 331, waiting for material to be loaded. When the tray 8 is full of transformers, the transformers in the tray 8 at the discharge end of the support platform 331 are all fed to the next mechanism. At this time, the lifting cylinder located at the discharge end (below the discharge end of the support platform 331) moves the empty tray 8 down to the set position, while the pushing cylinder drives the pushing plate to push the tray 8 at the feeding end to move along the length of the support platform 3311 towards the discharge end. When the tray 8 at the feeding end is completely detached from the magnetic suction plate 33521, the feeding process is complete. The lifting cylinder 33522 at the end (below the feeding end of the support platform 331) drives the pallet 8 to move down to the set position; the linear drive module 33532 drives the return plate 33531 to move towards the feeding end (below the feeding end of the support platform), thereby pushing the empty pallet 8 onto the magnetic suction plate 33521 at the feeding end (below the feeding end of the support platform). After that, the lifting cylinder 33522 at the feeding end (below the feeding end of the support platform 331) drives the pallet 8 to move up to the feeding end of the support platform 331, waiting for feeding; and repeats the above actions. The recycling component 335 of this structure can realize the recycling of the pallet 8, and the structure is simple and relatively compact. It is integrated with the support platform 331, reducing the space occupied.

[0030] refer to Figure 2 , Figure 4 and Figure 5 The limiting component 333 includes a strip-shaped limiting plate 3331 and a lifting cylinder 3332 that drives the strip-shaped limiting plate 3331 to move vertically. The lifting cylinder 3332 is installed on the support side plate 91 (i.e., the support side plate mentioned below) through a connecting plate. The strip-shaped limiting plate 3331 is located above the bearing platform between the two sets of detection probe groups 3321. The length of this strip-shaped limiting plate 3331 can completely cover the three bearing trays 8. Before the transformer in the bearing tray 8 is subjected to a withstand voltage test, the strip-shaped limiting plate 3331 is moved down by the lifting cylinder 3332 until the gap is located on the upper end face of the transformer and does not contact the transformer. When the transformer is subjected to a withstand voltage test, it plays a vertical limiting role for the transformer and will not jump upward.

[0031] refer to Figure 1 , Figure 2 and Figure 6The cabinet 1 also houses a first transplanting and feeding assembly 9, which includes a support side plate 91. The support side plate 91 is located on one side of the performance testing mechanism 3. Five independent and structurally identical transplanting components 92 (i.e., the first transplanting component, the second transplanting component, the third transplanting component, the fourth transplanting component, and the fifth transplanting component) are arranged on the side of the support side plate 91 opposite to the performance testing mechanism 3. The first transplanting component, the third transplanting component, and the fifth transplanting component are distributed at intervals along the length of the support side plate and are at the same height. The second transplanting component is located below the first transplanting component, the third transplanting component, and the fifth transplanting component. Below the transplanting component, part of the structure of the second transplanting component overlaps with the first and third transplanting components respectively. The first, second, and third transplanting components work together to transport the transformers delivered by the feeding mechanism to the first test assembly 31, the inter-turn test assembly 32, and the withstand voltage test assembly 33 in sequence. The fourth transplanting component is located to the right of the third transplanting component and is at the same height as the second transplanting component. The fourth and fifth transplanting components work together to transport the transformers that have passed the withstand voltage test to the laser marking mechanism 4 and the visual inspection mechanism 5 in sequence.

[0032] Specifically, refer to Figure 1 , Figure 2 and Figure 7 The support side plate 91 has two parallel sliding guide rails 10 horizontally arranged on it. Each transplanting component 92 includes a sliding plate 921, a second lifting cylinder 922, a gripper cylinder 923, a conveyor belt 924, and a drive motor (located on the back of the support side plate, not shown in the figure). The sliding plate 921 is vertically arranged and slidably connected to the two sliding guide rails 10. The second lifting cylinder 922 is arranged on the sliding plate 921, with its extension end facing downwards. The main body of the gripper cylinder 923 is connected to the extension end of the second lifting cylinder 922, and the gripper cylinder 923 is located directly above the performance testing mechanism. The conveyor belt 924 is rotatably connected to the support side plate 91 through a pulley, and the conveyor belt 924 is located between the two sliding guide rails 10. The upper part of the sliding plate 921 is connected to the upper part of the conveyor belt 924. The drive motor 925 is arranged on the other side of the support side plate 91, and the output shaft of the drive motor passes through the support side plate 91 and is connected to one of the pulleys through a coupling.

[0033] refer to Figure 1 , Figure 2 and Figure 7During operation, since the transfer distance of each group of transfer components 92 is different, in order to ensure the continuity and synchronicity of the transfer, the control component controls the different speeds of the drive motors in each group of transfer components 92 under the same transfer time, thereby achieving synchronous feeding of the five groups of transfer components 92. For example, when the first transfer component transports the transformer output from the feeding mechanism 2 to the integrated testing platform 3113, the second transfer component then transfers the transformer that has passed the previous inspection and is placed on the integrated testing defective product conveying track 312 to the inter-turn testing platform 311, and the third group of transfer components transports the transformer that has passed the test on the inter-turn testing defective product conveying track 312 to the support tray 8; Subsequently, when the first transfer component transports the transformer placed on the integrated testing platform 311 to the integrated testing defective product conveying track 312, the second set of transfer components transports the transformer on the inter-turn testing platform 311 to the inter-turn testing defective product conveying track 312, and the third set of transfer components transports the transformer that has passed the test on the inter-turn testing defective product conveying track 312 back to the support tray 8, and so on, thereby realizing continuous synchronous feeding of transformers.

[0034] refer to Figure 1 , Figure 2 and Figure 8 The laser marking mechanism 4 includes a first rotating component 41, a first temporary storage platform 42, and a laser marking device (not shown in the figure). The first rotating component 41 includes a marking placement seat 411 and a rotary cylinder 412 that drives the laser placement seat 411 to rotate 90° clockwise or counterclockwise. The laser marking device is located on one side of the first rotating component 41, and the laser emitted by the laser marking device is directed toward the laser placement seat 411. The first temporary storage platform 42 is located between the withstand voltage test component 33 and the first rotating component 41 and is used to place the transformer after the withstand voltage test. Three sets of defective product conveying tracks 421 are set on the first temporary storage platform 42. Each set of defective product conveying tracks 421 is also equipped with a defective product pushing cylinder at the feeding end. When the transformers have passed the withstand voltage test component 33, the fourth transfer component picks up the transformers in the tray 8 one by one and puts them onto the corresponding defective product conveying track 421 on the first temporary storage platform 42. Qualified products are transferred to the laser placement seat 411 by the fifth transfer component, while unqualified products are pushed out by the defective product pushing cylinder and discharged along the defective product conveying track 312. The transformers placed on the laser placement seat 411 are rotated 90° by the rotary cylinder 412 so that the upper end face of the transformer faces the laser coder. The laser coder marks the top end face of the transformer. After marking is completed, the marked transformers are conveyed to the next mechanism by the fifth transfer component.

[0035] refer to Figure 1 , Figure 2 and Figure 8A conveying assembly 11 is also provided between the laser marking mechanism 4 and the visual inspection mechanism 53. The conveying assembly 11 is used to receive and convey the transformers of the fifth group of transplanted parts, so that the transformers are conveyed one by one towards the visual inspection mechanism 5. The conveying assembly 11 includes a conveying track 111, a second pusher plate 112 provided at the feeding end of the conveying track 111, and a second pusher cylinder 113 provided on one side of the conveying track 111. The second pusher plate 112 is connected to the telescopic end of the second pusher cylinder 113. A second product arrival detector 114 is provided at the discharge end of the conveying track 111. When the second product arrival detector 114 detects that a transformer has arrived at the discharge end of the conveying track 111, it sends a signal to the control assembly. The control assembly then controls the second pusher cylinder 113 to stop continuous feeding and waits for the current transformer to be removed before resuming feeding.

[0036] refer to Figure 9 , Figure 10 and Figure 11 The visual inspection mechanism 5 includes, along the feeding direction, a bottom visual inspection component 51, a top visual inspection component 52, and a side visual inspection component 53. It also includes a second transfer feeding component 54 for sequentially conveying the laser-marked transformer to the bottom visual inspection component 51, the top visual inspection component 52, the side visual inspection component 53, and the unloading mechanism 6. The structure of the second transfer feeding component 54 is the same as that of the first transfer feeding component 9. The difference is that the second transfer feeding component 54 includes four sets of transfer components (namely, the sixth transfer component, the seventh transfer component, the eighth transfer component, and the ninth transfer component). The sixth transfer component and the eighth transfer component have the same height. The seventh transfer component is located below the sixth transfer component and the eighth transfer component, and part of it overlaps with the sixth transfer component and the eighth transfer component, respectively. The height of the ninth transfer component is the same as that of the seventh transfer component, and part of it overlaps with the eighth transfer component.

[0037] refer to Figure 9 , Figure 10 and Figure 11 The bottom surface visual inspection component 51 includes a height-adjustable bottom surface camera 511 and a bottom surface ring light source 512, which is also height-adjustable and located above the bottom surface camera 511. The top surface visual inspection component 52 includes a four-station loading component 521, a rotary loading motor 522 that drives the four-station loading component 521 to rotate, a top surface camera 523, and a top surface ring light source 524 located below the top surface camera 523. The four-station loading component 521 is arranged circumferentially as a loading position, an inspection position, an unloading position, and a waiting position. The top surface camera 523 is located above the inspection position. refer to Figure 9 , Figure 10 and Figure 11The side vision inspection component 53 includes a positioning module 531 and four sets of camera modules (i.e., side cameras, not shown in the figure) distributed circumferentially along the positioning module 531. Each camera module has a distance adjustment component 533 below it. The distance adjustment component 533 adjusts the movement of the four camera modules towards or away from each other, thereby adjusting the focal length of the camera modules. The transformer is sequentially transported to the bottom vision inspection component 51, the top vision inspection component 52, and the side vision inspection component 53 via the second transfer feeding component 54. During the transport process, the six sides of the transformer are inspected. The working principle of the second transfer feeding component 54 is the same as that of the first transfer feeding component 9.

[0038] refer to Figure 8 and Figure 12 The feeding mechanism 6 includes a position adjustment component 61, a feeding linear module 62, and a second temporary storage platform 63. The position adjustment component 61 includes an adjustment placement seat 611 and a second rotary cylinder 612 that drives the adjustment placement seat 611 to rotate 90° clockwise or counterclockwise. A feeding placement base 621 is provided on the sliding block of the feeding linear module 62, and a material tray 622 is provided on the feeding placement base 621. The feeding linear module 62 cooperates with the ninth transfer component to place qualified transformers in the material tray 622. According to the placement pattern of qualified transformers, the position of the transformer is adjusted by the position adjustment component 61 before placement to facilitate subsequent placement in the material tray 622. The second temporary storage platform 63 is located between the side visual inspection component 53 and the position adjustment component 61, and is used to place the transformer after visual inspection. The second temporary storage platform 63 has the same structure as the first temporary storage platform 42, and a pusher cylinder is also provided at the feeding end. When the transformer after inspection by the visual inspection mechanism 5 is placed on the second temporary storage platform 63, the unqualified transformer is pushed out by the pusher cylinder and discharged along the unqualified track.

[0039] refer to Figures 1-12 The working process of the integrated transformer testing machine of the present invention is as follows: The transformer to be tested is arranged by the vibrating feeder and then conveyed to the discharge end via the vibrating conveyor track 2. After the first product arrival detector 7 detects that the transformer has arrived, the control component controls the vibrating conveyor track 2 to stop feeding.

[0040] The first transfer component picks up the transformer from the discharge end of the vibrating conveyor track 2 and places it onto the comprehensive testing platform 311. The comprehensive tester then performs comprehensive tests on the transformer's performance parameters, such as voltage, current, insulation, and power. After the tests are completed, the product is transferred by the first transfer component to the defective product conveyor track 312. Qualified products are picked up by the second transfer component and placed onto the inter-turn testing platform, while unqualified products are pushed out by the defective product pusher cylinder 313.

[0041] The inter-turn test assembly 32 tests the interlayer insulation performance of the transformer coil. After the test is completed, the product is transferred to the inter-turn defective product conveying track by the second transfer component. The qualified products are picked up by the third transfer component and placed into the tray 8 of the withstand voltage test assembly 33. The unqualified products are pushed out by the defective product pusher cylinder.

[0042] In the withstand voltage test assembly 33, the pusher 334 pushes the support tray 8 to move step by step along the support platform 331, passing through three withstand voltage testers 332 in sequence. At each withstand voltage test station, the strip limit plate 3331 of the limiter 333 moves down to the top of the transformer without contacting it. The two sets of test probes 3321 move towards each other and make electrical contact with the transformer, applying an electric field to test the withstand capacity of the insulating medium inside the transformer. After the test is completed, the support tray 8 located at the discharge end of the support platform 331 is picked up one by one by the fourth transfer member and placed on the first temporary storage platform 42. The "empty" support tray 8 is returned to the feed end of the support platform 331 by the recycling member 335 for reuse.

[0043] The qualified products on the first temporary storage platform 42 are picked up by the fifth transfer component and placed on the coding placement seat 411. The rotary cylinder 412 drives the coding placement seat 411 to rotate, and the laser coding device codes the top end face of the transformer. After coding is completed, the fifth transfer component picks up the transformer and places it on the conveying track 111 of the conveying component 11.

[0044] The conveying component 11 conveys the transformers one by one to the discharge end. Then, the sixth transfer component grabs the transformers and places them on the bottom surface visual inspection component 51 for bottom surface appearance inspection. After the inspection is completed, the transformers are transferred to the loading position of the four-station loading component 521. Then, the four-station loading component 521 rotates counterclockwise to the inspection position. The top surface camera 523 takes pictures of the top surface appearance, analyzes and compares them. After the inspection is completed, it rotates from the inspection position to the unloading position to wait for grabbing and unloading. Subsequently, the transformer at the unloading position is fed to the side visual inspection component 53 via the seventh transfer component. The side visual inspection component 53 performs side appearance inspection on the transformer. After inspection, the transformer is fed to the second temporary storage platform 63 via the eighth transfer component. The qualified transformers after visual inspection are placed in the position adjustment component by the eighth transfer component for position adjustment. After adjustment, the qualified transformers are neatly placed in the material tray 622 by the ninth transfer component in conjunction with the unloading linear module 62 to complete the unloading. Products that fail visual inspection are pushed out by the corresponding defective product pusher cylinder on the second temporary storage platform 63. At this point, the integrated performance testing, laser marking, visual inspection and unloading of the transformer are all completed.

[0045] In summary, this integrated transformer performance testing and visual inspection machine has the following significant advantages: 1. High integration and end-to-end automation Process integration: The feeding, comprehensive electrical performance testing, inter-turn testing, withstand voltage testing, laser marking, six-sided visual inspection and unloading tray are integrated into a single cabinet, which greatly saves factory space and avoids transfer losses between multiple machines.

[0046] Unmanned operation: From vibratory feeder loading to final qualified product placement, the entire process is coordinated by the control components without human intervention, significantly reducing labor costs.

[0047] 2. A unique, highly efficient parallel synchronous transplanting system Overlapping transplanting structure: The first and second transplanting feeding components adopt a multi-layer, partially overlapping transplanting component layout, combined with independent drive motors and differentiated speed control, to achieve synchronous loading and unloading of multiple stations (comprehensive testing, inter-turn testing, pressure resistance testing, and visual inspection).

[0048] Cycle optimization: This design allows transplanting actions of different strokes to be completed in the same time, completely eliminating the idle time of traditional serial robotic arms waiting in sequence, and significantly improving the overall working efficiency of the machine.

[0049] 3. Comprehensiveness and high precision of performance testing Comprehensive electrical testing: Comprehensive tests (voltage / current / insulation / power), inter-turn insulation tests, and withstand voltage tests are set up in sequence to comprehensively control the electrical performance of the transformer.

[0050] Recirculating return tray design: The pressure test uses a pallet for loading, and the empty pallet is automatically circulated back inside through a compact lifting and sliding recovery component, eliminating the need for an external return line. The structure is compact and saves space.

[0051] Anti-jump limit mechanism: During withstand voltage testing, the strip limit plate presses down tightly against the upper surface of the transformer, effectively preventing poor contact or positional displacement caused by the product "jumping" under force during high voltage testing, thus ensuring the safety and accuracy of the test results.

[0052] 4. A precise and comprehensive visual inspection system Six-sided inspection without blind spots: By using the layout of the bottom, top (with four-station rotary feeding) and sides (with multi-angle camera module) and the flow of the second transfer feeding component, the defect detection of the six appearance surfaces of the transformer can be completed in one go.

[0053] 5. Scientific separation of good and defective products and intelligent material feeding. Immediate rejection upon inspection: Each performance testing station (comprehensive, inter-turn, withstand voltage) and visual inspection station is equipped with an independent defective product conveying track and pusher cylinder. Once a defective product is detected, it is immediately rejected on-site, preventing defective products from flowing into subsequent processes and greatly saving processing costs.

[0054] Intelligent material feeding and tray placement: The feeding mechanism, combined with the rotating position adjustment component, can automatically adjust the transformer angle according to preset rules, and work with the linear module to accurately place the material onto the tray, thus achieving orderly collection of finished products.

[0055] The above embodiments are only for illustrating the technical concept and features of the present invention. Their purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be used to limit the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. An integrated machine for comprehensive transformer testing, comprising a cabinet (1), characterized in that, The cabinet (1) is arranged in sequence along the feeding direction, including a feeding mechanism, a performance testing mechanism (3), a laser marking mechanism (4), a visual inspection device (5), and a unloading mechanism (6). The performance testing mechanism (3) includes a first test component (31), an inter-turn test component (32), and a withstand voltage test component (33). The cabinet (1) is also provided with a first transfer feeding component (9) for sequentially conveying the transformer under test to the first test component (31), the inter-turn test component (32), the withstand voltage test component (33), and the laser marking mechanism (4).

2. The integrated transformer testing machine according to claim 1, characterized in that, The first transplanting and feeding assembly (9) includes a support side plate (91). The support side plate (91) is located inside the cabinet (1) and on one side of the performance testing mechanism (3). Five independent and identical transplanting components (92) are provided on the side of the support side plate (91) opposite to the performance testing mechanism (3). The first three groups of transplanting components (92) cooperate to transport the transformer delivered by the feeding mechanism to the first test assembly (31), the inter-turn test assembly (32), and the withstand voltage test assembly (33) in sequence. The last two groups of transplanting components (92) cooperate to transport the transformer that has passed the withstand voltage test assembly (33) to the marking laser mechanism (4) and the visual inspection mechanism (5) in sequence.

3. The integrated transformer testing machine according to claim 2, characterized in that, The supporting side plate (91) is provided with two parallel sliding guide rails (10), and each of the transplanting components (92) includes: A sliding plate (921) is vertically arranged and slidably connected to two sliding guide rails (10); The second lifting cylinder (922) is mounted on the sliding plate (921), and the extension end of the second lifting cylinder (922) is positioned downwards; The gripper cylinder (923) has its main body connected to the telescopic end of the second lifting cylinder (922), and the gripper cylinder (923) is located directly above the performance testing mechanism (3). A conveyor belt (924) is rotatably connected to the support side plate (91) via a pulley. The conveyor belt (924) is located between the two sliding guide rails (10). The sliding plate (921) is connected to the upper part of the conveyor belt (924). A drive motor is disposed on the other side of the support side plate (91), and the output shaft of the drive motor passes through the support side plate (91) and is connected to one of the pulleys via a coupling.

4. The integrated transformer testing machine according to claim 1, characterized in that, The withstand voltage test assembly (33) includes: A support platform (331) on which a support tray (8) for placing a transformer is placed along its length. A pressure-resistant testing component (332) is provided with at least one component distributed along the length of the support platform (331). Each pressure-resistant testing component (332) includes two sets of mutually cooperating testing probe groups (3321) and a moving component (3322) that drives the two testing probe groups (3321) to move towards or away from each other. The two sets of testing probe groups (3321) are arranged opposite to each other on both sides of the width direction of the support platform (331). The limiting component (333) includes a strip limiting plate (3331) and a lifting cylinder (3332) that drives the strip limiting plate (3331) to rise and fall longitudinally. The lifting cylinder (3332) is installed on the supporting side plate (91) through a connecting plate. The strip limiting plate (3331) is located above the support platform (331) between the two sets of detection probe groups (3321). Pusher (334), the pusher (334) is disposed on one side of the feeding end of the support platform (331), and is used to push the support tray (8) from the feeding end of the support platform (331) to the discharging end; The recycling component (335) returns the tray (8) that has been conveyed to the discharge end of the support platform (331) to the feed end of the support platform (331).

5. The integrated transformer testing machine according to claim 4, characterized in that, The pusher (334) includes: A pusher plate (3341) is partially disposed above the feeding end of the support platform (331); A pusher cylinder (3342) is disposed on one side of the support platform (331), and the telescopic end of the pusher cylinder (3342) faces the feeding end of the support platform (331). One end of the pusher plate (3341) is connected to the telescopic end of the pusher cylinder (3342).

6. The integrated transformer testing machine according to claim 5, characterized in that, The recycling component (335) includes: A recycling table (3351) is disposed below the support table (331) and its length is adapted to the support table (331); The lifting component (3352) is provided with two sets of lifting components respectively located at both ends of the upper end face of the recycling platform (3351). The lifting component (3352) includes a magnetic suction plate (33521) and a lifting cylinder (33522) that drives the magnetic suction plate (33521) to rise and fall longitudinally. The main body of the lifting cylinder (33522) is located below the recycling platform (3351). The bearing platform (331) is provided with a through hole at a position corresponding to the magnetic suction plate (33521) for the magnetic suction plate (33521) to pass through. The return component (3353) includes a return plate (33531) disposed on the recycling table (3351) and a linear drive module (33532) disposed on the other side of the support table (331). One side of the return plate (33531) is connected to a sliding member on the linear drive module (33532), and the linear drive module (33532) drives the return plate (33531) to reciprocate along the length of the rotary table (3351).

7. The integrated transformer testing machine according to claim 1, characterized in that, The laser marking mechanism (4) includes: The first rotating assembly (41) includes a coding placement seat (411) and a rotary cylinder (412) that drives the coding placement seat (411) to rotate 90° clockwise or counterclockwise. A laser marking device is disposed on one side of the first rotating assembly (41), and the laser emitted by the laser marking device is directed toward the marking placement seat (411). The first temporary storage platform (42) is located between the withstand voltage test assembly (3) and the first rotating assembly (41) and is used to place the transformer after the withstand voltage test.

8. The integrated transformer testing machine according to claim 7, characterized in that, A conveying assembly (11) is also provided between the laser marking mechanism (4) and the visual inspection mechanism (5). The conveying assembly (11) includes a conveying track (111), a second pusher plate (112) provided at the feeding end of the conveying track (111), and a second pusher cylinder (113) provided on one side of the conveying track (111). The second pusher plate (112) is connected to the telescopic end of the second pusher cylinder (113). A second product arrival detector (114) is provided at the discharge end of the conveying track (111).

9. The integrated transformer testing machine according to claim 1, characterized in that, The visual inspection mechanism (5) includes, in sequence along the feeding direction, a bottom visual inspection component (51), a top visual inspection component (52), and a side visual inspection component (53). The visual inspection mechanism (5) also includes a second transplanting feeding component (54), which is disposed on one side of the visual inspection mechanism (5). The structure of the second transplanting feeding component (54) is the same as that of the first transplanting feeding component (9).

10. The integrated transformer testing machine according to claim 9, characterized in that, The feeding mechanism (6) includes: The position adjustment assembly (61) includes an adjustment placement seat (611) and a second rotary cylinder (612) that drives the adjustment placement seat (611) to rotate 90° clockwise or counterclockwise. The material feeding linear module (62) has a material feeding base (621) on its sliding block and a material tray (622) on its material feeding base (621). The material feeding linear module (62) cooperates with the last set of transplanting components in the second transplanting feeding assembly (54) to place qualified transformers in the material tray (622). The second temporary storage platform (63) is disposed between the side visual inspection component (53) and the position adjustment component (61) for placing transformers that have passed visual inspection.

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