An apparatus and control method for automatically inserting a PCB board in a deep cavity

Abstract

The application discloses a device and a control method for automatically inserting a PCB board in a deep cavity, and the device comprises a supporting platform, a three-axis gantry coordinate motion platform, a PCB board picking manipulator, a following machine vision mechanism, a second machine vision mechanism, a conveying chain, a jacking mechanism and a primary positioning assembly. The primary positioning assembly receives and preliminarily positions a PCB board to be inserted, the conveying chain conveys a deep cavity container product with the PCB board to be inserted to the position of the jacking mechanism and conveys the deep cavity container product with the inserted PCB board to the next process, the jacking mechanism lifts the deep cavity container product with the PCB board to be inserted to the height of an insertion position, the three-axis gantry coordinate motion platform drives the PCB board picking manipulator to perform the actions of clamping, detecting and inserting the PCB board, and the double machine vision system automatically positions and detects the inserted pin of the PCB board. The device is suitable for the use requirement of inserting the PCB board in a deep cavity container warehouse with a small space, is convenient and stable and reliable to operate, and can be used with a continuous production line.

Description

Technical Field

[0001] This invention belongs to the field of electronic equipment assembly technology, and specifically discloses a device and control method for automatically inserting PCB boards into deep cavities. Background Technology

[0002] Underwater robots, buoy communication devices, and drift monitoring devices, which operate for extended periods underwater, require protection against prolonged immersion. Typically, all electrical wiring and control equipment are housed in a sealed deep-cavity container. However, the confined space within this container makes inserting the control equipment's PCB board difficult due to the long distance and obstructed view. Blind insertion guidance is necessary, and precise alignment of pins and holes is crucial to prevent misalignment and damage to the PCB board's components and pins. This process is challenging and results in low yield. Therefore, a device and control method for automated PCB board insertion within a deep cavity are needed. Summary of the Invention

[0003] To address the aforementioned problems in the existing technology, the present invention aims to provide an equipment and control method for automatically inserting PCB boards into deep cavities. This equipment automatically positions and detects PCB board pins through a dual machine vision system, and automatically completes the PCB board detection and insertion process within deep cavities by driving a robotic arm through a three-axis module. It adapts to the needs of inserting PCB boards into deep cavity containers with limited space, is easy to operate, stable and reliable, and can be used in conjunction with continuous production lines.

[0004] The technical solution adopted in this invention is as follows: The first technical solution provides a primary positioning component for an automated PCB board insertion device in a deep cavity, including a primary support seat and a primary limiting seat. The primary limiting seat is fixedly supported and installed at the front end of the support platform of the automated PCB board insertion device in a deep cavity via the primary support seat. One surface of the primary limiting seat is provided with one or more downwardly recessed positioning grooves. Each positioning groove is provided with a main positioning groove and a pin avoidance groove. The bottom surface of the pin avoidance groove is provided with a plurality of pin positioning holes. The main positioning groove is used to provide positioning for the lower end of the PCB board to be inserted, and the pin clearance groove and the pin positioning hole are used to provide positioning for the pins at the lower end of the PCB board to be inserted. Alternatively, the bottom surface of the pin clearance groove is provided with an elongated slot, and the pin clearance groove and the elongated slot are used to provide positioning for the pins at the bottom of the PCB board to be inserted through clearance fit; The primary positioning component is used to receive and initially position the PCB board to be inserted.

[0005] In some embodiments, the main positioning groove is used to provide primary positioning for the lower end of the PCB board to be inserted through clearance fit, and the pin clearance groove and the pin positioning hole are used to provide positioning for the pins at the lower end of the PCB board to be inserted through clearance fit; or, the bottom surface of the pin clearance groove is provided with an elongated slot, and the pin clearance groove and the elongated slot are used to provide positioning for the pins at the lower end of the PCB board to be inserted through clearance fit. The upper surface of the primary positioning seat is also provided with a secondary positioning post located outside each positioning slot. The secondary positioning post is used to cooperate with the cantilever connector on the PCB board to be inserted to provide secondary positioning.

[0006] The second technical solution provides a robot for an automated PCB board insertion device in a deep cavity, including a three-axis gantry coordinate motion platform and a PCB board picking robot integrated on the three-axis gantry coordinate motion platform. The three-axis gantry coordinate motion platform includes an X-axis module, a Y-axis module and a Z-axis servo module. A Z-axis robot mounting plate is provided on the front side of the Z-axis servo module. The PCB board picking robot and the accompanying machine vision mechanism are mounted on the Z-axis servo module through the Z-axis robot mounting plate. The PCB board picking robot includes an arm base, an arm extension cylinder connected to the arm base, a finger cylinder connected below the extension end of the arm extension cylinder, a pair of grippers of the finger cylinder having a pair of contour gripper heads connected inside, and a clearance step provided at the lower end of the inner side of the gripper heads, with an anti-slip buffer strip embedded in the clearance step; a pressure sensor is provided between the arm extension cylinder and the finger cylinder, the pressure sensor being used to sense and detect the pressure of inserting the PCB board; The three-axis gantry coordinate motion platform is used to drive the PCB board picking robot to pick up the PCB board to be inserted from the primary positioning group as described in claim 1.

[0007] The third technical solution provides a device for automatic insertion of PCB boards in a deep cavity, including a support platform, a three-axis gantry coordinate motion platform above the support platform, a PCB board picking robot and a following machine vision mechanism integrated on the three-axis gantry coordinate motion platform, a second machine vision mechanism in the middle of the support platform, a conveyor chain in the front section of the support platform, a lifting mechanism in the middle of the conveyor chain, and a primary positioning component at the front end of the support platform. The conveyor chain is used to transport the deep cavity container product with PCB board to be inserted to the lifting mechanism position, and to transport the deep cavity container product with PCB board to be inserted to the next process. The three-axis gantry coordinate motion platform is used to drive the PCB board picking robot to perform PCB board gripping, inspection and insertion actions; The accompanying machine vision mechanism is used to identify and acquire the reference positioning spatial coordinates to provide precise insertion positioning for the three-axis gantry coordinate motion platform. The lifting mechanism is used to lift the deep cavity container product with the PCB board to be inserted to the insertion position height; The second machine vision mechanism is used for bottom-view imaging to detect pins at the bottom of the PCB board; The primary positioning component is used to receive and initially position the PCB board to be inserted.

[0008] In some embodiments, the support platform includes a support plate, a lifting channel is provided through the middle of the front section of the support plate, and the lifting mechanism is disposed within the lifting channel; The lifting mechanism includes a lifting base plate and a lifting support plate. The lifting mechanism is fixedly supported and connected to the support plate on both sides of the lifting base plate. A lifting cylinder is provided in the lower middle part of the lifting support plate. The lifting support plate is fixedly connected to the telescopic end of the lifting cylinder and is connected to the lifting support plate through a guide assembly. Multiple supporting rubber blocks are provided above the lifting plate; a reference positioning pin is provided at one corner of the lifting plate.

[0009] In some embodiments, double-speed chain sheet metal parts are symmetrically arranged on both sides of the front section of the support plate, and a double-speed chain is supported and installed by the double-speed chain sheet metal parts to form the conveyor chain; A diffuse reflection photoelectric sensor is installed on the support plate at the rear of the double-speed chain. The diffuse reflection photoelectric sensor is used to sense and detect whether there is product information of the deep cavity container of PCB board to be inserted on the lifting mechanism. The inner side of the double-speed chain is equipped with a proximity sensor and a buffer stop. The proximity sensor is used to sense and detect the arrival information of the deep cavity container product with inserted PCB board, and the buffer stop is used in conjunction with the proximity sensor to provide the conveying limit of the deep cavity container product with inserted PCB board.

[0010] In some embodiments, the PCB board picking robot is fixedly connected to one side of the Z-axis robot mounting plate; The accompanying machine vision mechanism includes a first camera housing, a first industrial camera, a first industrial lens, and a first light source assembly. The first industrial camera, the first industrial lens assembly, and the first light source assembly are fixedly connected to the other side of the Z-axis robot mounting plate via an accompanying vision mounting base in a top-to-bottom order. The first camera housing covers the outside of the first industrial camera, the first industrial lens, and the first light source assembly. A barcode scanner is also fixedly installed on one side of the arm base. The barcode scanner is used to scan barcodes to collect material information.

[0011] In some embodiments, the second machine vision mechanism includes a second vision support assembly, a second camera housing, a second industrial camera, a second industrial lens assembly, and a second light source assembly. The second industrial camera, the second industrial lens assembly, and the second light source assembly are fixedly mounted in the middle of the support platform in an upward order via the second vision support assembly. The second camera housing covers the exterior of the second industrial camera, the second industrial lens, and the second light source assembly.

[0012] In some embodiments, a second light source adjustment plate and a second camera adjustment plate are provided on the inner side of the second vision support component, the second industrial lens is fixedly connected to the upper end of the second industrial camera, the second industrial camera is vertically adjustable to the inner side of the second vision support component through the second camera adjustment plate, and the second light source component is vertically adjustable to the inner side of the second vision support component through the second light source adjustment plate.

[0013] The fourth technical solution provides a device control method for automatically inserting PCB boards into a deep cavity. The device for automatically inserting PCB boards into a deep cavity according to the first technical solution described above also includes a material rack for buffering PCB boards to be inserted, and includes the following operating steps: S01, Equipment assembly installation and commissioning; material preparation; start-up and reset; preset the insertion position, insertion depth parameters and insertion pressure threshold according to the product information of the deep cavity container of the PCB board to be inserted; S02, the conveyor chain receives the pallet containing the deep cavity container product with PCB board to be inserted from the previous process and transports it to the lifting mechanism position. The proximity sensor triggers the positioning signal and the double speed chain conveyor stops. S03, the diffuse reflection photoelectric sensor detects the product information of the deep cavity container with PCB board to be inserted on the lifting mechanism. The lifting cylinder of the lifting mechanism lifts the tray off the chain, completes the first-level coarse positioning, and enters the stable imaging static state. S05, the three-axis gantry coordinate motion platform drives the PCB board picking robot and the accompanying machine vision mechanism to move to the lifting mechanism station; the accompanying machine vision mechanism captures and obtains the reference positioning information; S06, the primary positioning component receives the inserted PCB board and completes the primary positioning; S07, the three-axis gantry coordinate motion platform drives the PCB board picking robot and the accompanying machine vision mechanism to move to the primary positioning component station; the barcode scanner scans to obtain the product information of the PCB board to be inserted, and traces and binds it; S08, the accompanying machine vision mechanism captures and obtains primary positioning information; S09, the vision system calculates and outputs X / Y / Z three-axis offset compensation data based on the insertion position, insertion depth parameter information, primary positioning information and reference positioning information, and uploads it to the control center; S10, the PCB board picking robot arm picks up a PCB board to be inserted; S11, the control center corrects the three-axis reference coordinates by superimposing offset data based on the received data, and controls the three-axis gantry coordinate motion platform to drive the PCB board picking robot to move to the bottom vision imaging detection station. S12, the second machine vision mechanism captures the pin information at the bottom of the PCB board to be inserted, and the vision system calculates and outputs an OK / NG quality signal; if it is an OK quality signal, then continue to execute step S13; if it is an NG quality signal, then discard it. S13, the three-axis gantry coordinate motion platform drives the PCB board picking robot and the accompanying machine vision mechanism to move to the lifting mechanism station; S14, the barcode scanner scans to obtain product information of the deep cavity container PCB board to be inserted, and traces and binds it; S15, the three-axis gantry coordinate motion platform drives the PCB board picking robot to descend linearly along the Z-axis to perform the PCB board insertion action; S16, the pressure sensor senses and detects the real-time insertion pressure to determine whether the insertion is normal and whether the insertion is in place; S17, Insertion complete, the three-axis gantry coordinate motion platform returns to the mechanical origin; S18, Repeat steps S06 to S17 until the mass production order is completed; Among them, multiple product process formulas are built into the human-computer interaction interface. When changing models, the formula data can be retrieved with one click, and the three-axis coordinates, light source brightness, cylinder working air pressure, and process cycle parameters can be automatically refreshed. The process is equipped with fault classification and handling logic. If a single process loses a signal for a short time, the equipment will be suspended. After the fault is cleared and the equipment is manually reset, production will continue. If the same fault triggers the automatic equipment lock-up program three times in a row, the entire machine will be shut down in an emergency if the air source pressure is lower than the lower limit.

[0014] The beneficial effects of this invention are as follows: A device and control method for automatically inserting PCBs into deep cavities includes a three-axis gantry coordinate motion platform, a PCB picking robot, a traveling machine vision mechanism, a second machine vision mechanism, a conveyor chain, a lifting mechanism, and a primary positioning component, all supported by a support platform. The conveyor chain transports the deep cavity container product to be inserted with PCBs to the lifting mechanism and then transports the deep cavity container product with the inserted PCBs to the next process. The three-axis gantry coordinate motion platform drives the PCB picking robot to perform gripping, inspection, and PCB insertion actions. The traveling machine vision mechanism identifies and acquires the reference positioning space. The coordinate system provides a three-axis gantry coordinate motion platform for precise insertion and positioning. The lifting mechanism raises the deep cavity container product with the PCB board to be inserted to the insertion position height. The second machine vision mechanism uses bottom-view imaging to detect the pins at the bottom of the PCB board. The primary positioning component is used to receive and initially position the PCB board to be inserted. The dual machine vision system automatically positions and detects the PCB board pins. The three-axis module drives the robot to automatically complete the PCB board detection and insertion process in the deep cavity. It is suitable for the use of inserting PCB boards in the confined space of deep cavity container. It is easy to operate, stable and reliable, and can be used in conjunction with continuous production lines. Attached Figure Description

[0015] Figures 1-2 This is a three-dimensional structural diagram of the equipment used for automatic PCB board insertion in a deep cavity, as described in Embodiment 1. Figure 3 This is a schematic diagram of the internal three-dimensional structure of the device used for automatic insertion of PCB boards into a deep cavity, as described in Embodiment 1. Figure 4 This is a three-dimensional structural diagram of the equipment material rack for automatic PCB board insertion in a deep cavity, as shown in Embodiment 1. Figures 5-8 This is a schematic diagram of the support platform structure of the device for automatic insertion of PCB boards into a deep cavity, as described in Embodiment 1. Figures 9-11 This is a three-dimensional structural diagram of the lifting mechanism of the device for automatically inserting PCB boards into a deep cavity, as described in Embodiment 1. Figure 12 This is a three-dimensional structural diagram of the three-axis gantry coordinate motion platform of the device used for automatic insertion of PCB boards in a deep cavity, as described in Embodiment 1. Figures 13-15 This is a three-dimensional structural diagram of the second machine vision mechanism of the device for automatic insertion of PCB boards in a deep cavity, as described in Embodiment 1. Figures 16-17 This is a three-dimensional structural diagram of the PCB board picking robot and the accompanying machine vision mechanism of the device for automatic PCB board insertion in a deep cavity, as described in Embodiment 1. Figure 18 This is a three-dimensional structural diagram of the primary positioning component of the device for automatic insertion of PCB boards into a deep cavity, as described in Embodiment 1. Figure 19 This is a three-dimensional structural diagram of the primary positioning component of the device used for automatic insertion of PCB boards into a deep cavity, as described in Embodiment 2. Detailed Implementation

[0016] To facilitate understanding of the present invention, a more detailed description is provided below with reference to the accompanying drawings and specific embodiments. It should be noted that when an element is described as being "fixed to" another element, it can be directly on the other element, or one or more intermediate elements may exist between them. When an element is described as being "connected" to another element, it can be directly connected to the other element, or one or more intermediate elements may exist between them. The terms "vertical," "horizontal," "left," "right," "inner," "outer," and similar expressions used in this specification are for illustrative purposes only. In the description of the present invention, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating relative importance or implying the number of indicated technical features. Thus, unless otherwise stated, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature; "multiple" means two or more. The term "comprising" and any variations thereof mean non-exclusive inclusion, where one or more other features, integers, steps, operations, units, components, and / or combinations thereof may be present or added.

[0017] Furthermore, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections via an intermediate medium, or internal communication between two components. All technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. The term "and / or" as used in this specification includes any and all combinations of one or more of the associated listed items.

[0018] 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.

[0019] Example 1: Please refer to Figures 1 to 18 As shown, this invention provides a device and control method for automatic PCB board insertion in a deep cavity. The technical solutions of the prior art are analyzed as follows: In equipment used in surface and underwater applications, vehicle-mounted systems, aerospace, communications electronics, and testing instruments, PCB board insertion is typically performed within a deep, sealed / semi-sealed cavity. These cavities are deep and have narrow openings, preventing PCBs from being inserted laterally; instead, they must be inserted linearly along the cavity's depth (plug-and-play). Current technologies for inserting PCBs into deep cavities fall into two categories: fully manual assembly and simple semi-automatic tooling assembly. 1. Manual assembly relies on visual alignment and manual locking by operators, and is highly susceptible to variations in operator fatigue, skill level, and environmental temperature and humidity, often resulting in PCB... 1. Batch defects include board impact damage, misaligned mounting holes, loose or missing fasteners, and component crushing damage; 2. Most commercially available semi-automatic equipment uses an integrated welded frame structure with only a single-direction, single-point limiting structure. It lacks a composite mechanical structure of lifting and chain-free coarse positioning and bidirectional flexible secondary fine positioning, failing to eliminate multiple positioning errors caused by conveyor chain gaps, pallet forming tolerances, and product placement offsets. Furthermore, defect detection is delayed, meaning damaged products are only detected after assembly, leading to complete disassembly and rework of the power battery module, resulting in high raw material and labor costs. In addition, traditional equipment electrical layouts do not differentiate between high-voltage, low-voltage, and pneumatic pipeline installation spaces. Pneumatic vibration and power frequency electromagnetic interference easily cause photoelectric sensor mis-triggers, excessive visual imaging noise, and irregular equipment shutdowns. Moreover, model changes require significant workload; replacing different PCB products necessitates extensive disassembly and assembly of the frame sheet metal, with each changeover typically taking over 4 hours, resulting in insufficient flexible production line capacity.

[0020] The first technical solution of Embodiment 1 provides a device for automatic insertion of PCB boards in a deep cavity. The overall outer contour dimensions of the machine are designed to be 1710.5mm×1596.25mm×1101.4mm. The machine consists of a base assembly, a machine shell, a material rack, an operating terminal, a support platform, a three-axis gantry coordinate motion platform, a PCB board picking robot, a traveling machine vision mechanism, a second machine vision mechanism, a conveyor chain, a lifting mechanism, and a primary positioning assembly. All parts processing, surface treatment, and assembly processes are carried out in accordance with technical requirements and current national standards. The outer casing 4, operating terminal, and base assembly 3 are all designed according to conventional industrial equipment technical solutions. The outer casing adopts a gantry-style load-bearing mounting base with a profile frame, modularly assembled from 6063-T5 industrial standard aluminum profiles, without welding processes, relying entirely on die-cast aluminum angle brackets and T-bolts for locking and splicing. The four vertical load-bearing main columns at the four corners of the frame are fixed to the support platform, and the horizontal main beam at the top forms the reference surface for the suspension and installation of the X-axis servo module. The hollow inner cavity of the profile serves as a closed wiring channel, realizing physical separation and isolation of strong and weak current cables. A closed protective plate is added to the outside of the frame, with a small door reserved for maintenance, and a cantilever bracket is set at the top. An HMI human-machine screen operating terminal 41 is installed at the end of the cantilever bracket, through which the human-machine interface is set.

[0021] The base assembly is the lowest load-bearing base of the entire device. The interior adopts a vertical partition sheet metal three-compartment isolation structure, which is divided into three large sealed independent cavities: the left air source integration chamber, the middle low-voltage wiring chamber, and the right high-voltage electrical control chamber. This achieves complete partition isolation of pneumatic pipelines, high-voltage power cables, and low-voltage shielded signal lines from the physical space, eliminating the adverse effects of pneumatic vibration and power frequency electromagnetic interference on the sensor and vision system. The base consists of a welded main frame, internal partitions, a full-circumference sealing plate, front and rear inspection doors, sheet metal for air source installation, electrical control installation base plate, bottom support casters and feet, heat dissipation and ventilation components, and door lock hinge accessories. The main frame adopts a closed cage structure of Q235B hot-rolled steel, which is stress-relieved and aged after welding, and the surface is coated with RAL7035 industrial gray epoxy. The bottom is equipped with M16 adjustable heavy-duty feet and D60 universal casters with brakes, realizing the dual-mode switching of equipment relocation and production fixation. The front and rear inspection doors are equipped with hinges, magnets, flat locks, and handles, and can be fully opened to 90° to realize independent maintenance of each compartment.

[0022] The main technical solution implemented in Example 1 is as follows: A support platform 2 is fixedly mounted on the base assembly 3. A three-axis gantry coordinate motion platform 5 is mounted above the support platform 2. A PCB board picking robot 7 and a traveling machine vision mechanism 70 are integrated on the three-axis gantry coordinate motion platform 5. A second machine vision mechanism 9 is mounted in the middle of the support platform through a connecting through hole 29. A conveyor chain 20 is mounted at the front of the support platform. A lifting mechanism 6 is mounted in the middle of the conveyor chain. A primary positioning assembly 8 is mounted at the front end of the support platform. The conveyor chain can transport the deep cavity container product to be inserted with the PCB board to the lifting mechanism position, and can also transport the deep cavity container product with the inserted PCB board 100 to the next process. The three-axis gantry coordinate motion platform can drive... The PCB board picking robot performs the actions of gripping, inspecting, and inserting PCB boards, forming a robotic structure for automatically inserting PCB boards into the deep cavity. A traveling machine vision mechanism identifies and acquires reference positioning coordinates to provide precise insertion positioning parameters for the three-axis gantry coordinate motion platform. A lifting mechanism elevates the deep cavity container product containing the PCB board to be inserted to the insertion position height. A second machine vision mechanism uses bottom-view imaging to inspect the quality of the pins at the bottom of the PCB board. A primary positioning component receives and initially positions the PCB board to be inserted, enabling the three-axis gantry coordinate motion platform to drive the PCB board picking robot to grip the PCB board and perform subsequent actions.

[0023] The specific structures of the support platform 2, the conveyor chain, and the lifting mechanism 6 are as follows: The core structure of the support platform 2 is a support plate 21. A lifting channel is installed through the middle of the front section of the support plate, and the lifting mechanism 6 is installed through the lifting channel. Symmetrical double-speed chain sheet metal parts 22 are arranged on both sides of the front section of the support plate 21, supporting and mounting double-speed chains 23 to form a conveyor chain. A diffuse reflection photoelectric sensor 24 is installed on the support plate behind the double-speed chain. The diffuse reflection photoelectric sensor can detect whether there is information about the PCB board deep cavity container product to be inserted on the lifting mechanism. The diffuse reflection photoelectric sensor 24 is adjustablely supported and mounted in the middle of the support plate 21 via an adjusting bracket 27. A proximity sensor 25 and a buffer stop 26 are arranged inside the double-speed chain. The proximity sensor can detect the positioning information of the inserted PCB board deep cavity container product. The buffer stop, in conjunction with the proximity sensor, provides precise conveying limit for the inserted PCB board deep cavity container product.

[0024] The main structure of the lifting mechanism consists of a lifting base plate 61 and a lifting support plate 62. The lifting mechanism is fixedly connected to the support plate located around the lifting channel via the two sides of the lifting base plate. A lifting cylinder 63 is installed in the lower center of the lifting support plate. The lifting support plate is fixedly connected to the telescopic end of the lifting cylinder and is connected to the lifting support plate via a guide assembly. Thus, the lifting cylinder can drive the lifting support plate to move up and down vertically. In standby mode, the lifting cylinder drives the lifting support plate to descend to a position lower than the height of the double-speed chain sheet metal parts. When the conveyor chain receives the pallet containing the deep cavity container product to be inserted into the PCB board transferred from the previous process, the pallet containing the deep cavity container product to be inserted into the PCB board slides along the double-speed chain sheet metal parts to be transported above the position of the lifting mechanism, close to the top. The sensor triggers a positioning signal, pausing the double-speed chain conveyor. A buffer stop assists in stopping the pallet containing the deep-cavity container product with the PCB board to be inserted. The pallet then falls onto the lifting platform. The lifting cylinder drives the lifting platform vertically upwards, raising the pallet to the preset insertion position height. Multiple support blocks 64 are installed above the lifting platform. These blocks provide elastic cushioning, buffering the impact of the pallet falling onto the platform, absorbing the impact of the lifting, suppressing pallet bouncing and swaying, and providing friction to prevent slight displacement due to equipment vibration, thus avoiding pallet deviation relative to the lifting platform and ensuring stable performance.

[0025] A reference positioning pin 65 is set at one corner of the lifting plate, and a diamond-shaped positioning pin 66 is set at the other corner. The reference positioning pin provides reference positioning. The accompanying machine vision mechanism takes pictures of the reference positioning pin and the diamond-shaped positioning pin fixed at one corner of the lifting plate. The reference center coordinates are extracted by the image algorithm, and the vertical height information of the Z-axis is calculated simultaneously. The three-axis plane offset (X, Y) and the Z-axis insertion pressing depth are output at one time. The PLC is directly sent to dynamically correct the three-axis motion trajectory and the insertion downward end point to achieve high-precision alignment and assembly of the PCB board.

[0026] The lifting and positioning assembly is vertically installed directly below the conveyor line supporting the large plate. It is the core actuator for the whole machine to achieve pallet lifting, chain detachment, and coarse positioning. It adopts a parallel lifting structure with a central SMC CDQ2 series thin cylinder drive, four-point parallel guide columns, double-layer pallet support, and end-face flexible buffer. The cylinder is vertically and centrally arranged, and the piston rod is connected to the center of the lifting pallet above via a floating joint. Four SUJ2 bearing steel guide shafts are symmetrically arranged at the four corners to constrain the lifting pallet to move in the vertical direction. The top surface of the lifting pallet is inlaid with a high-hardness polyurethane buffer pad, and the bottom surface is equipped with a hydraulic buffer. The lifting repeatability parallelism is ≤0.03mm, which can completely detach the pallet from the double-speed chain rollers and eliminate positioning deviations caused by chain pitch error and roller wear clearance.

[0027] The specific structure of the three-axis gantry coordinate motion platform and the PCB board picking robot is as follows: The three-axis gantry coordinate motion platform (hereinafter referred to as the three-axis) 5 is composed of an X-axis module 51, a Y-axis module 52, and a Z-axis servo module 53. A Z-axis robot arm mounting plate 54 is set on the front side of the Z-axis servo module. The PCB board picking robot arm 7 and the accompanying machine vision mechanism 70 are vertically and flexibly mounted on the Z-axis servo module through the Z-axis robot arm mounting plate. The specific structural basis of the PCB board picking robot arm 7 is an arm base 71, on which a vertical arm extension cylinder 72 is connected. A finger cylinder 73 is connected below the extension end of the arm extension cylinder. A pair of contour gripper heads 75 are connected inside a pair of grippers 74 of the finger cylinder. An avoidance step is set at the lower end of the inner side of the gripper head, and an anti-slip buffer strip is embedded in the avoidance step. The three-axis gantry coordinate motion platform 5 realizes coordinate movement in the XY direction in the horizontal plane through the X-axis module 51 and the Y-axis module 52, and realizes coordinate movement in the Z-axis servo module 53. 53. Achieve precise vertical lifting and lowering; the PCB board picking robot uses the piston rod of the arm-extending cylinder to drive the finger cylinder and the contour gripper head to descend, which can adapt to the operation stroke requirements of inserting PCB boards in the narrow space of the deep cavity; a pressure sensor 77 is set between the arm-extending cylinder and the finger cylinder, which can sense and detect the pressure of inserting the PCB board in real time; during the pressing and inserting of the PCB board, the axial insertion pressure is collected in real time, and the pressure analog signal is transmitted to the control center PLC in real time. The PLC compares it with the preset insertion pressure threshold to realize pressure closed-loop monitoring. The pressure signal serves as a supplementary condition for safety judgment of the insertion operation. When the three-axis clamping PCB board is pressed down into the installation position of the cavity container, if the pin hole is misaligned, the module boss interferes, or the component presses against the module housing, an abnormal axial pushing force will be generated. The pressure sensor monitors the insertion pressure in real time. If the pressure suddenly increases and exceeds the threshold, it is determined that the alignment is wrong and hard interference has occurred. The PLC immediately controls the Z-axis to lift and stops pressing down to prevent the pin from bending and deforming, the PCB board from cracking, and the components from being crushed. If the pressure is within the standard range, it is determined that the insertion is smooth and the alignment is normal. The pressing continues until the preset insertion depth is reached to complete the assembly. The pressure curve throughout the process is synchronously stored in the HMI for production line quality traceability.

[0028] The overall gantry crane is installed under the top crossbeam of the profile frame, adopting a right-angled three-axis orthogonal layout with X-axis horizontal strut, Y-axis longitudinal sliding mounting, and Z-axis vertical lifting suspension. It relies on three sets of independent servo ball screw linear modules to achieve planar X / Y full-domain coordinate positioning and Z-axis vertical lifting material picking. The lower flange of the Z-axis is completely suspended to suspend the guide rod cylinder. The extension end of the guide rod cylinder is suspended by an MHZ series pneumatic parallel gripper cylinder or an HFK series long-stroke finger cylinder through a pressure sensor, without any side wall auxiliary support structure. The entire axis is equipped with a closed bridge-type plastic drag chain to achieve compartmentalized storage and protection of power cables, encoder cables, and pneumatic hoses. The three-axis repeatability accuracy is ≤±0.02mm.

[0029] The specific structure of the accompanying machine vision mechanism 70 is as follows: A PCB board picking robot is fixedly connected to one side of the Z-axis robot mounting plate. The accompanying machine vision mechanism 70 specifically comprises a first camera housing 701, a first industrial camera 702, a first industrial lens 703, and a first light source assembly 704. The first industrial camera, the first industrial lens assembly, and the first light source assembly are fixedly connected to the other side of the Z-axis robot mounting plate via an accompanying vision mounting base 705 in a top-to-bottom order. The first camera housing covers the outside of the first industrial camera, the first industrial lens, and the first light source assembly. A first light source adjustment plate 706 and a first camera adjustment base 707 are provided on the inner side of the accompanying vision mounting base. The first industrial lens is fixedly connected to the middle of the inner side of the accompanying vision mounting base, or fixedly connected to the lower end of the first industrial camera. The back of the first industrial camera is fixedly connected to the first camera adjustment base 707, which is adjustable via an elongated slot and guide bolts. The first industrial camera is adjustablely connected to the upper section of the inner side of the accompanying vision mounting base, allowing it to be raised and lowered via a first camera adjustment seat. The height of the first industrial camera can be adjusted linearly up and down to regulate its imaging distance. The first light source adjustment plate 706 is adjustablely connected to the lower section of the inner side of the accompanying vision mounting base via an elongated slot and guide bolts. The first light source assembly is fixedly connected below the annular light source ring plate at the lower end of the first light source adjustment plate 706. The first light source assembly uses an annular diffuse reflection light source, allowing it to be raised and lowered via the first light source adjustment plate. The height of the first light source assembly can be adjusted linearly up and down to regulate its illumination intensity and incident angle, thereby controlling illumination, changing the incident angle, obtaining ideal contours, and adapting to workpiece height fluctuations. By adjusting the installation height of the first industrial camera and the first light source assembly, the working distance of the camera and the illumination distance of the light source are adjusted. On the one hand, the imaging clarity of the reference positioning pin on the lifting mechanism meets the sub-pixel positioning requirements, and the center coordinates of the reference positioning pin are obtained. On the other hand, the incident angle of the light is adjusted to suppress the interference of highlights on the surface of the positioning pin and shadows on the bottom, thereby improving the reliability of edge extraction of the positioning pin. At the same time, it can be compatible with pallet workpieces of different heights and specifications, reducing the impact of height deviation caused by pallet processing and clamping on visual positioning accuracy, and ensuring the precision insertion operation of the subsequent power PCB board.

[0030] On the side adjacent to the arm base and the accompanying machine vision mechanism, a barcode scanner 76 is also fixedly installed by a bracket. The barcode scanner can scan barcodes to collect product serial numbers, enabling traceability. The system binds the pallet ID, PCB board serial number, assembly time, equipment number, and insertion station information one by one to form a complete production traceability chain. In case of poor insertion or PCB board damage, the pallet batch and product batch can be traced back.

[0031] The specific structure of the second machine vision mechanism 9 is as follows: The second machine vision mechanism 9 is specifically composed of a second vision support assembly 91, a second camera housing 92, a second industrial camera 93, a second industrial lens assembly 94, and a second light source assembly 95. The second industrial camera, the second industrial lens assembly, and the second light source assembly are fixedly installed in the middle of the support platform in a bottom-up order via the second vision support assembly. The second camera housing covers the second industrial camera, the second industrial lens, and the second light source assembly. A tempered glass protective cover 98 is fixedly installed on the top of the second vision support assembly 91 via a fixed frame 99, which can isolate production line dust, lubricant splashes, and oil stains, protecting the internal industrial camera, lens, and light source assembly; preventing dust from directly falling on the lens lens and causing image dirt and black spots, preventing lens damage from bumps, ensuring safety protection performance, and facilitating cleaning of the external surface, reducing the workload of vision system maintenance; and AR anti-reflective tempered glass is used to reduce reflection.

[0032] Furthermore, a second light source adjustment plate 96 and a second camera adjustment plate 97 are provided on the inner side of the second vision support assembly; the second industrial lens is fixedly connected to the upper end of the second industrial camera, and the back of the second industrial camera is fixedly connected to the second camera adjustment plate 97. The second camera adjustment plate 97 is adjustablely connected to the lower section of the inner side of the second vision support assembly through an elongated slot and guide bolts, thereby enabling the second industrial camera to be adjustablely connected to the inner side of the second vision support assembly via the second camera adjustment plate, allowing for vertical linear movement to adjust the height of the second industrial camera and thus adjust the imaging distance of the second industrial camera; The second light source adjustment plate 96 is adjustablely connected to the upper inner side of the second vision support component via an elongated slot and guide bolts. The second light source component is fixedly connected above the annular light source ring plate at the top of the second light source adjustment plate 96. The second light source component adopts an annular diffuse reflection light source, thereby enabling the second light source component to be adjustablely connected to the inner side of the second vision support component via the second light source adjustment plate. The height of the second light source component can be adjusted by moving it linearly up and down to adjust the light intensity and incident angle of the second light source component, thereby controlling the light intensity, changing the incident angle, obtaining the ideal contour, and adapting to workpiece height fluctuations. The second vision support assembly specifically consists of a second vision support plate 961 and an L-shaped second vision mounting base 962. The lower horizontal section of the second vision mounting base is fixedly connected to the middle of the support plate 21 via connecting bolts and connecting through holes 29. Multiple long slots are parallel to each other on the vertical section of the second vision mounting base. The second vision support plate is slidably connected to the second vision mounting base via guide bolts and the long slots, allowing it to slide vertically up and down to adjust its vertical installation height. This, in turn, adjusts the overall vertical installation height of the two machine vision mechanisms to adapt to changes in production factors such as product changes, parameter adjustments, and process route improvements. By adjusting the installation height of the second industrial camera and the second light source assembly, the working distance of the camera and the illumination distance of the light source are adjusted. This ensures that the detection imaging clarity meets system requirements and adjusts the incident light angle, suppressing interference from highlights on the positioning pin surface and shadows at the bottom, improving the reliability of edge extraction in the detection imaging, and reducing the impact of height deviations caused by tooling equipment on visual inspection accuracy. The second machine vision mechanism 9 adopts a bottom-view imaging scheme. The industrial camera and ring light source are arranged directly below the product, with the lens pointing vertically upwards towards the bottom surface of the PCB board. A 2-megapixel global shutter industrial camera is used in conjunction with a 620nm wavelength ring red light source to provide ring diffuse reflection lighting from the bottom surface of the product upwards, completing the imaging and detection of the pins at the bottom of the PCB board. The vision system simultaneously determines the OK / NG quality result of the product and calculates the X / Y / Z axis position offset compensation value of the PCB board. The data is uploaded to the PLC in real time via Ethernet.

[0033] The specific structure of the primary positioning component 8 is as follows: The primary positioning component 8 consists of a primary support base 81 and a primary limiting base 82. The primary limiting base is fixedly supported and installed at the front center of the support plate 21 of the support platform via the primary support base. One or more downwardly recessed positioning grooves are provided on one surface of the primary limiting base. Each positioning groove is provided with a main positioning groove 83 and a pin clearance groove 84. Several pin positioning holes 85 are provided on the bottom surface of the pin clearance groove. The main positioning groove can provide positioning for the lower end of the PCB board to be inserted, and the pin clearance groove and pin positioning holes can provide clearance space and pin positioning for the pins at the lower end of the PCB board to be inserted. The primary positioning component, which has a single recessed positioning slot, can only hold one PCB board to be inserted at a time, which is insufficient to meet the continuous performance requirements of continuous insertion operations in a continuous production line. Therefore, in Embodiment 1, six recessed positioning slots are provided on one surface of the primary limiting seat, which can hold six PCB boards to be inserted at a time. Furthermore, materials can be replenished in real time during the production process. When the three-axis gantry coordinate motion platform drives the PCB board picking robot to perform the gripping of the PCB board to be inserted in the current positioning slot, PCB boards to be inserted are continuously fed to the positioning slots that are already empty, thus meeting the continuous performance requirements of continuous insertion operations in a continuous production line.

[0034] The positioning technology can be further optimized. A main positioning slot provides clearance fit positioning for the lower end of the PCB board to be inserted, while pin clearance slots and pin positioning holes also provide clearance fit positioning for the pins at the lower end of the PCB board. Furthermore, a secondary positioning post 87 is set on the upper surface of the primary limit seat, located outside each positioning slot. This secondary positioning post can cooperate with the cantilever connector on the PCB board to provide secondary precise positioning. While the main positioning slot and pin positioning hole are clearance fits, ensuring smooth placement of the PCB board, the clearance can cause slight wobbling and displacement. Primary positioning only provides approximate positioning, and the accuracy is insufficient for precise gripping by the robotic arm. The secondary positioning post, in cooperation with the cantilever connector on the PCB board, eliminates the displacement caused by the clearance, achieving secondary precise positioning and constraining the PCB board to a uniform and accurate position. The main positioning groove, pin positioning hole, and secondary positioning post provide dual limiting, respectively constraining the lower end of the board and the upper cantilever connector. The lower end of the PCB to be inserted is constrained by the main positioning groove and pin positioning hole to the bottom edge of the PCB to be inserted and the pin; the upper part is constrained by the secondary positioning post to the cantilever connector above the PCB to be inserted. The simultaneous constraint at both the top and bottom limits the PCB to be inserted from deflection, tilting, and small-angle swinging around the pin, avoiding PCB tilting and ensuring that the PCB to be inserted is placed in a uniform posture.

[0035] The entire machine is equipped with a PLC and vision-based hierarchical closed-loop electrical control system. The control center uses a PLC to achieve fully automated interlocking control. The electrical control system of the entire machine adopts a hierarchical closed-loop electrical control system with PLC control as the core, which is divided into five subsystems: HMI human-machine interaction unit, machine vision processing unit, full-point IO signal acquisition unit, pneumatic solenoid valve drive unit, and three-axis servo drive unit. Each subsystem realizes data interaction through an industrial bus. The HMI has built-in storage areas for multiple product process formulas. The three-axis reference coordinates, light source brightness, cylinder working air pressure, and process cycle parameters corresponding to different PCB boards are all independently saved. When changing models, the formula data can be retrieved with one click. The system adopts a segmented interlocking timing programming approach. The next process is allowed only when all the feedback signals of a single process are complete. If the signal is missing, the equipment will immediately stop and pop up an alarm, realizing full-process interlocking closed-loop control.

[0036] The machine features a three-compartment base for load-bearing, with physical isolation between the air source compartment, high-voltage compartment, and low-voltage compartment. The low-voltage compartment separately houses the shielded network cables for the upper and lower cameras. The dual-vision wiring and power lines are completely separated to avoid imaging interference. Bottom casters and adjustable feet, along with a separate access door, facilitate air source and electrical maintenance. The machine's air source input is standard 0.5~0.6MPa compressed air from the workshop. After stabilization by the air source triple unit, the main pipe is 0.5MPa, and the four branch air pressures are set as follows: lifting cylinder 0.4MPa, secondary positioning 0.32MPa, and gripper cylinder 0.38MPa. The secondary positioning POM tooling is machined according to the product's 185×72mm profile, with a 1.5mm pre-compression of the urethane rubber. The downward-facing camera uses a 2MP global shutter, with 65% brightness of the formula's light source. The system determines the offset threshold to be ±0.8mm; exceeding the threshold results in direct rejection and scrapping. The electronic control formula has a preset standard cycle time of 11.9 seconds per piece, with a theoretical hourly capacity of 302 pieces. In a 72-hour uninterrupted mass production test, a total of 21,726 pieces of products were produced. The visual inspection detected 179 pieces of defects in the appearance of incoming materials, and only 12 pieces of defects caused by misalignment or collision during equipment assembly. The overall yield rate was 99.945%, the equipment utilization rate was 98.8%, and it replaced 4 assembly and 1 quality inspection personnel on-site, saving 32,000 yuan in labor costs per month. It has maintained stable mass production for 6 consecutive months without structural modifications.

[0037] The entire machine uses a unified reference support plate, made of S45C heat-treated chrome-plated steel. The plate features a double-speed chain, secondary positioning station, and three-axis mounting reference. A pre-drilled lifting clearance hole is located below, and a scrap material receiving platform is positioned on the side. All upper mechanisms are traceable to the same reference plate, ensuring consistent coaxiality between the upper and lower camera optical axes. A rear gantry aluminum profile support frame carries the X / Y / Z three-axis modules. Independent cable trays within the profile separate the three-axis power lines and the shielded communication line for the upper camera. An external electrical box on the side houses the vision controller, and the HMI cantilever synchronously stores exposure and brightness formula parameters for both cameras. An X / Y / Z orthogonal servo gantry, with a PCB board-mounted robotic arm and accompanying machine vision mechanism suspended at the lower Z-axis, ensures three-axis repeatability ≤ ±0.02mm. A cable chain with compartments neatly stores the gripper tubing and upper camera signal lines, preventing cable entanglement and interference. The accompanying machine vision mechanism consists of a mini global shutter industrial upper camera, a C-mount short-focal-length fixed-focus lens, a coaxial ring light, and an L-shaped waist-hole fine-tuning bracket. Installation: The L-shaped bent bracket is fixed to the upper part of the backplate. The bracket has a vertically elongated waist-shaped groove, allowing for vertical adjustment of the upper camera's height to accommodate imaging distances on the top surface of PCB boards of varying thicknesses. Optical path logic: The lens is vertically downward, aligned vertically and coaxially with the downward-facing camera. The upper camera captures the position information of the reference positioning pin the moment the grippers clamp the product. Independent power supply: The upper camera's ring light source uses a separate DC24V supply. Isolated power supply, not sharing a circuit with the gripper solenoid valve, eliminating start-stop flicker; Wiring: The shielded mesh cable of the upper camera converges along the bracket cable channel into the three-axis drag chain, connecting to the vision processor in the low-voltage compartment; Vertical X / Y dual-axis micro-adjustment slide: Eccentric screws ±3mm lateral and longitudinal micro-calibration of the gripper center, synchronously correcting the upper camera's shooting center deviation; 360° rotating adapter flange: 45# tempered chrome plated, loosening the bolts allows rotation of the gripper and the overall circumferential angle of the upper camera, adapting to irregularly shaped PCBs; MHZ parallel pneumatic gripper and contouring gripper head: 0.3MPa low-pressure air supply, with A90 urethane embedded in the gripper head to prevent scratching the PCB; Pneumatic pipeline limit buckle: Segmented fixing of the gripper's PU hose, lifting without pulling, upper camera cable and air pipe separately stored without interference. Upper camera sequence actions: After primary secondary positioning is completed, the upper camera synchronously exposes and acquires the top surface image, the three-axis descending gripper clamps the PCB board into place, and the bottom lower camera data is synchronously uploaded to the vision processor, achieving synchronous quality inspection of both front and back sides. The second machine vision mechanism uses a 2-megapixel global camera and a 620nm ring red light lens vertically upwards to capture information on the pins and substrate cracks on the bottom of the PCB. Together with the upper camera, it forms a dual-vision, dual-sided inspection system, with the data from the two cameras processed in parallel.

[0038] The whole machine's dual-vision layered electronic control system is mainly controlled by a PLC, integrating an HMI, dual-vision processor, servo drive, and pneumatic drive. The vision unit is divided into two independent operation channels: an upper camera vision channel and a lower camera vision channel. The HMI independently stores the exposure of the upper camera, the brightness of the light source, the top surface defect threshold, and the complete set of bottom surface inspection formulas for each product, which can be retrieved with one click when changing models. Timing interlock: the upper and lower cameras take pictures synchronously, and the defect data of both sides are packaged and uploaded to the PLC. Fault logic: if the upper camera has no image or the light source fails, the equipment will stop with a pop-up window. The upper and lower cameras are distinguished by independent alarms, which facilitates rapid maintenance.

[0039] The equipment for automatic PCB board insertion in deep cavities of this invention has the following technical features: 1. Significantly improved positioning accuracy: The two-stage composite positioning structure eliminates multiple superimposed errors from a mechanical perspective, improving positioning accuracy from the traditional ±0.2mm to ±0.03mm. Assembly misalignment and PCB extrusion damage defects are reduced by more than 95%, significantly reducing PACK module rework and scrap costs. 2. Pre-defect interception: Bottom-view visual inspection completes full-dimensional defect screening before assembly, allowing for early sorting of products with missing materials or board cracks, reducing raw material scrap by 90%, and eliminating invalid assembly actions that occupy production time, thus improving overall production line efficiency by 30%. 3. Strong flexible changeover capability: The entire machine is modularly assembled with nine major components. Changeover only requires changing plastic tooling and retrieving the formula, reducing changeover time from 4-6 hours to 30 minutes. A single machine can be compatible with multiple products on the same line, reducing the OEM's investment in purchasing new models. 4. Significantly Improved Equipment Uptime: The compartmentalized layout of the base and the separate wiring for pneumatic and electrical systems eliminate vibration and electromagnetic interference, increasing equipment uptime from 85% to 98.5% and reducing unplanned downtime by 65%. 5. Significant Cost Reduction and Efficiency Improvement: Full automation replaces five frontline workers, saving approximately 700,000 RMB in labor costs per unit per year. The HMI's full data storage enables automatic classification of good and defective products, facilitating upstream material quality traceability and optimization. 6. High Convenience of Maintenance: The modular structure facilitates offline maintenance of individual components; partial failures do not require complete machine shutdown, significantly reducing the overall lifecycle maintenance costs of the equipment.

[0040] The second technical solution provides a device control method for automatically inserting PCB boards into a deep cavity. According to the first technical solution described above, the device for automatically inserting PCB boards into a deep cavity also includes a material rack 1. The material rack buffers the PCB boards to be inserted via a buffer box 11. The specific implementation process follows these steps: S01, Equipment assembly installation and commissioning; material preparation; start-up and reset; preset the insertion position, insertion depth parameters and insertion pressure threshold according to the product information of the deep cavity container of the PCB board to be inserted; S02, the conveyor chain receives the pallet containing the deep cavity container product with PCB board to be inserted from the previous process and transports it to the lifting mechanism position. The proximity sensor triggers the positioning signal and the double speed chain conveyor stops. S03, the diffuse reflection photoelectric sensor detects the product information of the deep cavity container with PCB board to be inserted on the lifting mechanism. The lifting cylinder of the lifting mechanism lifts the tray off the chain, completes the first-level coarse positioning, and enters the stable imaging static state. S05, the three-axis gantry coordinate motion platform drives the PCB board picking robot and the accompanying machine vision mechanism to move to the lifting mechanism station; the accompanying machine vision mechanism captures and obtains the reference positioning information; S06, the primary positioning component receives the inserted PCB board and completes the primary positioning; In the specific implementation process, the operator can take out multiple PCB boards to be inserted from the material rack buffer box 11 and insert them into multiple positioning slots of the primary positioning component in sequence, and perform secondary primary positioning through the pin positioning holes and secondary positioning posts. S07, the three-axis gantry coordinate motion platform drives the PCB board picking robot and the accompanying machine vision mechanism to move to the primary positioning component station; the barcode scanner scans to obtain the product information of a PCB board to be inserted at the current position on the primary positioning component, and traces and binds it; S08, the accompanying machine vision mechanism captures and obtains primary positioning information; the first industrial camera captures and captures secondary positioning posts to obtain primary positioning information; S09, the vision system calculates and outputs X / Y / Z three-axis offset compensation data based on the insertion position, insertion depth parameter information, primary positioning information and reference positioning information, and uploads it to the control center, i.e., PLC; S10, the PCB board picking robot grips a PCB board to be inserted at the current position on the primary positioning component; S11, the control center corrects the three-axis reference coordinates by superimposing offset data based on the received data, and controls the three-axis gantry coordinate motion platform to drive the PCB board picking robot to move to the bottom vision imaging detection station. S12, the second machine vision mechanism captures the pin information at the bottom of the PCB board to be inserted, and the vision system calculates and outputs an OK / NG quality signal; if it is an OK quality signal, then continue to execute step S13; if it is an NG quality signal, then discard it. In the specific operation process, a scrap platform or scrap bin can be set up in the idle space at the rear of the support plate to receive defective products; S13, the three-axis gantry coordinate motion platform drives the PCB board picking robot and the accompanying machine vision mechanism to move to the lifting mechanism station; S14, the barcode scanner scans to obtain product information of the deep cavity container PCB board to be inserted, and traces and binds it; S15, the three-axis gantry coordinate motion platform drives the PCB board picking robot to descend linearly along the Z-axis to perform the PCB board insertion action; S16, the pressure sensor senses and detects the real-time insertion pressure to determine whether the insertion is normal and whether the insertion is in place; The camera takes a picture of the reference positioning pin of the lifting plate. The standard Z-axis insertion downward stroke corresponding to this batch of pallets is calculated by converting the image size. The PLC stores the depth value as the theoretical positioning reference. The three-axis Z servo prioritizes to perform the pressing action according to the preset depth as the standard judgment basis for the insertion in place. The pressure sensor only collects the axial pushing pressure during the PCB pressing process. If the Z-axis reaches the visual preset depth range and the insertion pressure is always within the standard allowable range throughout the process, the insertion is judged to be qualified, the claw is released, and a signal indicating that the insertion is in place is fed back. If the preset depth is not reached, but the pressure instantly exceeds the upper limit threshold of the insertion pressure, it is determined that the module hole is misaligned or the components are in hard interference. The PLC immediately raises the Z-axis to terminate the insertion and the shunt is faulty. If the preset depth is reached, but the insertion pressure remains below the lower limit, it is determined that the PCB is not fully embedded in the module, and there are defects such as incomplete insertion or floating board. It is also judged as NG. S17, Insertion complete, the three-axis gantry coordinate motion platform returns to the mechanical origin; S18, Repeat steps S06 to S17 until the mass production order is completed; Among them, multiple product process formulas are built into the human-computer interaction interface. When changing models, the formula data can be retrieved with one click, and the three-axis coordinates, light source brightness, cylinder working air pressure, and process cycle parameters can be automatically refreshed. The process is equipped with fault classification and handling logic. If a single process loses a signal for a short time, the equipment will be suspended. After the fault is cleared and the equipment is manually reset, production will continue. If the same fault triggers the automatic equipment lock-up program three times in a row, the entire machine will be shut down in an emergency if the air source pressure is lower than the lower limit.

[0041] The present invention relates to an equipment and control method for automatically inserting PCB boards into deep cavities. The equipment comprises a three-axis gantry coordinate motion platform, a PCB board picking robot, a follow-up machine vision mechanism, a second machine vision mechanism, a conveyor chain, a lifting mechanism, and a primary positioning component, all supported by a support platform. The conveyor chain transports the deep cavity container product to be inserted with the PCB board to the lifting mechanism position and also transports the deep cavity container product with the inserted PCB board to the next process. The three-axis gantry coordinate motion platform drives the PCB board picking robot to perform gripping, inspection, and PCB board insertion actions. The follow-up machine vision mechanism identifies and acquires the reference positioning space. The three-axis gantry coordinate motion platform provides precise insertion positioning. The lifting mechanism raises the deep cavity container product to be inserted with the PCB board to the insertion position height. The second machine vision mechanism uses bottom-view imaging to detect the pins at the bottom of the PCB board. The primary positioning component is used to receive and initially position the PCB board to be inserted. The dual machine vision system automatically positions and detects the PCB board pins. The three-axis module drives the robot to automatically complete the PCB board detection and insertion process in the deep cavity. It is suitable for the use of inserting PCB boards in the confined space of deep cavity container. It is easy to operate, stable and reliable, and can be used in conjunction with continuous production lines.

[0042] Example 2: Based on the technical solution of Embodiment 1 above, another technical solution is implemented for the primary positioning component. A long slot 86 is provided on the bottom surface of the pin clearance groove. The pin clearance groove and the long slot can provide clearance space and lateral positioning for the pins at the bottom of the PCB board to be inserted through clearance fit. During the manufacturing process, there is a cumulative positional tolerance when processing multiple pin positioning holes, resulting in high processing costs. Metal shavings and dust are easy to accumulate in the holes, and the shavings are not easy to remove, which can easily cause pin jamming and PCB board misalignment. The long slot is simple to process, eliminates the cumulative positional tolerance of multiple holes, and can accommodate the positional deviation of the pins along the length of the slot.

[0043] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Under the concept of the present invention, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of the present invention as described above. For the sake of brevity, they are not provided in detail. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A primary positioning component for an automated PCB board insertion device in a deep cavity, characterized in that: It includes a primary support seat and a primary limiting seat. The primary limiting seat is fixedly supported and installed at the front middle of the support platform of the automatic PCB board insertion equipment in the deep cavity through the primary support seat. One surface of the primary limiting seat is provided with one or more downwardly recessed positioning grooves. Each positioning groove is provided with a main positioning groove and a pin avoidance groove. The bottom surface of the pin avoidance groove is provided with a plurality of pin positioning holes. The main positioning groove is used to provide positioning for the lower end of the PCB board to be inserted, and the pin clearance groove and the pin positioning hole are used to provide positioning for the pins at the lower end of the PCB board to be inserted. Alternatively, the bottom surface of the pin clearance groove is provided with an elongated slot, and the pin clearance groove and the elongated slot are used to provide positioning for the pins at the bottom of the PCB board to be inserted through clearance fit; The primary positioning component is used to receive and initially position the PCB board to be inserted.

2. The primary positioning component for an automated PCB board insertion device in a deep cavity according to claim 1, characterized in that: The main positioning groove is used to provide primary positioning for the lower end of the PCB board to be inserted through clearance fit; the pin clearance groove and the pin positioning hole are used to provide positioning for the pins at the lower end of the PCB board to be inserted through clearance fit; or, the bottom surface of the pin clearance groove is provided with an elongated slot, and the pin clearance groove and the elongated slot are used to provide positioning for the pins at the lower end of the PCB board to be inserted through clearance fit. The upper surface of the primary positioning seat is also provided with a secondary positioning post located outside each positioning slot. The secondary positioning post is used to cooperate with the cantilever connector on the PCB board to be inserted to provide secondary positioning.

3. A robot for automated PCB board insertion equipment in deep cavities, characterized in that: The device includes a three-axis gantry coordinate motion platform and a PCB board picking robot integrated on the three-axis gantry coordinate motion platform. The three-axis gantry coordinate motion platform includes an X-axis module, a Y-axis module and a Z-axis servo module. A Z-axis robot mounting plate is provided on the front side of the Z-axis servo module. The PCB board picking robot and the accompanying machine vision mechanism are mounted on the Z-axis servo module through the Z-axis robot mounting plate. The PCB board picking robot includes an arm base, an arm extension cylinder connected to the arm base, a finger cylinder connected below the extension end of the arm extension cylinder, a pair of grippers of the finger cylinder having a pair of contour gripper heads connected inside, and a clearance step provided at the lower end of the inner side of the gripper heads, with an anti-slip buffer strip embedded in the clearance step; a pressure sensor is provided between the arm extension cylinder and the finger cylinder, the pressure sensor being used to sense and detect the pressure of inserting the PCB board; The three-axis gantry coordinate motion platform is used to drive the PCB board picking robot to pick up the PCB board to be inserted from the primary positioning group as described in claim 1.

4. A device for automatically inserting PCB boards into a deep cavity, characterized in that: The device includes a support platform, on which a three-axis gantry coordinate motion platform as described in claim 3 and a PCB board picking robot are disposed. The three-axis gantry coordinate motion platform is also integrated with a traveling machine vision mechanism. A second machine vision mechanism is disposed in the middle of the support platform. A conveyor chain is disposed at the front end of the support platform. A lifting mechanism is disposed in the middle of the conveyor chain. A primary positioning component as described in claim 1 is disposed at the front end of the support platform. The conveyor chain is used to transport the deep cavity container product with PCB board to be inserted to the lifting mechanism position, and to transport the deep cavity container product with PCB board to be inserted to the next process. The three-axis gantry coordinate motion platform is used to drive the PCB board picking robot to perform PCB board gripping, inspection and insertion actions; The accompanying machine vision mechanism is used to identify and acquire the reference positioning spatial coordinates to provide precise insertion positioning for the three-axis gantry coordinate motion platform. The lifting mechanism is used to lift the deep cavity container product with the PCB board to be inserted to the insertion position height; The second machine vision mechanism is used for bottom-view imaging to detect pins at the bottom of the PCB board; The primary positioning component is used to receive and initially position the PCB board to be inserted.

5. The device for automatic PCB board insertion in a deep cavity according to claim 4, characterized in that: The support platform includes a support plate, and a lifting channel is provided through the middle of the front section of the support plate. The lifting mechanism is located in the lifting channel. The lifting mechanism includes a lifting base plate and a lifting support plate. The lifting mechanism is fixedly supported and connected to the support plate on both sides of the lifting base plate. A lifting cylinder is provided in the lower middle part of the lifting support plate. The lifting support plate is fixedly connected to the telescopic end of the lifting cylinder and is connected to the lifting support plate through a guide assembly. Multiple supporting rubber blocks are provided above the lifting plate; a reference positioning pin is provided at one corner of the lifting plate.

6. The device for automatic PCB board insertion in a deep cavity according to claim 5, characterized in that: The front section of the support plate is symmetrically provided with double-speed chain sheet metal parts on both sides, and the double-speed chain is supported and installed by the double-speed chain sheet metal parts to form the conveyor chain. A diffuse reflection photoelectric sensor is installed on the support plate at the rear of the double-speed chain. The diffuse reflection photoelectric sensor is used to sense and detect whether there is product information of the deep cavity container of PCB board to be inserted on the lifting mechanism. The inner side of the double-speed chain is equipped with a proximity sensor and a buffer stop. The proximity sensor is used to sense and detect the arrival information of the deep cavity container product with inserted PCB board, and the buffer stop is used in conjunction with the proximity sensor to provide the conveying limit of the deep cavity container product with inserted PCB board.

7. The device for automatic PCB board insertion in a deep cavity according to claim 4, characterized in that: The PCB board picking robot is fixedly connected to one side of the Z-axis robot mounting plate; The accompanying machine vision mechanism includes a first camera housing, a first industrial camera, a first industrial lens, and a first light source assembly. The first industrial camera, the first industrial lens assembly, and the first light source assembly are fixedly connected to the other side of the Z-axis robot mounting plate via an accompanying vision mounting base in a top-to-bottom order. The first camera housing covers the outside of the first industrial camera, the first industrial lens, and the first light source assembly. A barcode scanner is also fixedly installed on one side of the arm base. The barcode scanner is used to scan barcodes to collect material information.

8. The device for automatic PCB board insertion in a deep cavity according to claim 4, characterized in that: The second machine vision mechanism includes a second vision support assembly, a second camera housing, a second industrial camera, a second industrial lens assembly, and a second light source assembly. The second industrial camera, the second industrial lens assembly, and the second light source assembly are fixedly installed in the middle of the support platform in an upward order via the second vision support assembly. The second camera housing covers the outside of the second industrial camera, the second industrial lens, and the second light source assembly.

9. The device for automatic PCB board insertion in a deep cavity according to claim 4, characterized in that: The inner side of the second vision support component is provided with a second light source adjustment plate and a second camera adjustment plate. The second industrial lens is fixedly connected to the upper end of the second industrial camera. The second industrial camera is connected to the inner side of the second vision support component in a height-adjustable manner through the second camera adjustment plate. The second light source component is connected to the inner side of the second vision support component in a height-adjustable manner through the second light source adjustment plate.

10. A device control method for automatically inserting PCB boards into a deep cavity, the device for automatically inserting PCB boards into a deep cavity according to any one of claims 4 to 9, further comprising a material rack for buffering PCB boards to be inserted, characterized in that: The following steps are included: S01, Equipment assembly installation and commissioning; material preparation; start-up and reset; preset the insertion position, insertion depth parameters and insertion pressure threshold according to the product information of the deep cavity container of the PCB board to be inserted; S02, the conveyor chain receives the pallet containing the deep cavity container product with PCB board to be inserted from the previous process and transports it to the lifting mechanism position. The proximity sensor triggers the positioning signal and the double speed chain conveyor stops. S03, the diffuse reflection photoelectric sensor detects the product information of the deep cavity container with PCB board to be inserted on the lifting mechanism. The lifting cylinder of the lifting mechanism lifts the tray off the chain, completes the first-level coarse positioning, and enters the stable imaging static state. S05, the three-axis gantry coordinate motion platform drives the PCB board picking robot and the accompanying machine vision mechanism to move to the lifting mechanism station; the accompanying machine vision mechanism captures and obtains the reference positioning information; S06, the primary positioning component receives the inserted PCB board and completes the primary positioning; S07, the three-axis gantry coordinate motion platform drives the PCB board picking robot and the accompanying machine vision mechanism to move to the primary positioning component station; the barcode scanner scans to obtain the product information of the PCB board to be inserted, and traces and binds it; S08, the accompanying machine vision mechanism captures and obtains primary positioning information; S09, the vision system calculates and outputs X / Y / Z three-axis offset compensation data based on the insertion position, insertion depth parameter information, primary positioning information and reference positioning information, and uploads it to the control center; S10, the PCB board picking robot arm picks up a PCB board to be inserted; S11, the control center corrects the three-axis reference coordinates by superimposing offset data based on the received data, and controls the three-axis gantry coordinate motion platform to drive the PCB board picking robot to move to the bottom vision imaging detection station. S12, the second machine vision mechanism captures the pin information at the bottom of the PCB board to be inserted, and the vision system calculates and outputs an OK / NG quality signal; if it is an OK quality signal, then continue to execute step S13; if it is an NG quality signal, then discard it. S13, the three-axis gantry coordinate motion platform drives the PCB board picking robot and the accompanying machine vision mechanism to move to the lifting mechanism station; S14, the barcode scanner scans to obtain product information of the deep cavity container PCB board to be inserted, and traces and binds it; S15, the three-axis gantry coordinate motion platform drives the PCB board picking robot to descend linearly along the Z-axis to perform the PCB board insertion action; S16, the pressure sensor senses and detects the real-time insertion pressure to determine whether the insertion is normal and whether the insertion is in place; S17, Insertion complete, the three-axis gantry coordinate motion platform returns to the mechanical origin; S18, Repeat steps S06 to S17 until the mass production order is completed; Among them, multiple product process formulas are built into the human-computer interaction interface. When changing models, the formula data can be retrieved with one click, and the three-axis coordinates, light source brightness, cylinder working air pressure, and process cycle parameters can be automatically refreshed. The process is equipped with fault classification and handling logic. If a single process loses a signal for a short time, the equipment will be suspended. After the fault is cleared and the equipment is manually reset, production will continue. If the same fault triggers the automatic equipment lock-up program three times in a row, the entire machine will be shut down in an emergency if the air source pressure is lower than the lower limit.

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