Electrostatic spraying production line for photovoltaic frame
Patent Information
- Application Number
- CN202611392315.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-09-09
- Publication Date
- 2026-10-23
AI Technical Summary
[0003]然而，现有技术的吊挂方式在实际生产中存在明显弊端，大多采用在工件端部开设一个安装孔，工件通过安装孔吊挂在挂钩上，完成运转喷涂，直接吊挂作业过程中，挂钩会直接与型材边框表面、型腔边缘硬性接触，同时挂钩尖锐部位极易划伤、磕碰工件的外表面，已经磕碰损伤的位置经过喷涂之后会产生明显瑕疵，直接造成工件报废
[0015]与现有技术相比，本发明所达到的有益效果是：本发明，通过设置有二次挂具，工件依靠二次挂具的V型插接区插接于光伏边框型腔内部进行吊挂，悬挂输送线的吊挂挂钩直接与二次挂具的钩挂区相连，避免挂钩直接接触、磕碰工件表面，从源头减少型材划伤、型腔变形等吊挂损伤缺陷；通过在上料工位、喷漆单元入口外侧、喷漆单元出口外侧分别设置第一激光传感器、第二激光传感器、第三激光传感器，实现二次挂具插入深度的分段式检测，能够分别得到前段输送滑移量、喷房内部滑移量以及全程总滑移量，精准定位滑移下沉所发生的工序位置，便于针对性排查产线故障。
Smart Images
Figure CN122955595A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of photovoltaic frame spraying equipment technology, specifically to an electrostatic spraying production line for photovoltaic frames. Background Technology
[0002] During the production and processing of photovoltaic frame profiles, an electrostatic spraying process is required to form a uniform protective paint film on their surface to improve the profiles' corrosion resistance and appearance quality. Currently, the industry commonly uses suspended continuous spraying production lines to complete automated spraying operations. This involves the conveyor line hooks directly clamping and hanging the workpieces on the cavity or outer edge of the photovoltaic frame to achieve suspended transport.
[0003] However, the existing hanging methods have obvious drawbacks in actual production. Most of them involve opening a mounting hole at the end of the workpiece, and the workpiece is hung on the hook through the mounting hole to complete the spraying. During the direct hanging operation, the hook will directly contact the surface of the profile frame and the edge of the cavity. At the same time, the sharp part of the hook is very easy to scratch and bump the outer surface of the workpiece. The damaged areas will have obvious defects after spraying, directly causing the workpiece to be scrapped.
[0004] Therefore, it is necessary to design an electrostatic spraying production line for photovoltaic frames that avoids direct impact and scratches on the workpieces from hooks. Summary of the Invention
[0005] The purpose of this invention is to provide an electrostatic spraying production line for photovoltaic frames to solve the problems mentioned in the background art.
[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: an electrostatic spraying production line for photovoltaic frames, including a suspended conveyor line, and a feeding assembly unit, a pretreatment unit, a drying unit, a painting unit, a curing unit and a unloading unit are arranged sequentially along the conveying direction of the suspended conveyor line. The hanging hooks of the suspended conveyor line are equipped with secondary hangers, and the lower end of the secondary hangers is equipped with workpieces. The feeding assembly unit includes a chain machine and two sets of clamping plates. When the production line is running, the secondary hangers are located inside the two sets of clamping plates.
[0007] According to the above technical solution, the upper part of the load-bearing component of the chain machine is bolted with baffle one and baffle two. The workpiece is placed between baffle one and baffle two. The side of baffle one near baffle two abuts against one side of the workpiece. A spring is fixedly connected to the side of baffle two near baffle one. The axis of the spring is perpendicular to the axis of the workpiece length direction. A ball is fixedly connected to the side of the spring near baffle one. The ball abuts against the other side of the workpiece. A robot arm is set between the loading assembly unit and the unloading unit. The robot arm takes the workpiece out of the basket and places it on the chain machine for conveying.
[0008] According to the above technical solution, a limiting plate is fixedly connected to the side of the chain machine near the suspended conveyor line. One end of the workpiece abuts against the limiting plate. Four sets of cylinders are fixedly connected to the side of the chain machine away from the robot arm. The four sets of cylinders are symmetrically arranged along the axis of the chain machine's transport direction. An L-shaped baffle is fixedly connected to the piston rod of cylinder one. Two sets of cylinders on the same side are symmetrically arranged along the axis of the workpiece's length direction. When the piston rod of cylinder one extends, the workpiece is located between the two sets of baffles three, and the side and bottom surfaces of the workpiece abut against the baffles three.
[0009] According to the above technical solution, the chain machine is provided with two sets of frames 1 on the side near the suspended conveyor line. Two sets of supports 1 are fixedly connected to the opposite side of the two sets of frames 1. A lead screw 1 is connected between the two sets of supports 1 by a bearing. A motor 1 is bolted to the top of the support 1. The output shaft of the motor 1 is keyed to the lead screw 1. A slider 1 is threaded to the outer circle of the lead screw 1. A support 2 is fixedly connected between the two sets of slider 1. A pneumatic finger 1 is fixedly connected to the top of the support 2. A frame 2 is provided at the end of the workpiece away from the pneumatic finger 1. Two sets of supports 3 are fixedly connected to the frame 2. A lead screw 2 is connected between the two sets of supports 3 by a bearing. A motor 3 is bolted to the top of the support 3. The output shaft of the motor 3 is keyed to the lead screw 2. A slide is threaded to the outer circle of the lead screw 2. A pneumatic finger 2 is fixedly connected to the top of the slide. Pneumatic finger 1 and pneumatic finger 2 are located at the two ends of the workpiece, respectively. During assembly operations, the grippers of pneumatic finger 1 and pneumatic finger 2 can abut against the two sides of the workpiece.
[0010] According to the above technical solution, a support six is bolted to one side of the frame near the chain machine. The support six is L-shaped and a motor two is bolted inside. The output shaft of the motor two passes through the support six and is fixedly connected to a pressure plate. A pressure ball is provided below the end of the pressure plate near the workpiece. The position of the pressure ball corresponds to the position of the workpiece. When in the assembly process, the pressure ball abuts against the secondary hanger.
[0011] According to the above technical solution, two sets of frames three are provided on the side of the frame one away from the chain machine. A support four is bolted between the two sets of frames three. Two sets of slide rails are fixedly connected above the support four. A slider two is slidably connected above the slide rails. A fixed plate is fixedly connected above the two sets of slider two. A support five is bolted symmetrically along the axis of the slide rail length on the fixed plate. A cylinder two is fixedly connected above the support five. A cylinder three is fixedly connected above the support four. The cylinder three is located between the two sets of slide rails. The piston rod of the cylinder three is fixedly connected to the fixed plate.
[0012] According to the above technical solution, the piston rod of each set of cylinders is fixedly connected to the clamping plate. The two sets of clamping plates are arranged opposite each other and have a special groove on one side. The cross-section of the special groove is semi-circular and the shape of the special groove is adapted to the shape of the secondary hanger. The secondary hanger is divided into a hooking area, a bending area and an insertion area along its length. The hooking area is a C-shaped hook with the opening facing downward, which is used to hook onto the hanging hook of the suspension conveyor line. The hooking area extends downward to the bending area. The bending area is bent repeatedly to form a sawtooth bend. The bending area bends downward to form a V-shaped insertion area. The insertion area is used to insert into the cavity of the workpiece. The elasticity of the V-shaped structure is used to clamp the inner wall of the profile to realize the hanging of the workpiece. When the assembly is completed, the insertion area of the secondary hanger abuts against the cavity of the workpiece and produces elastic deformation.
[0013] According to the above technical solution, a first laser sensor is bolted to one side of the support column of the suspended conveyor line. The first laser sensor is located at one end of the suspended conveyor line near the loading assembly unit and is used to detect the insertion depth of the secondary hanger after loading. The overhead track of the suspended conveyor line passes through the painting unit and forms a U-shaped path inside the painting unit. The overhead track inside the painting unit includes an inlet straight section, a U-shaped turning section, and an outlet straight section in sequence along the conveying direction of the suspended conveyor line. A second laser sensor is fixedly connected to one side of the support column located in the inlet straight section, and a third laser sensor is fixedly connected to one side of the support column located in the outlet straight section.
[0014] According to the above technical solution, a linear module is fixedly connected above the painting unit. The slider bolt of the linear module is connected to the spraying mechanism. By driving the linear module to move, the rotary table can be moved up and down. The maximum stroke of the linear module is greater than the length of the workpiece. When the painting unit is not working, the spraying mechanism corresponds to the lower end of the workpiece.
[0015] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: The present invention, by setting a secondary hanger, allows the workpiece to be suspended inside the photovoltaic frame cavity by inserting it into the V-shaped insertion area of the secondary hanger. The hanging hook of the suspension conveyor line is directly connected to the hook area of the secondary hanger, avoiding direct contact and impact of the hook on the workpiece surface, thus reducing hanging damage defects such as profile scratches and cavity deformation from the source. By setting a first laser sensor, a second laser sensor, and a third laser sensor on the outside of the loading station, the inlet of the painting unit, and the outlet of the painting unit, respectively, segmented detection of the insertion depth of the secondary hanger can be achieved. This allows for the separate acquisition of the slippage amount of the front conveyor, the slippage amount inside the spray booth, and the total slippage amount throughout the process, accurately locating the process position where slippage and sinking occur, facilitating targeted troubleshooting of production line faults. Attached Figure Description
[0016] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the overall structure of the spraying line of the present invention; Figure 2 This is a schematic diagram of the spraying line structure from another perspective of the present invention; Figure 3 For the present invention Figure 2 Enlarged view of point A in the middle; Figure 4 This is a schematic diagram of the feeding and assembly unit structure of the present invention; Figure 5 For the present invention Figure 4 Enlarged view of point B in the middle; Figure 6 For the present invention Figure 4 Enlarged view of point C in the middle; Figure 7 This is a schematic diagram of the structure between frame one and frame three of the present invention; Figure 8 For the present invention Figure 4 Enlarged view of point D; Figure 9 For the present invention Figure 7 Enlarged diagram at point F; Figure 10 This is a schematic diagram of the secondary clamping fixture structure of the present invention; Figure 11 This is a schematic diagram of the irregular groove structure inside the clamping plate of the present invention; Figure 12 For the present invention Figure 1 Enlarged diagram of point G in the middle; Figure 13 This is a schematic diagram of the front structure of the painting unit of the present invention; Figure 14 For the present invention Figure 13 Enlarged view of section H in the middle; In the diagram: 1. Feeding assembly unit; 2. Suspended conveyor line; 3. Pre-treatment unit; 4. Drying unit; 5. Painting unit; 6. Curing unit; 7. Unloading unit; 8. Secondary hanging fixture; 9. Chain conveyor; 10. Clamping plate; 11. Baffle 1; 12. Baffle 2; 13. Spring; 14. Ball; 15. Limiting plate; 16. Cylinder 1; 17. Baffle 3; 18. Frame 1; 19. Support 1; 20. Lead screw 1; 21. Slider 1; 22. Support 2; 23. Pneumatic finger 1; 24. Frame 2; 25. Support 3; 26. Lead screw 2; 27. Slide table; 28. Pneumatic finger 2; 29. Frame 3; 30. Support 4; 31. Slide rail; 32. Linear module; 33. Slider 2; 34. Fixing plate; 35. Support 5; 36. Cylinder 2; 37. Cylinder 3; 38. Spraying mechanism; 39. Irregular groove; 40. Support 6; 41. Motor 2; 42. Pressure plate; 43. Downward pressure ball; 44. First laser sensor; 45. Second laser sensor; 46. Third laser sensor; 47. Motor 1. Detailed Implementation
[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0018] Please see Figure 1-14 The present invention provides a technical solution: an electrostatic spraying production line for photovoltaic frames, including a suspended conveyor line 2. Along the conveying direction of the suspended conveyor line 2, there are sequentially arranged a feeding assembly unit 1, a pretreatment unit 3, a drying unit 4, a painting unit 5, a curing unit 6, and a unloading unit 7. The suspended conveyor line 2 is composed of an overhead track, a traction chain, a hanging hook, and multiple sets of supporting columns, which is prior art and will not be described in detail. The hanging hook of the suspended conveyor line 2 is equipped with a secondary hanger 8, and the lower end of the secondary hanger 8 is equipped with a workpiece. The feeding assembly unit 1 includes a chain machine 9 and two sets of clamping plates 10. When the production line is running, the secondary hanger 8 is located inside the two sets of clamping plates 10.
[0019] The chain conveyor 9 consists of a drive reduction motor, sprockets, chains, and load-bearing components. It is an existing chain conveyor and will not be described in detail. The load-bearing components of the chain conveyor 9 are bolted to baffle 11 and baffle 22. The workpiece is placed between baffle 11 and baffle 22. The side of baffle 11 near baffle 22 abuts against one side of the workpiece. A spring 13 is fixedly connected to the side of baffle 22 near baffle 11. The axis of spring 13 is perpendicular to the axis of the workpiece's length. A ball 14 is fixedly connected to the side of spring 13 near baffle 11. The ball 14 abuts against the other side of the workpiece. A robot (not shown in the figure) is set between the loading assembly unit 1 and the unloading unit 7. The robot takes the workpiece out of the basket and places it on the chain conveyor 9 for conveying.
[0020] A limiting plate 15 is fixedly connected to the side of the chain machine 9 closest to the suspended conveyor line 2. One end of the workpiece abuts against the limiting plate 15. Four sets of cylinders 16 are fixedly connected to the side of the chain machine 9 furthest from the robot arm. The four sets of cylinders 16 are symmetrically arranged along the axis of the chain machine 9 in the transport direction. The piston rod of the cylinder 16 is fixedly connected to an L-shaped baffle 3 17. Two sets of cylinders 16 on the same side are symmetrically arranged along the axis of the length of the workpiece. When the piston rod of the cylinder 16 extends, the workpiece is located between the two sets of baffles 3 17 and the side and bottom surfaces of the workpiece abut against the baffles 3 17.
[0021] On the side of the chain conveyor 9 near the overhead conveyor 2, there are two sets of frames 18. On opposite sides of each set of frames 18, two sets of supports 19 are fixedly connected. A lead screw 20 is connected between the two sets of supports 19 via a bearing. A motor 47 is bolted to the top of each support 19. The output shaft of the motor 47 is keyed to the lead screw 20. A slider 21 is threaded onto the outer diameter of the lead screw 20. A support 22 is fixedly connected between the two sets of sliders 21. A pneumatic finger 23 is fixedly connected above the support 22. A frame 24 is located at the end of the workpiece furthest from the pneumatic finger 23. A component is fixedly connected to the frame 24. Two sets of supports 25 are connected by bearings to lead screw 26 between the two sets of supports 25. A motor 3 is bolted to the top of the supports 25. The output shaft of the motor 3 is keyed to lead screw 26. A slide 27 is connected to the outer thread of lead screw 26. A pneumatic finger 28 is fixedly connected to the top of slide 27. Pneumatic finger 1 23 and pneumatic finger 28 are located at both ends of the workpiece. Pneumatic finger 1 23 and pneumatic finger 28 are both composed of a drive cylinder, parallel grippers, etc., which are existing technologies and will not be described in detail. During assembly, the grippers of pneumatic finger 1 23 and pneumatic finger 28 can abut against both sides of the workpiece.
[0022] A set of frame 18 is bolted to a support 6 40 on the side near the chain machine 9. The support 6 40 is L-shaped and is bolted to a motor 2 41. The output shaft of the motor 2 41 passes through the support 6 40 and is fixedly connected to a pressure plate 42. A pressure ball 43 is provided below the end of the pressure plate 42 near the workpiece. The pressure ball 43 is a universal ball that can rotate freely. This is existing technology and will not be described in detail. The position of the pressure ball 43 corresponds to the position of the workpiece. When in the assembly process, the pressure ball 43 abuts against the secondary hanger 8.
[0023] Two sets of frames 29 are provided on the side of frame 18 away from chain machine 9. Support 4 30 is bolted between the two sets of frames 29. Two sets of slide rails 31 are fixedly connected above support 4 30. Sliding slider 2 33 is slidably connected above slide rails 31. Fixing plate 34 is fixedly connected above the two sets of sliding slider 2 33. Support 5 35 is bolted symmetrically along the length axis of slide rail 31 on fixing plate 34. Cylinder 2 36 is fixedly connected above support 5 35. Cylinder 37 is fixedly connected above support 4 30. Cylinder 37 is located between the two sets of slide rails 31. The piston rod of cylinder 37 is fixedly connected to fixing plate 34.
[0024] The piston rod of each set of cylinders 36 is fixedly connected to the clamping plate 10. The two sets of clamping plates 10 are arranged opposite each other and have a special groove 39 on one side. The cross-section of the special groove 39 is semi-circular and the shape of the special groove 39 is adapted to the shape of the secondary hanger 8. The secondary hanger 8 is divided into a hooking area, a bending area and an insertion area along its length. The hooking area is a C-shaped hook with the opening facing downward, which is used to hook onto the hanging hook of the suspension conveyor line 2. The hooking area extends downward to the bending area. The bending area is bent repeatedly to form a sawtooth bend. The bending area bends downward to form a V-shaped insertion area. The insertion area is used to insert into the cavity of the workpiece. The elasticity of the V-shaped structure is used to clamp the inner wall of the profile to realize the hanging of the workpiece. When the assembly is completed, the insertion area of the secondary hanger 8 abuts against the cavity of the workpiece and produces elastic deformation.
[0025] A first laser sensor 44 is bolted to one side of the support column of the suspended conveyor line 2. The first laser sensor 44 is located at one end of the suspended conveyor line 2 near the loading assembly unit 1 and is used to detect the insertion depth of the secondary hanger 8 after loading. The overhead track of the suspended conveyor line 2 passes through the painting unit 5 and forms a U-shaped path inside the painting unit 5. The overhead track inside the painting unit 5 includes an inlet straight section, a U-shaped turning section, and an outlet straight section in sequence along the conveying direction of the suspended conveyor line 2. A second laser sensor 45 is fixedly connected to one side of the support column located in the inlet straight section, and a third laser sensor 46 is fixedly connected to one side of the support column located in the outlet straight section.
[0026] A linear module 32 is fixedly connected above the painting unit 5. The linear module 32 consists of a housing, a slider, a drive screw, a drive motor, and other structures, which are existing technologies and will not be described in detail. The slider of the linear module 32 is bolted to a spraying mechanism 38, which consists of a rotary table, a pneumatic motor, a lifting rod, and other structures, which are existing technologies and will not be described in detail. By driving the linear module 32 to move, the rotary table can be moved up and down. The maximum stroke of the linear module 32 is greater than the length of the workpiece. When the painting unit 5 is not working, the spraying mechanism 38 corresponds to the lower end of the workpiece.
[0027] Example 1: A method of using an electrostatic spraying production line for photovoltaic frames, comprising the following steps: Step 1: Material loading, assembly, and initial inspection.
[0028] Specifically, the robotic arm removes the workpiece from the basket and places it between baffle 11 and baffle 212 of the chain machine 9. The side of the workpiece abuts against baffle 11, and the other side contacts the ball 14. The ball 14 provides preload through spring 13 to achieve lateral positioning of the workpiece. At the same time, one end of the workpiece abuts against the limiting plate 15 to complete axial limiting. The chain machine 9 starts to realize workpiece conveying. When the workpiece is conveyed to the tail end of the chain machine 9, the piston rods of the four sets of cylinders 16 extend, driving the L-shaped baffle 317 to move upward along the piston rod axis. The baffle 317 lifts and limits the workpiece from the side and bottom to prevent the workpiece from shifting when it moves upward.
[0029] Subsequently, motors 1 and 3 drive lead screws 1 and 26 to rotate, respectively, which in turn move pneumatic fingers 1 and 28 upwards to the two ends of the workpiece and clamp them. Then, pneumatic fingers 1 and 28 continue to move the workpiece up and down along the axis of lead screws 1 and 26. The piston rods of the four sets of cylinders 16 reset, and the secondary hanger 8 is manually placed between the two sets of clamping plates 10, so that the secondary hanger 8 fits against the shaped groove 39. The two sets of cylinders 2 and 36 are driven to move synchronously, causing the two sets of clamping plates 10 to close and clamp the secondary hanger 8. Cylinder 3 and 37 are activated, and their piston rods extend to push the fixed plate 34 along the slide rail 31, moving the secondary hanger... The hanger 8 is positioned opposite the workpiece cavity. Motor 2 41 drives the pressure plate 42 to rotate around the output shaft axis, thereby pressing the insertion area of the secondary hanger 8 with the lower pressure ball 43. Cylinder 3 37 continues to extend its piston rod, bringing the secondary hanger 8 closer to the workpiece along the slide rail 31, thus pressing the V-shaped insertion area at the bottom of the secondary hanger into the upper cavity of the workpiece. The V-shaped insertion area undergoes elastic deformation due to the pressure of the lower pressure ball 43 and the inner wall of the cavity, relying on the elastic tension force to hold the inner wall of the profile. After assembly, the clamping plate 10 is released, and the support 22 and the slide table 27 release the pneumatic fingers 23 and 28 respectively. The workpiece with the secondary hanger 8 assembled is then manually hung on the hanging hook of the suspension conveyor line 2. When the workpiece is transported to the detection position of the first laser sensor 44 along the suspension conveyor line 2, the first laser sensor 44 collects the initial insertion depth S1 of the secondary hanger 8 and uploads the detection data to the control system.
[0030] Step 2: Pre-treatment. The workpiece undergoes pre-treatment along the conveyor channel and is then transferred towards the spray booth.
[0031] Specifically, the secondary hanger 8 carrying the workpiece follows the suspended conveyor line 2 through the pretreatment unit 3 and the drying unit 4 in sequence to complete the pretreatment work of oil removal, dust removal and surface drying on the workpiece surface. After the pretreatment is completed, the workpiece continues to be transferred along the overhead track towards the painting unit 5.
[0032] Step 3: Spray booth entrance detection and pre-compensation.
[0033] Specifically, the workpiece is conveyed to the outside of the inlet of the painting unit 5. The second laser sensor 45 installed on the support column detects the current insertion depth S2 of the secondary hanger 8. The control system receives the detection data and calculates the front conveying slippage S1-S2. Based on the workpiece sinking offset, it sends a compensation signal to control the linear module 32 to move the reciprocating working range of the spraying mechanism 38 upward as a whole, pre-compensating for the height deviation caused by the workpiece sinking. Subsequently, the workpiece enters the spray booth along the straight section of the inlet of the U-shaped track inside the painting unit 5. The paint is fed into the spraying mechanism 38 from the top center of the rotary nozzle. The linear module 32 drives the rotary disc to make vertical reciprocating motion from the lower end of the workpiece to the upper end. The high-speed rotation of the rotary disc centrifugally atomizes the paint, completing the workpiece surface spraying operation. The U-shaped overhead track can extend the travel distance of the workpiece inside the painting unit 5 and increase the effective spraying time.
[0034] Step 4: Export inspection and solidification.
[0035] Specifically, after the workpiece is sprayed, it moves out of the spraying unit 5 along the U-shaped rotating section inside the spraying unit 5 and the straight section at the exit. The third laser sensor 46 located outside the straight section at the exit detects the insertion depth S3 of the secondary hanger 8 after spraying. The control system calculates the slippage amount S2-S3 generated inside the spray booth based on the detection value and determines the risk level of workpiece slippage and sinking. Then, the workpiece is transferred to the curing unit 6 by the suspended conveyor line 2, and the workpiece completes the heating and curing of the paint film at the curing station.
[0036] Step 5: Unloading. The cured workpiece is transported to the unloading station to complete the unloading process.
[0037] Specifically, after the paint film has cured, the workpiece is conveyed to the unloading unit 7 along the overhead conveyor line 2. The secondary hanger 8 and the workpiece are removed from the hanging hook of the overhead conveyor line 2 by the operator, thus completing the separation and unloading of the workpiece and the secondary hanger 8. The workpiece is removed from the line, and the secondary hanger returns with the conveyor loop, waiting for the next round of assembly operations.
[0038] Example 2: This example is based on the logic of Example 1, and analyzes the feedback values of S1, S2 and S3.
[0039] In step one, the workpiece is transported to the detection station of the first laser sensor 44 by the suspended conveyor line 2. The system uses the initial insertion depth S1 of the secondary fixture 8 collected by the first laser sensor 44 as the reference assembly depth of the current workpiece. The operator presets the sliding safety range as [a,b]. The inflection point of the bending area and the V-shaped insertion area is used as the reference point. The insertion depth is the length of the insertion area connected to the bending area minus the length of the reference point and the end face of the workpiece.
[0040] Moving to the next step, the secondary hanger 8 carrying the workpiece follows the suspended conveyor line 2 through the pretreatment unit 3 and the drying unit 4 in sequence, completing the pretreatment processes such as degreasing, dust removal, and drying on the workpiece surface. After processing, the workpiece continues to be transferred along the overhead track to the painting unit 5. The vibration and impact generated by the chain starting and stopping and the track turning may cause the secondary hanger 8 to slide and sink relative to the profile cavity, waiting for the detection signal from the second laser sensor 45. When the workpiece is transported to the outside of the entrance of the painting unit 5, the second laser sensor 45 on the support column detects the current actual insertion depth S2 of the secondary hanger 8 in real time. The control system calculates the slippage S1-S2 generated during the front-end conveying process in real time and compares S1-S2 with the slippage safety range.
[0041] Specifically, when S1-S2 < a, it is determined that the workpiece has no obvious sinking or slippage and the hanging state is normal. The linear module 32 maintains the factory-preset standard reciprocating stroke and does not compensate for the offset of the movement range of the spraying mechanism 38. When a < S1-S2 ≤ b, it is determined that the workpiece has slightly sinked or slipped. The linear module 32 is driven to move the entire reciprocating range of the spraying mechanism 38 upward by a distance of S1-S2 to compensate for the height deviation caused by the sinking of the workpiece and ensure that the top area of the profile is always in the deceleration and supplementary spraying area near the top dead center of the rotary nozzle. When S1-S2 > b, it is determined that the workpiece has significantly sinked or slipped. The control system controls the entire spraying mechanism to shift upward by S1-S2 and simultaneously modifies the motion parameters of the linear module 32, extending the deceleration dwell time when the nozzle reaches the top dead center position, increasing the spraying time at the upper end of the photovoltaic frame, and alerting the staff.
[0042] After the spraying parameters are adjusted, the workpiece is fed into the spray booth through the inlet straight section of the U-shaped track inside the spraying unit 5. The paint is introduced into the spraying mechanism 38 through the top center of the rotary nozzle. The linear module 32 drives the rotary nozzle to move vertically back and forth from the lower end of the workpiece to the upper end. The high-speed rotation of the rotary nozzle atomizes the paint by centrifugal force, completing the spraying operation on the profile surface. After the spraying is completed, the workpiece leaves the spraying unit 5 along the outlet straight section. At this time, the third laser sensor 46 installed on the outside of the outlet straight section detects the insertion depth S3 of the secondary hanger 8 after spraying. The control system calculates the newly added slippage S2-S3 inside the spray booth and the total slippage S1-S3 from the completion of assembly to the end of spraying, and compares it with the safe range.
[0043] Specifically, if both S1-S2 and S2-S3 are less than the safety lower limit 'a', it indicates that the workpiece slippage is within the normal range. The workpiece is directly transported to the curing unit 6, where conventional curing parameters are used to complete the paint film heating and drying. If the values of S1-S2 or S2-S3 fall within the range of [a, b], the workpiece is determined to be a workpiece with slight slippage. The workpiece is normally sent to the curing unit for drying. After curing, it is transferred to the re-inspection station, where the paint film thickness is specifically tested at the upper corner of the photovoltaic frame, and qualified products are tested. When S1-S2 > b or S2-S3 > b, it is determined to be a workpiece with high slippage risk. The control system outputs a sorting signal, and the workpiece is sent to the film thickness detection station first. The paint film thickness at the top of the profile is tested. Workpieces with substandard paint film indicators are separately diverted for rework. Workpieces that pass the inspection are then sent to the curing unit 6. After curing, the workpiece is conveyed to the unloading unit 7. The operator removes the workpiece and the secondary fixture 8 as a whole from the hanging hook, separates the workpiece and the secondary fixture 8, and the workpiece is unloaded. The control system records the complete sliding data S1-S2 and S2-S3 of the secondary fixture during this processing. If the sliding amount of a batch of secondary fixtures 8 continuously exceeds the safety limit b during multiple cycles of operation, the secondary fixtures 8 of that batch are sorted out separately at the unloading station for elasticity testing. Faults such as elastic fatigue of the V-type plug end and wear of the rod are checked. Only after the repair is qualified can it be put into assembly again. If the repair is unqualified, a new batch of secondary fixtures 8 is replaced. The repaired secondary fixtures 8 are returned along the conveyor loop to wait for the next round of assembly operation.
[0044] Furthermore, if S2-S3 > b and S1-S2 is within the normal range, it indicates that the workpiece sinks significantly after entering the spray booth. This means that paint mist and dust adhere to the V-shaped insertion area, causing a decrease in the friction of the contact surface. Therefore, the spraying amount of the spraying mechanism 38 should be reduced, and the running speed of the suspended conveyor line 2 should be reduced to extend the dwell time of the workpiece in the spraying unit 5 and ensure that the paint thickness is qualified. If both S1-S2 and S2-S3 > b, it indicates that the elastic performance of the corresponding secondary fixture 8 has been severely degraded. A new secondary fixture needs to be replaced immediately to prevent slippage and scratching of the workpiece cavity and ensure that the paint thickness of the workpiece is uniform.
[0045] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.
[0046] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. An electrostatic spraying production line for photovoltaic frames, comprising a suspended conveyor line (2), characterized in that, Along the conveying direction of the overhead conveyor line (2), there are sequentially arranged a feeding assembly unit (1), a pretreatment unit (3), a drying unit (4), a painting unit (5), a curing unit (6), and a unloading unit (7). The hanging hooks of the overhead conveyor line (2) are equipped with secondary hangers (8). The lower end of the secondary hangers (8) is equipped with workpieces. The feeding assembly unit (1) includes a chain machine (9) and two sets of clamps (10). When the production line is running, the secondary hangers (8) are located inside the two sets of clamps (10). The first laser sensor (44) is located at one end of the overhead conveyor line (2) near the loading assembly unit (1). The first laser sensor (44) is bolted to one side of the support column of the overhead conveyor line (2). The overhead track inside the painting unit (5) includes an inlet straight section, a U-shaped rotary section and an outlet straight section in sequence along the conveying direction of the overhead conveyor line (2). A second laser sensor (45) is fixedly connected to one side of the support column of the inlet straight section. A linear module (32) is fixedly connected above the painting unit (5), and the slider bolt of the linear module (32) is connected to the spraying mechanism (38). The system uses the initial insertion depth S1 of the secondary fixture (8) collected by the first laser sensor (44) as the reference assembly depth of the current workpiece. The operator presets the sliding safety range as [a, b]. The second laser sensor (45) on the support column detects the current actual insertion depth S2 of the secondary fixture (8) in real time. When a < S1 - S2 ≤ b, it is determined that the workpiece has slightly sunk and slipped. The linear module (32) is driven to move the entire reciprocating section of the spraying mechanism (38) upward by a distance of S1 - S2.
2. The electrostatic spraying production line for photovoltaic frames according to claim 1, characterized in that, The chain machine (9) has a first baffle (11) and a second baffle (12) bolted on the upper part of the bearing component. The workpiece is set between the first baffle (11) and the second baffle (12). The side of the first baffle (11) near the second baffle (12) abuts against one side of the workpiece. The side of the second baffle (12) near the first baffle (11) is fixedly connected to a spring (13). The axis of the spring (13) is perpendicular to the axis of the workpiece length direction. The side of the spring (13) near the first baffle (11) is fixedly connected to a ball (14). The ball (14) abuts against the other side of the workpiece. A robot arm is set between the loading assembly unit (1) and the unloading unit (7).
3. The electrostatic spraying production line for photovoltaic frames according to claim 2, characterized in that, The chain machine (9) is fixedly connected to a limiting plate (15) on the side near the suspended conveyor line (2). One end of the workpiece abuts against the limiting plate (15). The chain machine (9) is fixedly connected to four sets of cylinders (16) on the side away from the robot arm. The four sets of cylinders (16) are symmetrically arranged along the transport direction axis of the chain machine (9). The piston rod of the cylinder (16) is fixedly connected to an L-shaped baffle (17). The two sets of cylinders (16) on the same side are symmetrically arranged along the length direction axis of the workpiece. When the piston rod of the cylinder (16) extends, the workpiece is located between the two sets of baffles (17) and the side and bottom surfaces of the workpiece abut against the baffles (17).
4. The electrostatic spraying production line for photovoltaic frames according to claim 3, characterized in that, The chain machine (9) has two sets of frames (18) on one side near the suspended conveyor line (2). Two sets of supports (19) are fixedly connected to the opposite side of the two sets of frames (18). A lead screw (20) is connected between the two sets of supports (19) by a bearing. A motor (47) is bolted to the top of the support (19). The output shaft of the motor (47) is keyed to the lead screw (20). A slider (21) is threaded to the outer diameter of the lead screw (20). A support (22) is fixedly connected between the two sets of sliders (21). A pneumatic finger (23) is fixedly connected above the support (22). The workpiece is away from the pneumatic finger (23). 23) is provided with a frame two (24) at one end. The frame two (24) is fixedly connected with two sets of supports three (25). The two sets of supports three (25) are connected by a bearing with a lead screw two (26). The support three (25) is bolted to the top of the support three (25). The output shaft of the motor three is keyed to the lead screw two (26). The lead screw two (26) is connected to a slide table (27) by a thread on its outer circle. The slide table (27) is fixedly connected to a pneumatic finger two (28). The pneumatic finger one (23) and the pneumatic finger two (28) are located at both ends of the workpiece. When the assembly operation is performed, the grippers of the pneumatic finger one (23) and the pneumatic finger two (28) can abut against the two sides of the workpiece.
5. The electrostatic spraying production line for photovoltaic frames according to claim 4, characterized in that, A set of the frame one (18) is bolted to a support six (40) on the side near the chain machine (9). The support six (40) is L-shaped and is bolted to a motor two (41). The output shaft of the motor two (41) passes through the support six (40) and is fixedly connected to a pressure plate (42). A pressure ball (43) is provided below the end of the pressure plate (42) near the workpiece. The position of the pressure ball (43) corresponds to the position of the workpiece. When in the assembly process, the pressure ball (43) abuts against the secondary hanger (8).
6. The electrostatic spraying production line for photovoltaic frames according to claim 5, characterized in that, Two sets of three frames (29) are provided on the side of the frame one (18) away from the chain machine (9). The two sets of three frames (29) are bolted together with a support four (30). Two sets of slide rails (31) are fixedly connected above the support four (30). A slider two (33) is slidably connected above the slide rails (31). A fixing plate (34) is fixedly connected above the two sets of slider two (33). The fixing plate (34) is bolted symmetrically along the length axis of the slide rails (31) with a support five (35). A cylinder two (36) is fixedly connected above the support five (35). A cylinder three (37) is fixedly connected above the support four (30). The cylinder three (37) is located between the two sets of slide rails (31). The piston rod of the cylinder three (37) is fixedly connected to the fixing plate (34).
7. The electrostatic spraying production line for photovoltaic frames according to claim 6, characterized in that, The piston rod of each set of cylinders (36) is fixedly connected to the clamping plate (10). The two sets of clamping plates (10) are arranged opposite each other and a special groove (39) is opened on the opposite side. The cross-section of the special groove (39) is semi-circular and the shape of the special groove (39) is adapted to the shape of the secondary hanger (8). The secondary hanger (8) is divided into a hook area, a bending area and an insertion area along the length direction. The hook area is a C-shaped hook with the opening facing downward. The hook area extends downward to the bending area. The bending area is bent repeatedly to form a sawtooth bend. The bending area bends downward to form a V-shaped insertion area. When the assembly is completed, the insertion area of the secondary hanger (8) abuts against the workpiece cavity and produces elastic deformation.
8. The electrostatic spraying production line for photovoltaic frames according to claim 7, characterized in that, The overhead track of the suspended conveyor line (2) passes through the painting unit (5) and forms a U-shaped path inside the painting unit (5). A third laser sensor (46) is fixedly connected to one side of the support column located in the straight section of the outlet.
9. The electrostatic spraying production line for photovoltaic frames according to claim 8, characterized in that, The maximum stroke of the linear module (32) is greater than the length of the workpiece. When the painting unit (5) is not working, the painting mechanism (38) corresponds to the lower end position of the workpiece.